Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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440

CHAPTER ELEVEN

Compression Rebound Adjustment

(FXDX, FXDXT)

The compression rebound adjuster (Figure 15)

has ten stop positions. The No. 1 position which is

all the way clockwise, is the hardest, while the No.

10 position, all the way counterclockwise, is the

softest. The standard factory setting is No. 3.

To adjust the compression damping, turn the

compression damping adjuster with a small blade

screwdriver located at the top of the shock absorber.

NOTE

When turning the adjuster, make sure

2. Remove the bolts and nuts securing the drive

it clicks into one of the detent posi-

belt upper guard (A, Figure 19) and remove the

tions. Otherwise, the adjuster will au-

guard.

tomatically be set at the stiffest

3. Remove the rear wheel (B, Figure 19) as de-

position.

scribed in Chapter Nine.

4. On 1999 models, slide the rear brake caliper off

REAR SWING ARM

the swing arm as described in Chapter Twelve.

5. Remove the mounting bolts securing the left side

Refer to Figure 16 and Figure 17.

rear footpeg and mounting bracket assembly (A,

Figure 20). Remove the assembly.

Rear Swing Arm Bearing Check

6. Remove the acorn nut and washer (A, Figure

21) securing each shock absorber to the swing arm.

The swing arm pivots on a combination bushing

Pivot both shock absorbers up and tie it to the frame.

and bearing assembly. Service limit specifications

7. On the right side, remove the bolts securing the

for the bushing and bearing assemblies are not

muffler support bracket (A, Figure 22) to the frame

available; therefore, check for wear or damage with

and remove it.

the swing arm mounted on the frame.

8. Remove the clamps securing the rear brake hose

1. Remove the rear wheel (A, Figure 18) as de-

to the swing arm.

scribed in this chapter.

9. On the right side, pry the pivot shaft chrome cap

2. Remove the lower acorn nut and washer (B, Fig-

(B, Figure 22) from the swing arm.

ure 18) securing both shock absorbers to the swing

10A. On 1999 models, perform the following:

arm. Move them up away from the swing arm.

3. Check that the swing arm pivot shaft nut or bolt

a. On the left side, remove the cotter pin from

is tight.

the end of the pivot shaft (Figure 23). Install a

4. Have an assistant hold the motorcycle securely.

new cotter pin during installation.

5. Grasp the back of the swing arm and try to move

b. Hold the nut and loosen the pivot shaft (Fig-

it from side to side. Any play (movement) between

ure 24) on the right side. Remove the nut and

the swing arm and the frame and transmission may

washer.

suggest worn or damaged swing arm bearings

c. Support the swing arm and remove the pivot

and/or bushings. If there is any play, remove the

shaft (Figure 24) from the right side.

swing arm and inspect the bushing and bearing as-

d. Remove the swing arm (Figure 25).

semblies.

10B. On 2000-on models, perform the following:

6. Install all components removed.

a. On the right side, hold onto the hex fitting on

the end of the pivot shaft to keep the shaft

from rotating.

Rear Swing Arm Removal

b. On the left side, remove the bolt and

1. Remove the exhaust system as described in

lockwasher (B, Figure 20) from the pivot

Chapter Seven.

shaft.

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REAR SUSPENSION

441

REAR SWING ARM (1999)

1. Adjust bolt

12. O-ring

2. Plate

13. Washer

3. Block

14. Cotter pin

4. Swing arm

15. Nut

5. Chrome cap

16. Left side spacer

6. Pivot shaft

17. O-ring

7. Right side spacer

18. Bearing

8. Bushing

19. Bearing cup

9. Dust shield

20. Lock ring

10. Bearing cup

21. Spacer

11. Bearing

c. Support the swing arm and remove the pivot

The left side of the swing arm is equipped with

shaft (B, Figure 22) from the right side.

the two roller bearings and the right side is equipped

d. Remove the swing arm (B, Figure 21).

with the pivot bushing.

11. Clean and lubricate the swing arm assembly as

described in the following procedure.

NOTE

If reusing the roller bearings, install

Rear Swing Arm Bushing

them in their original operating posi-

and Bearing Lubrication

tions. Wear patterns have developed

on the individual bearing and cup

To prevent premature wear of the bushings and

assemblies and rapid wear could oc-

bearings lubricate them at the interval in Chapter

cur if the bearings are intermixed.

Three.

Also, the two washers installed on

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444

CHAPTER ELEVEN

c. Remove the inner washer (A, Figure 29) and

roller bearing (B).

NOTE

Do not remove the swing arm bushing

and bearing cups unless they are go-

ing to be replaced. Refer to Swing

Arm Overhaul in this section.

3. Clean the pivot shaft, spacer, bushing, bearing

cups, and washers in solvent and dry with com-

pressed air, if available.

4. Inspect the O-rings installed in the outer edge of

each washer (Figure 30). Replace worn or damaged

O-rings.

5. Wipe off all excess grease from one roller

bearing and then soak it in a container filled with

kerosene. Brush the bearing with a soft nylon

brush and then blow with low pressure com-

pressed air to remove as much of the old grease as

possible. Repeat until the bearing is clean, with

none of the old grease visible. When the bearing

is clean, dip it in a container of new kerosene,

then remove and blow it off. Repeat for the oppo-

site bearing.

6. To assemble the roller bearing into the left side

of the swing arm, perform the following:

a. Apply wheel bearing grease to each cup (Fig-

ure 31) installed in the swing arm.

b. Pack the bearing with wheel bearing grease.

If a bearing packer is not available, thor-

oughly work the grease into the bearing by

hand until it is fully packed.

c. Repeat to lubricate the opposite bearing.

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REAR SUSPENSION

445

NOTE

When installing the washers (Figure

30) in the following steps, note that the

washers are different. Install the

washer with the smaller inside diameter

hole into the outside of the swing arm.

The pivot shaft will not pass through

this washer if it is installed on the inside

of the swing arm. Figure 32 shows the

pivot shaft and outer washer.

Apply grease to each of the washer O-rings

(Figure 30).

Install the outer bearing and washer (Figure

27) into the swing arm. Install the outer

washer with its wider edge (Figure 33) facing

out. Make sure the washer is flush with the

swing arm as shown in Figure 34.

Grease the bearing spacer (Figure 28) and in-

stall it against the outer bearing.

CAUTION

Install the bearing spacer between the

bearing races; otherwise, the bear-

ings may fail during operation.

Install the inner bearing and washer (Figure

29) into the swing arm. Install the inner

washer with its wider edge (Figure 35) facing

out. Make sure the washer is flush with the

swing arm as shown in Figure 36.

To install the right side spacer and dust cover,

perform the following:

a. Lubricate the spacer and bushing (Figure 37)

with wheel bearing grease.

b. Install the dust cover (Figure 38) into the

swing arm and seat it against the bushing. The

dust cover must seat flush with or be recessed

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446

CHAPTER ELEVEN

0.06 in. (1.5 mm) from the edge of the swing

arm. See Figure 39.

c. Install the spacer

(Figure 26) through the

bushing and seat it against the dust cover.

8. Install the rear swing arm as described in this

chapter.

Rear Swing Arm Overhaul

This procedure describes the replacement of the

swing arm bushing and bearing cup assemblies.

1. Remove the spacer and roller bearing assemblies

as described under Swing Arm Bushing and Bearing

Lubrication in this chapter.

2. To replace the bushing (Figure 37) on the left

side, perform the following:

a. Before removing the bushing (Figure 37),

measure its installed position from the inside

edge of the swing arm to the bushing edge.

b. Using an expandable puller or a press, re-

move the bushing (Figure 37) from the swing

arm.

c. Clean the swing arm bushing bore with sol-

vent and dry with compressed air, if available.

d. Align the new bushing with the swing arm

and press it into the swing arm. Press it into

the recorded dimension.

Rear swing arm

3. To remove the bearing cups (Figure 31) on the

right side, perform the following:

a. Figure 40 shows a complete roller bearing as-

Bushing

sembly. Do not intermix the bearing assem-

blies.

Dust

b. Remove the inner and outer bearing cups

cover

(Figure 41) from the swing arm with a puller.

0.06 in.

NOTE

(1.5 mm)

The lock ring (Figure 42) is seated in

a groove inside the swing arm bore.

Do not try to pry the lock ring out of

the groove as it is under considerable

tension. Perform the following proce-

dure to safely remove the lock ring.

4. To replace the lock ring (Figure 42), perform the

following:

NOTE

In the following steps the hacksaw

will only cut through the exposed por-

tion of the lock ring. Cut down only to

the swing arm bore surface. These

cuts are not meant to cut completely

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REAR SUSPENSION

447

through the lock ring, only weaken it

so it can be removed safely from the

swing arm bore groove.

Insert a fine tooth hacksaw blade (24 or 32

teeth per inch) through the swing arm bearing

bore and mount it onto a hacksaw (Figure

43).

With the lock ring opening positioned at 12

o’clock, make a cut at the 4 o’clock and the 8

o’clock positions. Cut the lock ring down to

the swing arm bore surface. Do not cut into

the swing arm bore.

WARNING

Wear safety glasses when removing

and installing the lock ring.

Using a screwdriver at one end of the lock

ring, carefully pry it up and out of the swing

arm groove. If the lock ring is still under suffi-

cient tension, try to remove it at the other end.

Remove and discard the lock ring.

Clean the swing arm bore and the lock ring

groove of all metal particles with solvent and

dry.

WARNING

Wear safety glasses when installing

the lock ring.

To install the new lock ring (Figure 44), lu-

bricate the swing arm bore and the lock ring

with oil. Start one end of the lock ring in the

bore, then tap the other end into place with a

hammer. Tap it in until both ends are in the

bore and parallel with the groove. Then drive

or press it into the groove with a suitable bear-

ing driver. Check that the lock ring (Figure

42) is correctly seated in the groove.

Press the inner and outer bearing cups (Figure

41) into the swing arm (Figure 31). Seat both bear-

ings against the lock ring.

6. Install the spacer and roller bearing assemblies

as described under Swing Arm Bushing and Bearing

Lubrication in this chapter.

Rear Swing Arm Installation

1. Lubricate the pivot shaft with wheel bearing

grease.

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448

CHAPTER ELEVEN

2. If removed, install the spacer, roller bearings and

washers as described under Swing Arm Bushing and

Bearing Lubrication in this chapter.

3. Slide the swing arm onto the transmission hous-

ing mounting boss. Be sure to install and position

the drive belt over the front of the swing arm.

Correct installation

4A. On 1999 models, perform the following:

of cotter pin

a. Install the pivot shaft (Figure 24) from the

right side through the swing arm and the

transmission. Install the washer and nut on

the left side.

b. Hold the pivot shaft (Figure 24) on the right

side and tighten the nut to the specification in

Table 1.

c. Install a new cotter pin (Figure 23) and bend

8. On the right side, install the muffler support

the ends over completely (Figure 45).

bracket (A, Figure 22) and bolts. Tighten the bolts

4B. On 2000-on models, perform the following:

securely.

9. Move both shock absorbers down into position

a. Install the pivot shaft (B, Figure 22) from the

and install the acorn nut and washer (A, Figure 21).

right side. Install the bolt and lockwasher (B,

Tighten the nuts to the specification in Table 1.

Figure 20) on the left side.

10. Install the left side rear footpeg and mounting

b. Hold onto the hex fitting on the end of the

bracket assembly (A, Figure 20) and bolts. Tighten

pivot shaft on the right side and tighten the

the bolts securely.

bolt to the specification in Table 1.

11. On 1999 models, slide the rear brake caliper

5. Grasp the swing arm by hand and swing it up and

onto the swing arm mounting boss as described in

down. The swing arm must move without binding

Chapter Twelve.

or excessive bearing play.

12. Install the rear wheel (B, Figure 19) as de-

scribed in Chapter Nine.

6. Install the rear brake hose and clamps securing it

13. Install the drive belt upper guard (A, Figure

to the swing arm.

19) and tighten the bolts and nuts securely.

7. On the right side, install the pivot shaft chrome

14. Install the exhaust system as described in

cap (B, Figure 22) onto the swing arm.

Chapter Seven.

Table 1 REAR SUSPENSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Shock absorber upper

and lower nuts

25-40

34-54

Swing arm pivot bolt

Nut 1999 models

Bolt 2000 and later

45-50

61-68

Swing arm debris

deflector screws

40-60

4-7

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CHAPTER TWELVE

BRAKES

This chapter describes repair and replacement

pletely different types of brake fluid,

procedures for all brake components.

doing so will lead to brake component

damage and possible brake failure.

Table 1 contains brake system specifications and

Table 2 contains the brake system torque specifica-

WARNING

tions. Table 1 and Table 2 are located at the end of

Do not intermix DOT 3, DOT 4, or

this chapter.

DOT 5.1 brake fluids, as they are not

silicone-based. Use of non-silicone

BRAKE SERVICE

brake fluid in the Dyna Glide can

cause brake failure.

WARNING

Do not use brake fluid labeled DOT

WARNING

5.1. This is a glycol-based fluid that is

When working on the brake system,

not compatible with silicone based

do not inhale brake dust. It may con-

DOT 5. DOT 5 brake fluid is purple

tain asbestos, which is a known car-

while DOT 5.1

is an amber/clear

cinogen. Do not use compressed air to

color. Do not intermix these two com-

blow off brake dust. Use an aerosol

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450

CHAPTER TWELVE

brake cleaner. Wear a facemask and

wash thoroughly after completing the

work.

The disc brake system transmits hydraulic pres-

sure from the master cylinders to the brake calipers.

This pressure is transmitted from the caliper(s) to

the brake pads, which grip both sides of the brake

disc(s) and slow the motorcycle. As the pads wear,

the pistons move out of the caliper bores to auto-

matically compensate for wear. As this occurs, the

fluid level in the reservoir goes down. This must be

compensated for by occasionally adding fluid.

The proper operation of this system depends on a

supply of clean brake fluid (DOT 5) and a clean

work environment when any service is being per-

formed. Any tiny particle of debris that enters the

system can damage the components and cause poor

brake performance.

Brake fluid is hygroscopic (easily absorbs mois-

ture) and moisture in the system will reduce brake

performance. It is a good idea to purchase brake

fluid in small containers and discard any small

quantities that remain. Small quantities of fluid will

quickly absorb the moisture in the container. Use

only fluid clearly marked DOT 5. If possible, use

the same brand of fluid. Do not replace the fluid

with a non-silicone fluid. It is not possible to re-

move all of the old fluid. Other types are not com-

patible with DOT 5. Do not reuse drained fluid and

discard old fluid properly. Do not combine brake

fluid with fluids for recycling.

Proper service also includes carefully performed

procedures. Do not use any sharp tools inside the

master cylinders or calipers or on the pistons. Any

damage to these components could cause a loss in

the system’s ability to maintain hydraulic pressure.

If there is any doubt about having the ability to cor-

rectly and safely service the brake system, have a

Do not

allow

brake

fluid

contact

plastic,

professional technician perform the task.

painted or plated parts. It will damage the surface.

Consider the following when servicing the brake

5. Dispose of brake fluid properly.

system:

6. If the hydraulic system has been opened (not in-

1. The hydraulic components rarely require disas-

cluding the reservoir cover) the system must be bled

sembly. Make sure it is necessary.

to remove air from the system. Refer to Bleeding the

2. Keep the reservoir covers in place to prevent the

System in this chapter.

entry of moisture and debris.

7. The manufacturer does not provide wear limit

3. Clean parts with an aerosol brake part cleaner or

specifications for the caliper and master cylinder as-

isopropyl alcohol. Never use petroleum-based sol-

semblies. Use good judgment when inspecting

vents on internal brake system components. They

these components or consult a professional techni-

will cause seals to swell and distort.

cian for advice.

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BRAKES

451

1. Read the information under Brake Service in this

chapter.

2. Park the motorcycle on a level surface.

3. To prevent the front brake lever from being ap-

plied, place a spacer between the brake lever and the

throttle grip and secure it in place. If the brake lever

is inadvertently squeezed, this will prevent the pis-

ton from being forced out of the cylinder.

4. Loosen the brake caliper upper mounting bolt

(A, Figure 1) and the lower mounting pin (B, Fig-

ure 1). Remove the upper mounting bolt, washer

and the lower mounting pin.

5. Slide the brake caliper off the brake disc.

NOTE

If the brake pads are going to be re-

used, mark them so they can be rein-

stalled in their original locations.

6. Remove the outboard pad, pad holder and spring

clip as an assembly (Figure 2).

7. Remove the screw (A, Figure 3) and the pad re-

tainer (B) securing the inner pad to the caliper.

8. Remove the inboard pad (Figure 4).

9. Push the outboard pad (A, Figure 5) free of the

spring clip (B, Figure 5) and remove it.

FRONT BRAKE PAD REPLACEMENT

10. Check the brake pads for wear or damage. Mea-

(1999 MODELS)

sure the thickness of the brake pad friction material.

Replace the brake pads if they are worn to the ser-

There is no recommended mileage interval for

vice limit listed in Table 1. On dual-disc models, re-

changing the brake pads. Pad wear depends greatly

place both pad sets at the same time.

on riding habits and conditions. Frequently check

11. Check the friction surface of the new pads for

the pads for wear. After removal, measure the thick-

any debris or manufacturing residue. If necessary,

ness of each brake pad with a vernier caliper or ruler

clean off with an aerosol brake cleaner.

and compare to the dimensions in Table 1.

To maintain even brake pressure on the disc, al-

NOTE

ways replace both pads in the caliper at the same

When purchasing new pads, check

with the dealer to make sure the fric-

time. Also, on dual-disc models, replace both brake

tion compound of the new pad is com-

pads in both calipers at the same time. Do not dis-

patible with the disc material.

connect the hydraulic brake hose from the brake

Remove any roughness from the backs

caliper for brake pad replacement. Disconnect the

of the new pads with a fine-cut file,

hose only if the caliper assembly is going to be re-

then thoroughly clean them off.

moved.

12. Inspect the upper mounting bolt and the lower

CAUTION

mounting pin. Replace if damaged or badly cor-

Check the pads more frequently when

roded.

the lining approaches the pad metal

13. Replace the pad retainer if damaged.

backing plate. If pad wear happens to

be uneven for some reason, the back-

14. Check the piston dust boot (Figure 6) in the

ing plate may come in contact with the

caliper. Remove and overhaul the caliper if the boot

disc and cause damage.

is swollen or damaged, or if brake fluid is leaking

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452

CHAPTER TWELVE

from the caliper. Refer to Front Brake Caliper

(1999 Models) in this chapter.

15. Remove all corrosion from the pad holder.

16. Replace the spring clip if damaged or badly

corroded.

17. Check the brake disc for wear as described un-

der Brake Disc in this chapter. Service the brake

disc if necessary.

18. Assemble the pad holder, spring clip and out-

board brake pad as follows:

a. Lay the pad holder on a workbench so that the

upper mounting screw hole is positioned at

the upper right as shown in A, Figure 7.

b. Install the spring clip (B, Figure 7) at the top

of the pad holder so that the spring loop faces

in the direction shown in Figure 8.

c. The outboard brake pad has an insulator pad

mounted on its backside (A, Figure 5).

d. Center the outboard brake pad into the pad

holder so that the lower end of the pad rests

inside the pad holder. Push firmly on the up-

per end of the brake pad, past the spring clip

and into the holder (Figure 7).

19. After installing new brake pads, the caliper pis-

ton must be relocated into the caliper before install-

ing the caliper over the brake disc. Doing so will

force brake fluid back up into the reservoir. To pre-

vent the reservoir from overflowing, perform the

Spring clip

following:

a. Remove the screws (A, Figure 9) securing

Pad holder

the cover and remove the cover and dia-

phragm (B).

Pad

b. Use a large shop syringe and remove about 50

percent of the brake fluid from the reservoir.

This will prevent the master cylinder from

overflowing when the piston is pushed back

into the caliper bore. Do not drain more than

50 percent of the brake fluid or air will enter

the system. Discard the brake fluid.

CAUTION

Do not allow the master cylinder to

overflow when performing this step.

Slowly push the outer brake pad and piston

Wash brake fluid off any painted,

back into the caliper and watch the brake fluid

plated or plastic surfaces or plastic

level in the master cylinder reservoir. If nec-

parts immediately, as it will damage

essary, siphon off fluid prior to it overflow-

most surfaces it contacts. Use soapy

ing.

water and rinse completely.

Remove the old brake pad.

c. Install the old outer brake pad into the caliper

Temporarily install the diaphragm and cover.

and against the piston.

Install the screws finger-tight at this time.

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BRAKES

453

20. Install the inner brake pad into the caliper (Fig-

ure 4) from the inside surface. Push the pad into

place.

21. Install the pad retainer (B, Figure 3), onto the

backside of the caliper, indexing the tabs into the

caliper recesses.

22. Install the screw through the pad retainer and

into the backside of the inner brake pad. Tighten the

screw to the specification in Table 2.

WARNING

The bushings on the fork slider (Fig-

ure 10) locate the brake caliper on the

fork slider in relation to the brake

disc. The bushings must be in place as

noted in Step 23. If not installed, the

brake may lock up when applied and

cause a loss of motorcycle control.

23. If removed, install the caliper bushings into the

fork slider lugs (Figure 10).

24. Install the outer brake pad/pad holder assembly

(Figure 2) as follows:

WARNING

The spring clip loop and the brake

pad friction material (Figure 8) must

face away from the piston when the

pad holder is installed in the caliper.

Brake failure will occur if this assem-

bly is installed incorrectly.

a. Insert the outer brake pad/pad holder assem-

bly into the caliper so that the brake pad insu-

lator backing faces against the piston.

CAUTION

The brake caliper threaded bushing

shoulder (Figure 11) must be posi-

tioned as described in this step. Oth-

erwise, the pad holder rivet and

bushing will be damaged when the

caliper mounting screw and pin are

tightened.

b. Position the threaded bushing flange (Figure

11) with its shoulder between the pad holder

and the rivet head. Position the bushing so

that one notch engages the rivet (Figure 12).

25. Carefully install the caliper over the brake disc,

making sure the friction surface on each pad faces

against the disc.

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454

CHAPTER TWELVE

26. Coat the lower mounting pin shoulder (Figure

13) and O-ring with Dow Corning Moly 44 grease

or an equivalent prior to installation.

27. Align the caliper mounting holes with the fork

slider mounting lugs.

28. Install the brake caliper upper mounting bolt

and washer (A, Figure 1) through the fork slider

mounting lug and thread it into the caliper bushing.

Tighten the bolt finger-tight at this time.

29. Insert the lower mounting pin (B, Figure 1)

through the caliper and thread it into the slider

mounting lug. Tighten the mounting pin finger-tight

at this time.

30. First tighten the lower mounting pin, then the

upper mounting bolt, to the specification in Table 2.

31. On dual-disc models, repeat this procedure for

the other caliper assembly.

32. Refill the master cylinder reservoir with DOT 5

silicone-based brake fluid, if necessary, to maintain

the correct fluid level. Install the diaphragm, top

cover and tighten the screws to the specification in

Table 2.

33. Apply the front brake lever several times to seat

the pads against the disc.

CAUTION

WARNING

Check the pads more frequently when

Do not ride the motorcycle until the

the lining approaches the pad metal

front brakes operate correctly with

backing plate. If pad wear happens to

full hydraulic advantage. If neces-

be uneven for some reason, the back-

sary, bleed the brake as described in

ing plate may come in contact with the

this chapter.

disc and cause damage.

FRONT BRAKE PAD REPLACEMENT

Read the information under Brake Service in this

(2000-2001 MODELS)

chapter.

2. Park the motorcycle on level ground.

There is no recommended mileage interval for

3. Place a spacer between the brake lever and the

changing the brake pads. Pad wear depends greatly

throttle grip and secure it in place. If the brake lever

on riding habits and conditions. Frequently check

is inadvertently squeezed, this will prevent the pis-

the pads for wear. After removal, measure the thick-

tons from being forced out of the cylinders.

ness of each brake pad with a vernier caliper or ruler

4. Clean the top of the master cylinder of all debris.

and compare to the dimensions in Table 1.

5. Remove the screws (A, Figure 9) securing the

To maintain an even brake pressure on the disc,

cover. Remove the cover and diaphragm (B).

always replace both pads in the caliper at the same

time. Also, on dual-disc models, replace both brake

6. Use a shop syringe and remove about 50 percent

pads in both calipers at the same time. Do not dis-

of the brake fluid from the reservoir. This will pre-

connect the hydraulic brake hose from the brake

vent the master cylinder from overflowing when the

caliper for brake pad replacement. Disconnect the

pistons are compressed for reinstallation. Do not

hose only if the caliper assembly is going to be re-

drain more than 50 percent of the brake fluid or air

moved.

will enter the system. Discard the brake fluid.

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BRAKES

455

11. Check the brake pads for wear or damage. Mea-

sure the thickness of the brake pad friction material.

Replace the brake pads if they are worn to the ser-

vice limit listed in Table 1.

12. Carefully remove any rust or corrosion from

the disc.

13. Thoroughly clean the pad pin bolts of any cor-

rosion or road dirt.

14. Check the friction surface of the new pads for

any debris or manufacturing residue. If necessary,

clean off with an aerosol brake cleaner.

NOTE

When purchasing new pads, check

with the dealer to make sure the fric-

tion compound of the new pad is com-

patible with the disc material.

Remove any roughness from the backs

of the new pads with a fine-cut file;

then thoroughly clean off.

NOTE

The brake pads are not symmetrical.

The pad with two tabs (Figure 15)

must be installed on the outboard side

of the left side caliper and on the in-

board side of the right side caliper.

CAUTION

The pad with one tab (Figure 16)

Do not allow the master cylinder to

must be installed on the inboard side

overflow when performing Step

of the left side caliper and on the out-

Wash brake fluid off any painted,

board side of the right side caliper

plated or plastic surfaces immedi-

ately, as it will damage most surfaces

15. Install the inboard pad (Figure 16) and the out-

it contacts. Use soapy water and rinse

board pad (Figure 15) into the caliper.

completely.

16. Hold the pads in place and install the pad pin

Loosen the pad pin bolts (Figure 14).

bolts through the caliper and both brake pads (Fig-

ure 14).

CAUTION

17. Tighten the pad pins to the specification in Ta-

The brake disc is thin in order to dissi-

ble 2.

pate heat and therefore may bend eas-

18. On dual-disc models, repeat Steps 7-17 and re-

ily. When pushing against the disc in

the following step, support the disc

place the brake pads in the other caliper assembly.

adjacent to the caliper to prevent

19. Remove the spacer from the front brake lever.

damage to the disc.

20. Check to make sure there is sufficient brake fluid

in the master cylinder reservoir. Top off if necessary.

Hold the caliper body from the outside and push

21. Pump the front brake lever to reposition the

it toward the brake disc. This will push the outer pis-

brake pads against the brake disc. Roll the motorcy-

tons into the caliper bores to make room for the new

cle back and forth and continue to pump the brake

brake pads. Constantly check the reservoir to make

lever as many times as it takes to refill the cylinders

sure brake fluid does not overflow. Remove fluid, if

in the calipers and correctly locate the brake pads

necessary, prior to it overflowing. Install the dia-

against the disc.

phragm and cover. Tighten the screws finger-tight.

9. Remove the pad pin bolts.

NOTE

10. Remove the inboard and outboard brake pads

To control the flow of fluid, punch a

from the caliper.

small hole into the seal of a new con-

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456

CHAPTER TWELVE

FRONT BRAKE CALIPER (1999)

1. Screw

11. Lower mounting

2. Pad retainer

3. Brake pads

12. Spring clip

4. Retaining ring

13. Pin boot

5. Dust boot

14. Threaded

6. Piston

bushing

7. Piston seal

15. Pad holder

8. Body

16. Washer

9. Bleed valve

17. Upper mounting

10. O-ring

bolt

tainer of brake fluid next to the edge

can cause brake component damage

of the pour spout. This will help elimi-

leading to brake system failure.

nate fluid spillage, especially while

adding fluid to the very small reser-

22. Refill the master cylinder reservoir, if neces-

voir.

sary, to maintain the correct fluid level as indicated

on the side of the reservoir. Install the diaphragm

WARNING

and the top cover. Tighten the screws to the specifi-

Use brake fluid clearly marked DOT 5

from a sealed container. Other types

cation in Table 2.

may vaporize and cause brake failure.

Always use the same brand name; do

WARNING

not intermix, as many brands are not

Do not ride the motorcycle until the

compatible. Do not intermix DOT 3,

front brakes operate correctly with

DOT 4 or DOT 5.1 brake fluid, as it

full hydraulic advantage. If neces-

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BRAKES

457

Using the spacer block as mentioned

in the previous step can prevent this

from happening.

d. Support the caliper to the frame with a bungee

cord or piece of heavy wire.

Installation

(Caliper Was Not Disassembled)

WARNING

The bushings on the fork slider (Fig-

ure 10) locate the brake caliper on the

sary, bleed the brake as described in

fork slider in relation to the brake

this chapter.

disc. The bushings must be in place as

noted in Step 1. If not installed, the

brake may lock up when applied and

FRONT BRAKE CALIPER

cause loss of control.

(1999 MODELS)

1. If removed, install the caliper bushings into the

Removal

fork slider lugs (Figure 10).

(Caliper Will Not Be Disassembled)

2. If removed, install the brake pads as described in

this chapter.

Refer to Figure 17.

3. Carefully install the caliper over the brake disc,

To remove the brake caliper without disassem-

making sure the friction surface on each pad faces

bling it, perform this procedure. To disassemble the

against the disc.

brake caliper, refer to Caliper Removal/Piston Re-

4. Coat the lower mounting pin shoulder (Figure

moval in this chapter.

13) and O-ring with Dow Corning Moly 44 grease

1A. To remove the brake caliper from the motorcy-

or an equivalent prior to installation.

cle, perform the following:

5. Align the caliper’s two mounting holes with the

a. Loosen and remove the banjo bolt at the cali-

fork slider mounting lugs.

per (A, Figure 18). Remove the bolt and the 2

6. Install the brake caliper upper mounting bolt and

washers.

washer (A, Figure 1) through the fork slider mount-

b. Remove the upper mounting bolt and washer

ing lug and thread it into the caliper bushing.

(B, Figure 18) and the lower mounting pin

Tighten the bolt finger-tight at this time.

(C).

7. Insert the lower mounting pin (B, Figure 1)

c. Lift the brake caliper off the brake disc and re-

through the caliper and thread it into the slider

move it.

mounting lug. Tighten the mounting pin finger-tight

1B. To remove the brake caliper partially from the

at this time.

motorcycle (brake hose will not be disconnected),

8. First tighten the lower mounting pin, then the

perform the following:

upper mounting bolt, to the specification in Table 2.

a. Remove the upper mounting screw and

washer (B, Figure 18) and the lower mount-

NOTE

ing pin (C).

Install new steel/rubber banjo bolt

b. Lift the brake caliper off the brake disc.

washers in Step 9.

c. Insert a wooden or plastic spacer block be-

9. If removed, assemble the brake line onto the cal-

tween the brake pads in the caliper.

iper with a new washer on both sides of the brake

line fitting, then secure the fitting to the caliper with

NOTE

Squeezing the brake lever with the

the banjo bolt (A, Figure 18). Tighten the banjo bolt

caliper removed from the brake disc

to the specification in Table 2. Make sure the fitting

will force the piston out of its bore.

seats against the caliper as shown in A, Figure 18.

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458

CHAPTER TWELVE

10. On dual-disc models, if necessary, repeat this

procedure for the other caliper assembly.

11. Refill the master cylinder reservoir with DOT 5

silicone-based brake fluid, if necessary, to maintain

the correct fluid level. Install the diaphragm, top

cover and tighten the screws to the specification in

Table 2.

12. Apply the front brake lever several times to seat

the pads against the disc.

WARNING

Do not ride the motorcycle until the

front brakes operate correctly with

full hydraulic advantage. If neces-

sary, bleed the brake as described in

this chapter.

Caliper Removal/Piston Removal

(Caliper Will Be Disassembled)

Force is required to remove the piston from the

caliper. This procedure describes how to remove

the piston with the caliper connected to the brake

hose.

1. Remove the brake pads as described in this chap-

ter.

2. Insert a small screwdriver into the notched

groove machined in the bottom of the piston bore

(Figure 19). Then pry the retaining ring (Figure 20)

out of the caliper body.

3. Wrap a large cloth around the brake caliper.

4. Hold the caliper by hand away from the pis-

ton/brake pad area.

5. Operate the front brake lever to force the piston

part way out of the caliper. Do not completely re-

move the piston until after it is removed for disas-

Wooden block

Air hose

sembly. Leaving the piston partially in the bore

Rag

Caliper

prevents brake fluid from spilling out.

Piston

NOTE

If the piston did not come out, remove

Disassembly

it as described under Disassembly in

this section.

Service specifications for the caliper components

are not available. Replace any worn, damaged or

6. Remove the caliper banjo bolt (A, Figure 18)

questionable part.

and washers. Seal the brake hose to prevent brake

fluid from dripping out.

Refer to Figure 17.

7. Place the caliper on a workbench for disassem-

1. Partially remove the piston from the caliper as

bly.

described under Caliper Removal/Piston Removal

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BRAKES

459

(Caliper Will Be Disassembled) in the previous pro-

cedure.

WARNING

Compressed air will force the piston

out of the caliper under considerable

force. Do not block the piston by

hand, as injury will result.

2. If the piston did not come partially out of the cal-

iper bore, perform the following:

a. Place a rag and a piece of wood in the caliper

(Figure 21). Keep fingers out of the way of

the piston.

b. Apply compressed air through the brake

hose port and force the piston out of the cali-

per.

3. Remove the piston and dust boot assembly (Fig-

ure 22).

4. Remove the piston seal (Figure 23) from the

groove in the caliper body.

5. Pull the threaded bushing out of the caliper, then

remove the pin boot (Figure 24).

6. Remove the three O-rings from the caliper body

(Figure 25).

Inspection

1. Clean the caliper body and piston in clean DOT

5 brake fluid or isopropyl alcohol and dry with com-

pressed air.

2. Make sure the fluid passageway in the base of

the piston bore is clear. Apply compressed air to the

opening to make sure it is clear. Clean out, if neces-

sary, with clean brake fluid.

3. Inspect the piston seal groove in the caliper body

for damage. If damaged or corroded, replace the

caliper assembly.

4. Inspect the banjo bolt threaded hole in the cali-

per body. If worn or damaged, clean out with a met-

ric thread tap or replace the caliper assembly.

5. Inspect the bleed screw threaded hole in the cali-

per body. If worn or damaged, clean out with a met-

ric thread tap or replace the caliper assembly.

6. Inspect the bleed screw. Apply compressed air

to the opening and make sure it is clear. Clean out

if necessary with clean brake fluid. Install the

bleed screw and tighten to the specification in Ta-

ble 2.

7. Inspect the caliper body for damage.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 23