Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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CHAPTER TWELVE

8. Inspect the cylinder wall and piston (Figure 26)

for scratches, scoring or other damage.

Assembly

1. The following parts are included in a H-D re-

build kit (part No. 44020-83): piston seal (A, Fig-

ure 27), piston (B), dust boot (C) and retaining ring

(D).

NOTE

Never reuse an old dust boot or piston

seal. Very minor damage or age dete-

rioration can make the boot and seal

useless.

2. Soak the new dust and piston seal in clean DOT5

brake fluid.

3. Carefully install the new piston seal into the

groove. Make sure the seal is properly seated in its

groove.

4. Install new O-rings into the caliper grooves.

5. Wipe the inside of the pin boot with Dow

Corning MOLY 44 grease. Then insert the boot into

the bushing bore with the boots flange end seating

in the bore groove (Figure 28).

6. Insert the threaded bushing into the boot (Figure

29).

7. Install the piston dust boot on the piston before

the piston is installed in the caliper bore. Perform

the following:

a. Place the piston on the workbench with its

open side facing up.

b. Align the piston dust boot with the piston so

that the shoulder on the dust boot faces up.

c. Slide the piston dust boot onto the piston until

the inner lip on the dust boot seats in the pis-

ton groove (Figure 22).

8. Coat the piston and the caliper bore with DOT 5

brake fluid.

9. Align the piston with the caliper bore so that its

open end faces out (Figure 22). Then push the pis-

ton in until it bottoms.

10. Seat the piston dust boot (Figure 30) into the

caliper bore.

11. Locate the retaining ring groove in the top end

of the caliper bore. Align the retaining ring so that

its gap (Figure 31) is at the top of the caliper bore

and install the ring into the ring groove. Make sure

the retaining ring is correctly seated in the groove.

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BRAKES

461

15. Bleed the brake as described under Bleeding

the System in this chapter.

FRONT BRAKE CALIPER

(2000-ON MODELS)

Removal/Installation

CAUTION

Do not spill any brake fluid on the

front fork or front wheel. Wash brake

fluid off any painted, plated or plastic

surfaces or plastic parts immediately,

as it will destroy most surfaces it con-

tacts. Use soapy water and rinse com-

pletely.

Align gap with top of caliper bore

1. If the caliper assembly is going to be disassem-

bled for service, perform the following:

NOTE

By performing Steps 1a and 1b, com-

pressed air may not be necessary for

Retaining

piston removal during caliper disas-

ring

sembly.

a. Remove the brake pads as described in this

chapter.

CAUTION

Do not allow the pistons to travel out

far enough to come in contact with the

brake disc. If this happens, the pistons

may scratch or gouge the disc during

caliper removal.

b. Slowly apply the brake lever to push the pis-

tons part way out of the caliper assembly for

ease of removal during caliper service.

c. Loosen the two body mounting bolts (A, Fig-

ure 32).

d. Loosen the brake hose banjo bolt (B, Figure

32).

2. Remove the banjo bolt and sealing washers (B,

Figure 32) attaching the brake hose to the caliper

12. Apply a light coat of Dow Corning MOLY 44

assembly. Do not lose the sealing washer on each

grease to the caliper mounting lug bores.

side of the hose fitting(s).

13. If removed, install the bleed screw assembly

3. Place the loose end of the brake hose in a

and tighten to the specification in Table 2.

reclosable plastic bag to prevent the entry of foreign

14. Install the caliper and brake pads as described

matter and prevent any residual brake fluid from

in this chapter.

leaking out.

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462

CHAPTER TWELVE

4. Remove the bolts (Figure 33) securing the brake

caliper assembly to the front fork and remove the

caliper.

5. If necessary, disassemble and service the caliper

assembly as described in this chapter.

6. Install by reversing these removal steps while

noting the following:

a. Carefully install the caliper assembly onto the

disc, being careful not to damage the leading

edge of the brake pads.

b. Install the bolts

(Figure 33) securing the

brake caliper assembly to the front fork and

tighten to the specifications in Table 2.

4. Place a piece of soft wood or folded shop cloth

c. Apply clean DOT 5 brake fluid to the rubber

over the end of the pistons and the caliper body.

portions of the new sealing washers prior to

Turn this assembly over with the pistons facing

installation.

down.

d. Install a new sealing washer on each side of

5. Perform this step over and close to a workbench

the brake hose fitting and install the banjo

top.

bolt (B, Figure 32). Tighten the banjo bolt to

the specification in Table 2.

WARNING

Compressed air will force the pistons

e. Bleed the brake as described under Bleeding

out of the caliper bodies under con-

the System in this chapter.

siderable force. Do not block the pis-

ton by hand, as injury will result.

WARNING

Do not ride the motorcycle until the

6. Apply the air pressure in short spurts to the hy-

front brakes operate correctly with

draulic fluid passageway and force out the pistons.

full hydraulic advantage. If neces-

Repeat for the other caliper body half. Use a service

sary, bleed the brake as described in

this chapter.

station air hose if compressed air is not available.

CAUTION

Disassembly

In the following step, do not use a

sharp tool to remove the dust and pis-

ton seals from the caliper cylinders.

Refer to Figure 34.

Do not damage the cylinder surface.

1. Remove the caliper and brake pads as described

in this chapter.

7. Use a piece of wood or plastic scraper and care-

2. Remove the two caliper body bolts (Figure 35)

fully push the dust seal and the piston seal (Figure

loosened during the removal procedure.

37) in toward the caliper cylinder and out of their

3. Separate the caliper body halves. Remove the

grooves. Remove the dust and piston seals.

O-ring seals (Figure 36). New O-ring seals must be

8. If necessary, unscrew and remove the bleed

installed every time the caliper is disassembled.

valve (A, Figure 38).

9. Inspect the caliper assembly as described in this

NOTE

section.

If the pistons were partially forced out

of the caliper body during removal,

steps 4-6 may not be necessary. If the

Inspection

pistons or caliper bores are corroded

or very dirty, a small amount of com-

pressed air may be necessary to com-

1. Clean both caliper body halves and pistons in

pletely remove the pistons from the

clean DOT 5 brake fluid or isopropyl alcohol and

body bores.

dry with compressed air.

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464

CHAPTER TWELVE

2. Make sure the fluid passageways (Figure 39) in

the piston bores are clear. Apply compressed air to

the openings to make sure they are clear. Clean out,

if necessary, with clean brake fluid.

3. Make sure the fluid passageways (A, Figure 40)

in both caliper body halves are clear. Apply com-

pressed air to the openings to make sure they are

clear. Clean out, if necessary, with clean brake fluid.

4. Inspect the piston and dust seal grooves (Figure

41) in both caliper bodies for damage. If damaged

or corroded, replace the caliper assembly.

5. Inspect the banjo bolt threaded hole (B, Figure

38) in the outboard caliper body. If worn or dam-

aged, clean out with a metric thread tap or replace

the caliper assembly.

6. Inspect the bleed valve threaded hole in the cali-

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

ric thread tap or replace the caliper assembly.

7. Inspect the bleed valve. 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 Table 2.

8. Inspect both caliper bodies for damage. Check

the inboard caliper mounting bolt hole threads (B,

Figure 40) for wear or damage. Clean up with an

appropriately sized metric tap or replace the caliper

assembly.

9. Inspect the cylinder walls and pistons for

scratches, scoring or other damage.

10. Check the anti-rattle spring (Figure 42) for

wear or damage.

Assembly

NOTE

Never reuse old dust seals or piston

seals. Very minor damage or age dete-

rioration can make the seals useless.

1. Soak the new dust and piston seals in clean

DOT5 brake fluid.

2. Coat the piston bores and pistons with clean

DOT5 brake fluid.

3. Carefully install the new piston seals into the

lower grooves. Make sure the seals are properly

seated in their respective grooves.

4. Carefully install the new dust seals into the up-

per grooves. Make sure all seals are properly seated

in their respective grooves (Figure 43).

5. Repeat Step 3 and Step 4 for the other caliper

body half.

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BRAKES

465

6. Position the pistons with the open end facing out

and install the pistons into the caliper cylinders (A,

Figure 44). Push the pistons in until they bottom (B,

Figure 44).

7. Repeat Step 6 for the other caliper body half.

Make sure all pistons are installed correctly.

8. Coat the new O-ring seals in DOT5 brake fluid

and install the O-rings (Figure 36) into the inboard

caliper half.

9. Install the anti-rattle spring (Figure 45) onto the

boss on the outboard caliper half.

10. Make sure the O-rings are still in place and as-

semble the caliper body halves.

11. Install one of the caliper mounting bolts

through the upper hole (A, Figure 46) to correctly

align the caliper halves.

12. Install the two caliper body bolts (B, Figure

46) and tighten securely. They will be tightened to

the specification after the caliper is installed on the

front fork.

13. If removed, install the bleed valve assembly

and tighten to the specification in Table 2.

14. Install the caliper and brake pads as described

in this chapter.

15. Tighten the two caliper body mounting bolts

(A, Figure 32) to the specification in Table 2.

16. Bleed the brake as described under Bleeding

the System in this chapter.

FRONT MASTER CYLINDER

Removal

CAUTION

Cover the fuel tank and front fairing

with a heavy cloth or plastic tarp to

protect them from accidental brake

fluid spills. Wash brake fluid off any

painted, plated or plastic surfaces im-

mediately, as it will damage most sur-

faces it contacts. Use soapy water and

rinse completely.

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

2. Remove the screws (A, Figure 47) securing the

top cover.

3. Remove the top cover (B, Figure 47) and dia-

phragm from the master cylinder reservoir.

4. Use a shop syringe and draw all of the brake

fluid out of the master cylinder reservoir. Tempo-

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466

CHAPTER TWELVE

rarily reinstall the diaphragm and the cover. Tighten

the screws finger-tight.

5. On models so equipped, remove the windshield

or front fairing.

6. Loosen and remove the mirror (A, Figure 48)

from the master cylinder.

7. On models so equipped, remove the front turn

signal assembly (B, Figure 48) from the master cyl-

inder.

CAUTION

Failure to install the spacer in Step 8

will result in damage to the rubber

boot and plunger on the front brake

switch.

8. Insert a 5/32 in. (4 mm) thick spacer (A, Figure

49) between the brake lever and lever bracket.

Make sure the spacer stays in place during the fol-

lowing steps.

9. Remove the banjo bolt and sealing washers (B,

Figure 49) securing the brake hose to the master

cylinder.

10. Place the loose end of the brake hose in a

reclosable plastic bag to prevent the entry of mois-

ture and debris. Tie the loose end of the hose up to

the handlebar.

11. Remove the screw securing the right side

switch together and separate the switch (A, Figure

50).

12. Remove the T27 Torx bolts and washers (B,

Figure 50) securing the clamp and master cylinder

to the handlebar.

13. Remove the master cylinder assembly (C, Fig-

ure 49) from the handlebar.

14. Drain any residual brake fluid from the master

cylinder and dispose of properly.

15. If the master cylinder assembly is not going to

be serviced, reinstall the clamp and Torx bolts to the

master cylinder. Place the assembly in a reclosable

plastic bag to protect it from foreign matter.

Installation

1. If not in place, insert the 5/32 in. (4 mm) thick

spacer (A, Figure 49) between the brake lever and

lever bracket. Make sure the spacer stays in place

during the following steps.

2. Position the front master cylinder onto the han-

dlebar. Align the master cylinder notch (A, Figure

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BRAKES

467

(B, Figure

53) into place. Install the switch’s

clamping screw and tighten securely.

4. Position the clamp and install the clamping Torx

bolts and washers (B, Figure 50). Tighten the upper

mounting bolt first, then the lower bolt. Tighten the

bolts to the specification in Table 2.

5. Apply clean DOT 5 brake fluid to the rubber por-

tions of the new sealing washers prior to installa-

tion.

6. Install new sealing washers and the banjo bolt

(B, Figure 49) securing the brake hose to the master

cylinder. Tighten the banjo bolt to the specification

in Table 2.

7. Remove the spacer (A, Figure 49) from the

brake lever.

8. On models so equipped, install the front turn sig-

nal assembly (B, Figure 48) onto the master cylin-

der. Aim the lens in the same direction as the one on

the left side.

9. Install the mirror (A, Figure 48) onto the master

cylinder. Correctly adjust the mirror.

10. On models so equipped, install the windshield

or front fairing.

11. Temporarily install the diaphragm and top

cover (B, Figure 47) onto the reservoir. Tighten the

screws finger-tight at this time.

12. Refill the master cylinder reservoir and bleed

the brake system as described under Bleeding the

System in this chapter.

Disassembly

Refer to Figure 54.

1. Store the master cylinder components in a di-

vided container, such as a restaurant-size egg car-

ton, to help maintain their correct alignment

position.

2. If still in place, remove the screws securing the

51) with the

locating

tab

(B,

Figure

51) on the

top cover. Remove the top cover and the diaphragm

lower portion of the right side switch.

from the master cylinder.

3. Remove the master cylinder assembly as de-

CAUTION

scribed in this chapter.

Do not damage the front brake light

4. Remove the snap ring (A, Figure 55) and pivot

switch and rubber boot (Figure 52)

pin securing the hand lever to the master cylinder.

when installing the master cylinder in

Remove the hand lever (B, Figure 55).

Step 3.

5. Remove the retainer (A, Figure 56) and the rub-

ber boot (B, Figure 56) from the area where the

3. Push the master cylinder all the way onto the

hand lever actuates the piston assembly.

handlebar (A, Figure 53), hold it in this position

6. Remove the piston assembly (Figure 57) and the

and install the upper portion of the right side switch

spring.

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468

CHAPTER TWELVE

FRONT MASTER CYLINDER

1. Screw

2. Sight glass

3. Top cover

4. Diaphragm

5. Pivot pin

6. T27 Torx screw

7. Washer

8. Clamp

9. Body

10. Piston assembly

11. Bushing

12. Hand lever

13. Snap ring

14. Washer

15. Acorn nut

7. Inspect all parts as described in this section.

Inspection

Replace worn or damage parts as described in this

section. It is recommended that a new piston kit as-

sembly be installed every time the master cylinder

is disassembled.

1. Clean all parts in isopropyl alcohol or clean

DOT5 brake fluid. Inspect the body cylinder bore

surface for signs of wear and damage. If less than

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BRAKES

469

perfect, replace the master cylinder assembly. The

body cannot be replaced separately.

2. Inspect the piston cup (A, Figure 58) and O-ring

(B) for signs of wear and damage.

3. Make sure the fluid passage (Figure 59) in the

bottom of the master cylinder reservoir is clear.

Clean out if necessary.

4. Inspect the piston contact surface for signs of

wear and damage.

5. Check the end of the piston (C, Figure 58) for

wear caused by the hand lever.

6. Check the hand lever pivot lugs in the master

cylinder body for cracks or elongation.

7. Inspect the hand lever pivot hole and bushing (A,

Figure 60) and the pivot pin (B) for wear, cracks or

elongation.

8. Inspect the piston cap and retainer (Figure 61)

for wear or damage.

9. Inspect the threads in the bore for the banjo bolt.

If worn or damaged, clean out with a thread tap or

replace the master cylinder assembly.

10. Check the top cover and diaphragm for damage

and deterioration.

11. If necessary, separate the cover from the dia-

phragm as follows:

a. Pull straight up on the sight glass (Figure 62)

and remove it from the cover and diaphragm.

b. Separate the diaphragm from the cover.

c. The trim plate may separate from the cover.

Assembly

NOTE

If installing a new piston assembly,

coat all parts with the lubricant pro-

vided in the new H-D parts kit instead

of using DOT5 brake fluid. If install-

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470

CHAPTER TWELVE

ing existing parts, coat them with

DOT5 brake fluid.

NOTE

Be sure to purchase the correct new

piston parts kit for the specific motor-

cycle being worked on. The piston

bore diameter is larger on models

equipped with dual front discs. The

parts for the two different master cyl-

inders are not interchangeable.

NOTE

The cover and diaphragm must be as-

sembled as follows. If the sight glass

is not installed correctly through the

cover and diaphragm neck, brake

fluid will leak past these components.

1. If disassembled, assemble the cover and the dia-

phragm as follows:

a. If removed, install the trim plate (Figure 63)

onto the cover.

b. Insert the neck of the diaphragm into the

cover. Press it in until it seats correctly and the

outer edges are aligned with the cover.

c. Push the sight glass

(Figure

62) straight

down through the cover and the neck of the

diaphragm (Figure 64) until it snaps into

place. The sight glass must lock these two

parts together to avoid a brake fluid leak.

2. Soak the new cup and O-ring and piston assem-

bly in clean DOT5 brake fluid for at least 15 min-

utes to make them pliable. Coat the inside of the

cylinder bore with clean brake fluid prior to the as-

sembly of parts.

CAUTION

When installing the piston assembly,

do not allow the cup to turn inside out

as it will be damaged and allow brake

fluid leakage within the cylinder bore.

3A. On 1999 and 2000 models, position the flared

end of the spring so it enters the master cylinder first.

3B. On 2001 models, position the metal tab end of the

spring (Figure 65) so it enters the master cylinder first.

4. Install the spring and piston assembly into the

cylinder (Figure 66). Push them in until they bot-

tom in the cylinder (Figure 57).

5. Position the retainer with the flat side going on

first and install the piston cap and retainer onto the

piston end.

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471

REAR BRAKE PAD REPLACEMENT

(1999 MODELS)

There is no recommended mileage interval for

changing the brake pads. Pad wear depends greatly

on riding habits and conditions. Frequently check

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

ness of each brake pad with a vernier caliper or ruler

and compare to the dimensions in Table 1.

To maintain an even brake pressure on the disc, al-

ways replace both pads in the caliper at the same time.

CAUTION

Check the pads more frequently when

the lining approaches the pad metal

backing plate. If pad wear happens to

be uneven for some reason, the back-

ing plate may come in contact with the

disc and cause damage.

1. Read the Brake Service information in this chapter.

2. Park the motorcycle on level ground.

3. Tie the end of the brake pedal up to the frame. If

the brake pedal is inadvertently applied, this will pre-

vent the piston from being forced out of the cylinder.

4. On models so equipped, remove the right side

saddlebag.

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

6. Remove the screws securing the cover (Figure

68) and remove the cover and diaphragm.

7. Use a shop syringe and remove about 50 percent

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

vent the master cylinder from overflowing when the

pistons are compressed for reinstallation. 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

Push down on the piston cap (Figure 67), hold it

overflow when performing Step

there and press the retainer down until it correctly

Wash brake fluid off any painted,

plated or plastic surfaces immedi-

seats in the cylinder groove (A, Figure 56).

ately, as it will damage most surfaces

7. Make sure the bushing is in place in the hand le-

it contacts. Use soapy water and rinse

ver pivot area.

completely.

8. Install the hand lever (B, Figure 55) into the

master cylinder, install the pivot pin and secure it

8. Loosen both pad pin bolts (A, Figure 69).

with the snap ring. Make sure the snap ring is cor-

rectly seated in the pivot pin groove (A, Figure 55).

CAUTION

9. Slowly apply the lever to make sure it pivots freely.

The brake disc is thin and easily dam-

10. Install the master cylinder as described in this

aged. When pushing against the disc

chapter.

in the following step, support the disc

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472

CHAPTER TWELVE

adjacent to the caliper to prevent

damage.

9. Hold the caliper body from the outside and push

it toward the brake disc. This will push the piston

into the caliper bore to make room for the new brake

pads. Constantly check the reservoir to make sure

brake fluid does not overflow. Remove fluid, if nec-

essary, prior to it overflowing. Install the diaphragm

and cover. Tighten the screws finger-tight.

10. Remove the two caliper pin bolts (A, Figure

69) and lift the caliper (B, Figure 69) off the mount-

ing bracket. Do not disconnect the brake hose from

the caliper. Support the caliper with a piece of heavy

wire.

11. Lift and then pull the retainer clip (Figure 70)

over the mounting bracket and remove it.

NOTE

If the pads are to be reused, mark

them so they will be reinstalled in

their original locations.

12. Slide the outboard brake pad (A, Figure 71) off

the mounting bracket.

13. Slide the inboard brake pad (B, Figure 71) to-

ward the wheel and off the mounting bracket.

14. Remove both pad shims (Figure 72) from the

mounting bracket.

15. 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. Replace both pads as a

set.

16. Clean the pad shims and check for cracks or

damage.

17. Clean the pad shim mounting areas on the

mounting bracket.

18. Check the retainer clip for rust, cracks or other

damage.

19. Inspect the caliper pin bolts for cracks, corro-

sion or other damage. Replace if necessary.

20. Check the piston dust boot (Figure 73) for

damage. Remove and overhaul the caliper if the

boot is swollen or damaged or if brake fluid is leak-

ing from the caliper. Refer to Rear Brake Caliper

(1999 Models) in this chapter.

21. Check the brake disc for wear.

22. Install the pad shims so that their retaining

loops face against the outer caliper mounting

bracket rails, as shown in Figure 72.

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BRAKES

473

26. Insert the retainer clip into the two large holes

(Figure 76) in the back of the caliper mounting

bracket. Then swing the retainer clip over the top of

the brake pads and snap it in place against the outer

brake pad (Figure 70).

CAUTION

The brake pads must seat against both

pad shims evenly (Figure 70). If not,

the rear brake will drag, causing un-

even pad wear and caliper bracket

damage.

NOTE

When installing the caliper over the

brake pads, do not dislodge the brake

pads and pad shims.

27. Slide the caliper (B, Figure 69) over the brake

pads. Install the two pad pin bolts (A, Figure 69)

and tighten to the specificationin Table 2.

28. Check to make sure there is sufficient brake

fluid in the master cylinder reservoir. Top off if nec-

essary.

29. Untie the brake pedal from the frame and pump

the rear brake pedal to reposition the brake pads

against the brake disc. Roll the motorcycle back and

forth and continue to pump the brake pedal as many

times as it takes to refill the cylinder in the caliper

and correctly locate the brake pads against the disc.

NOTE

To control the flow of hydraulic fluid,

punch a small hole into the seal of a

new container of hydraulic (brake)

fluid next to the edge of the pour

spout. This will help eliminate fluid

spillage, especially while adding fluid

to the very small reservoir.

WARNING

23. Slide the outboard brake pad (Figure

74) over

Use brake fluid clearly marked DOT 5

the pad shims and against the outer brake disc sur-

from a sealed container. Other types

may vaporize and cause brake failure.

face.

Always use the same brand name; do

24. Slide the inboard brake pad (Figure 75) over the

not intermix, as many brands are not

pad shims and against the inner brake disc surface.

compatible. Do not intermix DOT 3,

25. Check that the pad shims did not move out of

DOT4 or DOT5.1 brake fluid, as it

position.

can cause brake component damage,

leading to brake system failure.

NOTE

Figure 76 shows the caliper mounting

30. Refill the master cylinder reservoir, if neces-

bracket removed to better illustrate

sary, to maintain the correct fluid level as indicated

the step.

on the side of the reservoir. Install the diaphragm

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474

CHAPTER TWELVE

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

cation in Table 2.

WARNING

Do not ride the motorcycle until the

rear brake is operating correctly with

full hydraulic advantage. If neces-

sary, bleed the brake as described in

this chapter.

31. On models so equipped, install the right side

saddlebag.

REAR BRAKE PAD REPLACEMENT

(2000-2001 MODELS)

There is no recommended mileage interval for

changing the brake pads. Pad wear depends greatly

on riding habits and conditions. Frequently check

the pads for wear. Increase the inspection interval

when the wear indicator reaches the edge of the

brake disc. After removal, measure the thickness of

each brake pad with a vernier caliper or ruler and

compare to the dimensions listed in Table 1.

To maintain an even brake pressure on the disc,

always replace both pads in the caliper at the same

time. Do not disconnect the hydraulic brake hose

pistons

are

compressed for reinstallation.

Do not

from the brake caliper for brake pad replacement,

drain more than 50 percent of the brake fluid or air

disconnect the hose only if the caliper assembly is

will enter the system. Discard the brake fluid.

going to be removed.

CAUTION

Do not allow the master cylinder to

Check the pads more frequently when

overflow when performing Step

the lining approaches the pad metal

Wash brake fluid off any painted,

backing plate. If pad wear happens to

plated or plastic surfaces immedi-

be uneven for some reason, the back-

ately, as it will damage most surfaces

ing plate may come in contact with the

it contacts. Use soapy water and rinse

disc and cause damage.

completely.

1. Read the Brake Service section in this chapter.

8. Loosen the pad pin bolts (Figure 77).

2. Park the motorcycle on level ground.

3. Tie the end of the brake pedal to the frame. If the

CAUTION

The brake disc is thin and easily dam-

brake pedal is inadvertently applied, this will prevent

aged. When pushing against the disc

the pistons from being forced out of the cylinders.

in the following step, support the disc

4. On models so equipped, remove the right side

adjacent to the caliper to prevent

saddlebag.

damage.

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

6. Remove the screws securing the cover and re-

9. Hold the caliper body from the outside and push

move the cover (Figure 68) and diaphragm.

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

7. Use a shop syringe and remove about 50 percent

tons into the caliper bores to make room for the new

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

brake pads. Constantly check the reservoir to make

vent the master cylinder from overflowing when the

sure brake fluid does not overflow. Remove fluid, if

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BRAKES

475

14. Thoroughly clean the pad pins of any corrosion

or debris.

15. 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 one tab (A, Figure 78)

must be installed on the outboard

side. The pad with two tabs (B, Figure

78) must be installed on the inboard

side of the caliper.

16. Install the outboard pad (Figure 79) into the

caliper.

17. Hold the pad in place and install the pad pin

bolts (Figure 80) part way in to hold the outboard

pad in place.

18. Install the inboard pad (Figure 81) into the cal-

iper.

19. Push the pad pin bolts through the inboard pad

(Figure 77) and tighten to the specification in Table 2.

20. Check to make sure there is sufficient brake fluid

in the master cylinder reservoir. Top off if necessary.

21. Untie the brake pedal from the frame and

pump the rear brake pedal to reposition the brake

pads against the brake disc. Roll the motorcycle

back and forth and continue to pump the brake

pedal as many times as it takes to refill the cylin-

ders in the calipers and correctly locate the brake

pads against the disc.

necessary, prior to it overflowing. Install the dia-

phragm and cover. Tighten the screws finger-tight.

NOTE

To control the flow of hydraulic fluid,

10. Remove the pad pin bolts (Figure 77).

punch a small hole into the seal of a

11. Remove the inboard and outboard brake pads

new container of hydraulic (brake)

from the caliper.

fluid next to the edge of the pour

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

spout. This will help eliminate fluid

sure the thickness of the brake pad friction material.

spillage, especially while adding fluid

to the very small reservoir.

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

vice limit listed in Table 1.

WARNING

13. Carefully remove any rust or corrosion from

Use brake fluid clearly marked DOT 5

the disc.

from a sealed container. Other types

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476

CHAPTER TWELVE

may vaporize and cause brake failure.

Always use the same brand name; do

not intermix, as many brands are not

compatible. Do not intermix DOT 3,

DOT 4 or DOT 5.1 brake fluid, as it

can cause brake component damage

leading to brake system failure.

22. Refill the master cylinder reservoir, if neces-

sary, to maintain the correct fluid level as indicated

on the side of the reservoir. Install the diaphragm

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

cation in Table 2.

WARNING

Do not ride the motorcycle until the

rear brake is operating correctly with

full hydraulic advantage. If neces-

sary, bleed the brake as described in

this chapter.

REAR BRAKE CALIPER

(1999 MODELS)

Removal/Installation

1. If the caliper assembly is going to be disassem-

NOTE

bled for service, perform the following:

If the piston did not come out, remove

it as described under Disassembly in

NOTE

this section.

By performing Steps

1a-1e, com-

pressed air may not be necessary for

Remove the banjo bolt (B, Figure 82) and seal-

piston removal during caliper disas-

ing washers attaching the brake hose to the caliper

sembly.

assembly.

3. To remove the rear caliper mounting bracket, re-

a. Remove the caliper pad pin bolts (A, Figure

fer to Rear Wheel Removal in Chapter Eleven.

82) and remove the caliper from the caliper

4. Install by reversing these removal steps while

mounting bracket and the brake pads.

noting the following:

b. Insert a small screwdriver into the notched

a. If removed, install the piston assembly as de-

groove machined in the bottom of the piston

scribed in this chapter.

bore (A, Figure 83). Then pry the retaining

ring (A, Figure 83) out of the caliper body.

b. If removed, install the brake pads as de-

c. Wrap a large cloth around the brake caliper.

scribed in this chapter.

d. Hold the caliper away from the piston/brake

c. Carefully install the caliper assembly onto the

pad area.

brake pads.

e. Operate the rear brake pedal to force the pis-

d. Install the bolts (A, Figure 82) securing the

ton part way out of the caliper. Do not com-

brake caliper assembly and tighten to the

pletely remove the piston until after it is

torque specifications listed in Table 2.

removed for disassembly. Leaving the piston

e. Apply clean DOT 5 brake fluid to the rubber

partially in the bore helps prevent brake fluid

portions of the new sealing washers prior to

from spilling out.

installation.

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BRAKES

477

REAR BRAKE CALIPER (1999)

1. Retaining ring

8. Pad pin bolt

2. Dust boot

9. Retaining clip

3. Piston

10. Mounting bracket

4. Piston seal

11. Bumper

5. Cap

12. Rubber boot

6. Bleed valve

13. Brake pads

7. Body

14. Shim

f. Install a new sealing washer on each side of

sary, bleed the brake as described in

the brake hose fitting and install the banjo

this chapter.

bolt (B, Figure 82). Tighten the banjo bolt to

the specification in Table 2.

Disassembly

g. Bleed the brake as described under Bleeding

Refer to Figure 84.

the System in this chapter.

1. Remove the brake caliper as described in this

chapter.

WARNING

Do not ride the motorcycle until the

NOTE

rear brake is operating correctly with

If the piston was partially forced out

full hydraulic advantage. If neces-

of the caliper body during removal,

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478

CHAPTER TWELVE

Steps 2-4 may not be necessary. If the

piston or caliper bore is corroded or

very dirty, a small amount of com-

Wooden block

Air hose

Rag

Caliper

pressed air may be necessary to com-

Piston

pletely remove the piston from the

body bore.

2. Insert a screwdriver into the caliper body

notched groove (A, Figure 83) and pry the retaining

ring out of the groove (Figure 85).

3. Place a piece of soft wood or folded shop cloth

over the end of the piston and the caliper body (Fig-

ure 86). Turn this assembly over with the piston

facing down.

WARNING

Compressed air will force the piston

out of the caliper bodies under con-

siderable force. Do not block the pis-

ton by hand, as injury will result.

4. Apply the air pressure in short spurts to the hy-

draulic fluid passageway and force out the piston.

Use a service station air hose if compressed air is

not available.

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

ure 87).

6. Remove the piston seal (Figure 88) from the

groove in the caliper body.

Inspection

Service specifications for the caliper components

Inspect

the

hydraulic

fluid

passageway in the

are not available (except brake pads). Replace any

cylinder bore. Make sure it is clean and open. Clean

worn, damaged or questionable part.

with compressed air.

1. Clean the caliper body and piston in clean DOT

5 brake fluid or isopropyl alcohol and dry with com-

3. Inspect the piston and cylinder bore wall for

pressed air.

scratches, scoring or other damage.

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BRAKES

479

Align gap with top of caliper bore

Retaining

ring

Assembly

1. The following parts are included in a H-D rebuild

kit (part No. 43946-86): piston seal (A, Figure 89),

piston (B), dust boot (C) and retaining ring (D).

NOTE

Never reuse an old dust boot or piston

seal. Minor damage or age deteriora-

tion can make the boot and seal useless.

2. Soak the new dust and piston seal in clean DOT5

brake fluid.

3. Make sure the retaining ring, piston and caliper

bore are thoroughly clean.

4. Install the piston seal (Figure 88) into the caliper

body groove.

5. Before installing the piston in the caliper bore,

iInstall the piston dust boot on the piston as follows:

a. Place the piston on the workbench with its

open side facing up.

b. Align the piston dust boot with the piston so

that the shoulder on the dust boot faces up.

c. Slide the dust boot over the piston until the in-

4. Make sure the hole in the bleed valve screw is

ner lip on the dust boot seats in the piston

clean and open. Clean with compressed air.

groove (Figure 90).

6. Coat the piston and caliper bore with DOT 5

5. Check the pin bolts for wear or damage.

brake fluid.

6. Replace the pad shims if corroded or damaged.

7. Align the piston with the caliper bore so that its

open end faces out (Figure 91), then push the piston

7. Check the brake pads for excessive wear or dam-

in until it bottoms out.

age. Measure the thickness of the brake pad friction

8. Seat the piston dust boot (B, Figure 83) into the

material. Replace the brake pads if they are worn to

caliper bore.

the service limit dimension listed in Table 1.

9. Find the retaining ring groove in the end of the

8. Check all of the rubber parts for cracks, wear or

caliper bore. Then install the retaining ring (Figure

deterioration.

85) so that the gap in the ring (Figure 92) is at the

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 24