Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

480

CHAPTER TWELVE

top of the caliper bore. Make sure the retaining ring

seats in the groove and pushes against the piston

dust boot.

10. Install the brake pads as described in this chap-

ter.

REAR BRAKE CALIPER

(2000-ON MODELS)

Removal/Installation

CAUTION

Do not spill any brake fluid on the

rear wheel. 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. If the caliper assembly is going to be disassem-

bled for service, perform the following:

NOTE

By performing Steps 1b and 1c, com-

pressed air may not be necessary for

piston removal during caliper disas-

sembly.

Refer

Rear

Wheel

Removal/Installation

Chapter Nine and follow the procedure until the rear

a. Remove the brake pads as described in this

axle is removed sufficiently to allow removal of the

chapter.

rear caliper assembly as shown in Figure 94. After

CAUTION

removal of the caliper assembly, push the rear axle

Do not allow the pistons to travel out

back into place and install the nut on the other side.

far enough to come in contact with the

5. If necessary, disassemble and service the caliper

brake disc. If this happens the pistons

assembly as described in this chapter.

may scratch or gouge the disc during

6. Install by reversing these removal steps while

caliper removal.

noting the following:

a. Carefully install the caliper assembly onto the

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

disc, being careful not to damage the leading

tons part way out of caliper assembly for ease

edge of the brake pads.

of removal during caliper service.

b. Refer to Chapter Nine and complete the in-

c. Loosen the three body mounting bolts (A,

stallation of the rear axle.

Figure 93).

c. Apply clean DOT5 brake fluid to the rubber

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

portions of the new sealing washers prior to

93).

installation.

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

d. Install a new sealing washer on each side of

Figure 93) attaching the brake hose to the caliper

the brake hose fitting and install the banjo

assembly.

bolt (B, Figure 93). Tighten the banjo bolt to

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

the specification in Table 2.

reclosable plastic bag to prevent the entry of debris

e. If disassembled, tighten the three caliper

and prevent any residual brake fluid from leaking

body bolts (A, Figure 93) to the specification

out.

in Table 2.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

481

REAR BRAKE CALIPER (2000-ON)

1. Caliper body bolt

10. O-ring

2. Pad pin bolt

11. Rubber bumper

3. Trim plate

12. Bushing

4. Bleed valve

13. Outboard caliper

5. Cap

body

6. Piston seal

14. Brake pads

7. Dust seal

15. Inboard caliper

8. Piston

body

9. Anti-rattle spring

f. Bleed the brake as described under Bleeding

the System in this chapter.

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.

Disassembly

Refer to Figure 95.

1. Remove the caliper and brake pads as described

in this chapter.

2. Remove the three caliper body bolts (Figure 96)

loosened during the removal procedure.

3. Separate the caliper body halves. Remove the

O-ring seals (Figure 97). New O-ring seals must be

installed every time the caliper is disassembled.

NOTE

If the pistons were partially forced out

of the caliper body during removal,

steps 4-6 may not be necessary. If the

pistons or caliper bores are corroded

-------------------------------------------------------------------------------------------------------------------------------------------------------------

482

CHAPTER TWELVE

or very dirty, a small amount of com-

pressed air may be necessary to com-

pletely remove the pistons from the

body bores.

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

over the end of the pistons and the caliper body.

Turn this assembly over with the pistons facing

down.

5. Perform this step over and close to a workbench

top.

WARNING

Compressed air will force the pistons

out of the caliper bodies under con-

siderable force. Do not block the pis-

ton by hand, as injury will result.

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

draulic fluid passageway and force out the pistons.

Repeat for the other caliper body half. Use a service

station air hose if compressed air is not available.

CAUTION

In the following step, do not use a

sharp tool to remove the dust and pis-

ton seals from the caliper cylinders.

Do not damage the cylinder surface.

100

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

fully push the dust seal and the piston seal in toward

the caliper cylinder and out of their grooves. Re-

move the dust and piston seals.

8. If necessary, unscrew and remove the bleed

screw (Figure 98).

9. Inspect the caliper assembly as described in this

section.

Inspection

Inspect the piston and dust seal grooves in both

1. Clean both caliper body halves and pistons in

caliper bodies for damage. If damaged or corroded,

clean DOT5 brake fluid or isopropyl alcohol and

replace the caliper assembly.

dry with compressed air.

5. Inspect the banjo bolt threaded hole in the out-

2. Make sure the fluid passageways (Figure 99) in

board caliper body. If worn or damaged, clean out

the piston bores are clear. Apply compressed air to

with a metric thread tap or replace the caliper as-

the openings to make sure they are clear. Clean out

sembly.

if necessary with clean brake fluid.

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

3. Make sure the fluid passageways (Figure 100)

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

in both caliper body halves are clear. Apply com-

ric thread tap or replace the caliper assembly.

pressed air to the openings to make sure they are

7. Inspect the bleed valve. Apply compressed air to

clear. Clean out if necessary with clean brake fluid.

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

483

Assembly

101

NOTE

Never reuse old dust seals or piston

seals. Very minor damage or age de-

terioration can make the seals use-

less.

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

102

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.

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

body half.

6. Position the pistons with the open end facing out

and install the pistons into the caliper cylinders.

Push the pistons in until they bottom.

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

Make sure all pistons are installed correctly.

103

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

and install the O-rings (Figure 97) into the inboard

caliper half.

9. Install the anti-rattle spring (Figure 102) 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 the three caliper body bolts (Figure 96)

and tighten securely. They will be tightened to the

specification after the caliper is installed on the rear

swing arm.

necessary with clean brake fluid. Install the bleed

12. If removed, install the rubber bumper (Figure

valve and tighten to the specification in Table 2.

103).

8. Inspect both caliper bodies for damage. Check

13. If removed, install the bleed screw assembly

the inboard caliper mounting bolt hole threads (Fig-

(Figure 98) and tighten to the specification in Table

ure 101) for wear or damage. Clean up with an ap-

propriate size metric tap or replace the caliper

14. Install the caliper and brake pads as described

assembly.

in this chapter.

9. Inspect the cylinder walls and pistons for

15. Tighten the three caliper body mounting bolts

scratches, scoring or other damage.

to the specification in Table 2.

10. Check the anti-rattle spring for wear or dam-

16. Bleed the brake as described under Bleeding

age.

the System in this chapter.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

484

CHAPTER TWELVE

REAR MASTER CYLINDER

104

Removal

1. Remove the exhaust system as described in

Chapter Seven.

2. On models so equipped, remove the right side

saddlebag.

3. At the rear brake caliper, perform the following:

a. Insert a hose onto the end of the bleed valve.

Insert the open end of the hose into a con-

tainer.

b. Open the bleeder valve and operate the rear

brake pedal to drain the brake fluid. Remove

the hose and close the bleeder valve after

105

draining the assembly. Discard the brake fluid

properly.

4. Remove the screws securing the cover and re-

move the cover (Figure 104) and diaphragm.

5. Remove the banjo bolt and sealing washers (Fig-

ure 105) securing the brake hose to the rear of the

master cylinder cartridge body.

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

reclosable plastic bag to prevent the entry of debris

and prevent any residual brake fluid from leaking

out.

7. Remove the cotter pin and pivot pin securing the

pushrod to the brake pedal. Disconnect the pushrod

106

from the brake pedal.

8. Loosen and remove the nut (Figure 106) from

the cartridge body securing the rear portion of the

master cylinder to the mounting bracket on the

frame.

9. Pull the master cylinder and pushrod (Figure

107) forward out of the mounting bracket and re-

move it.

10. If necessary, service the master cylinder as de-

scribed in this chapter.

Installation

107

1. Insert the master cylinder cartridge body threads

through the square hole in the frame mounting

bracket (Figure 107). Index the square portion of

the cartridge body into the square hole in the mount-

ing bracket.

2. Install the nut (Figure 106) onto the cartridge

body. Ensure that the cartridge body is engaged

properly with the mounting bracket prior to tighten-

ing the nut. Tighten the nut to the specification in

Table 2.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

485

108

REAR MASTER CYLINDER

1. Screw

9. Retainer

2. Top cover

10. Snap ring

3. Diaphragm

11. Body

4. Pushrod

12. Nut

5. Seal and snap ring

13. Retainer

6. Spring

14. Sight glass

7. Retainer

15. Body rebuild kit

8. Rubber boot

16. Piston assembly

6. Bleed the brake as described under Bleeding the

109

System in this chapter.

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.

Disassembly

Refer to Figure 108.

3. Connect the pushrod onto the brake pedal and in-

1. Clean the exterior master cylinder housing with

stall the pivot pin. Install a new cotter pin and bend

clean DOT 5 brake fluid or isopropyl alcohol and

the ends over completely.

dry.

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

2. Store the master cylinder components in a di-

tions of the new sealing washers prior to installa-

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

tion.

ton, to help maintain their correct alignment

position.

5. Install a new steel/rubber washer on each side of

the brake hose banjo fitting. Insert the banjo bolt

3. If still installed, remove the master cylinder

through the washers and banjo fitting and thread

cover and diaphragm.

into the cartridge body (Figure 105). Then tighten

4. Unscrew and disconnect the brake rod (Figure

the banjo bolt to the specification in Table 2.

109) from the master cylinder.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

486

CHAPTER TWELVE

110

111

5. Remove the snap ring (A, Figure 110) and the

washer (B, Figure 110).

112

6. Remove the boot (A, Figure 111), the spring seat

(B) and the spring (C).

7. Depress the pushrod (A, Figure 112) and re-

move the snap ring (B).

8. Remove the pushrod (Figure 113).

9. Remove the piston assembly (A, Figure 114)

and spring from the cartridge.

NOTE

On some models and years, the car-

tridge (B, Figure 114) within the mas-

ter cylinder reservoir is not available

as a replacement part. Prior to re-

113

moving the cartridge, check with a

Harley-Davidson dealership to make

sure the cartridge is available.

Inspection

1. Clean all parts in clean DOT5 brake fluid or

isopropyl alcohol and dry with compressed air.

2. 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.

3. Inspect the cartridge body cylinder bore surface

114

for signs of wear and damage. Do not hone the car-

tridge bore to clean or repair it. If less than perfect,

replace the cartridge and/or the master cylinder res-

ervoir.

4. Check the piston primary cup (A, Figure 115)

and the O-ring (B) for deterioration or damage.

5. Check the spring for bending, unequally spaced

coils or corrosion.

6. Check the pushrod and washer (Figure 116) for

bending, wear or damage.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

487

115

119

7. Inspect the boot for tears or deterioration.

116

8. Check the reservoir body for corrosion or other

damage.

9. Check the reservoir cap and diaphragm for dam-

age.

10. Check the brake rod and nut for thread damage.

Repair if necessary.

Assembly

1. Coat all parts with clean DOT5 brake fluid.

2. Soak the primary cup, 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

117

cartridge bore with clean brake fluid prior to the as-

sembly of parts.

CAUTION

When installing the piston assembly,

do not allow the primary cup to turn

inside out as it will be damaged and

allow brake fluid leakage within the

cartridge cylinder bore.

3. Install the spring (A, Figure 117) into the car-

tridge.

4. Position the piston assembly with the primary

118

cup (B, Figure 117) end going in first. Make sure

the piston cup does not tear as it passes through the

bore entrance.

5. Turn the reservoir on end on a shop cloth. Care-

fully push the piston assembly into the cartridge

with a Phillips screwdriver (Figure 118). Push the

piston assembly in and then let it move out several

times and check for ease of movement.

6. Position the pushrod onto the end of the piston

and push the piston into the cartridge (Figure 119).

Hold the pushrod (A, Figure 112) and install the

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

489

brake caliper(s). When purchasing a new hose,

123

compare it to the old hose to make sure that the

length and angle of the steel hose portion are cor-

rect. Install new banjo bolt washers at both ends.

CAUTION

Do not spill any brake fluid on the

front fork or front wheel. Wash brake

fluid off any painted, plated or plastic

surfaces immediately, as it will dam-

age most surfaces it contacts. Use

soapy water and rinse completely.

1. Drain the front brake system as follows:

snap ring (B). Make sure the snap ring is correctly

a. Connect a hose over the bleed valve.

seated in the cartridge groove (Figure 120).

b. Insert the loose end of the hose in a container

7. Install the spring and spring seat (A, Figure 121)

to catch the brake fluid.

onto the pushrod.

c. Open the bleed valve and apply the front

8. Install the boot (B, Figure 121), washer (C) and

brake lever to pump the fluid out of the master

snap ring (D). Make sure the snap ring (A, Figure

cylinder and brake line. Continue until the

110) is correctly seated in the push rod groove.

fluid is removed.

9. Connect the brake rod (Figure 109) onto the

master cylinder and tighten the locknut securely.

d. Close the bleed valve and disconnect the

10. Install the diaphragm and reservoir cover.

hose.

11. Install the master cylinder as described in this

e. On models with dual front brakes, repeat for

chapter.

the opposite side.

f. Dispose of this brake fluid—never reuse

WARNING

brake fluid. Contaminated brake fluid will

Do not ride the motorcycle until the

cause brake failure.

rear brake is operating correctly with

2. Before removing the brake line(s), note the

full hydraulic advantage. If neces-

sary, bleed the brake as described in

brake line routing from the master cylinder to the

this chapter.

caliper(s). In addition, note the number and position

of the metal hose clamps and plastic ties used to

hold the brake line(s) in place. Install the brake hose

BRAKE HOSE AND

along its original path. The metal clamps can be re-

LINE REPLACEMENT

used.

3. Cut any plastic ties and discard them.

A combination of steel and flexible brake lines

connect the master cylinder to its brake calipers.

4. On dual disc models, remove the bolt (A, Figure

Banjo fittings and bolts connect brake hoses to the

123) securing the brake hose mounting plate to the

master cylinder and brake calipers. Steel/rubber

lower steering stem. Do not lose the guide plate (B,

washers seal the banjo fittings.

Figure 123) between the hose mounting plate and

Replace a hose if the flexible portion shows

the steering stem.

swelling, cracking or other damage. Likewise, re-

5. Remove the screw or nut securing the metal

place the brake hose if the metal portion leaks or if

clamps around the brake line. Spread the clamp and

there are dents or cracks.

remove it from the brake line.

6. Remove the banjo bolt and washers (A, Figure

124) securing the hose to the brake caliper(s).

Front Brake Hose

7. Remove the banjo bolt and washers securing the

Removal/Installation

hose to the master cylinder (Figure 125).

A combination steel/flexible brake hose (Figure

8. Cover the ends of the brake hose(s) to prevent

122) connects the front master cylinder to the front

brake fluid from leaking out.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

490

CHAPTER TWELVE

9. Remove the brake hose(s) (B, Figure 124) from

the motorcycle.

124

10. If the existing brake hose assembly is going to

be reinstalled, inspect it as follows:

a. Check the metal pipe where it enters and exits

at the flexible hose. Check the crimped clamp

for looseness or damage.

b. Check the flexible hose portion for swelling,

cracks or other damage.

c. If any wear or damage is found, replace the

brake hose assembly.

11. Install the brake hose, washers (Figure 122)

and banjo bolts in the reverse order of removal

while noting the following:

125

a. Install new sealing washers against the side of

each hose fitting.

b. Carefully install the clips and guides to hold

the brake hose in place.

c. Tighten the banjo bolts to the specification in

Table 2.

d. Refill the master cylinder with clean brake

fluid clearly marked DOT 5. Bleed the front

brake system as described in this chapter.

WARNING

Do not ride the motorcycle until the

126

REAR BRAKE LINE

front brakes operate correctly with

full hydraulic advantage. If neces-

sary, bleed the brake as described in

this chapter.

Rear Brake Hose

Removal/Installation

A single combination steel and rubber brake hose

(Figure 126) connects the rear master cylinder to

the rear brake caliper. The rear brake switch is in-

stalled in the rear brake hose. When buying a new

hose, compare it to the old hose. Make sure the

length and angle of the steel hose portion is correct.

Install new banjo bolt washers at both hose ends.

CAUTION

Do not spill any brake fluid on the

swing arm, frame or rear wheel.

Wash brake fluid off any painted,

plated or plastic surfaces immedi-

1. Sealing washer

2. Brake line

ately, as it will damage most surfaces

3. Banjo bolt

it contacts. Use soapy water and

rinse completely.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

491

1. Remove the exhaust system as described in

127

Chapter Seven.

2. On models so equipped, remove the right side

saddlebag.

3. Drain the hydraulic brake fluid from the rear

brake system as follows:

a. Connect a hose to the bleed valve. Refer to A,

Figure 127, typical.

b. Insert the loose end of the hose in a container

to catch the brake fluid.

c. Open the caliper bleed valve and operate the

rear brake pedal to pump the fluid out of the

master cylinder and brake line. Continue until

all of the fluid is removed.

128

d. Close the bleed valve and disconnect the

hose.

e. Dispose of this brake fluid—never reuse

brake fluid. Contaminated brake fluid will

cause brake failure.

4. Before removing the brake line, note the brake

line routing from the master cylinder to the caliper.

In addition, note the number and position of the

metal hose clamps and plastic ties used to hold the

brake line in place. Install the brake hose along its

original path. The metal clamp can be reused. How-

ever, new plastic ties will have to be installed.

5. Cut the plastic ties and discard them.

129

6. Remove the bolt and clamp securing the brake

hose to the rear swing arm (Figure 128).

7. Disconnect the electrical connector (A, Figure

129) from the rear brake switch.

8. Remove the banjo bolt and washers securing the

hose to the brake caliper. Refer to B, Figure 127,

typical.

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

129) securing the hose to the master cylinder.

10. Remove the brake hose from the motorcycle.

11. If the existing brake hose assembly is going to

be reinstalled , inspect it as follows:

a. Check the metal pipe (A, Figure 130) where

130

it enters and exits the flexible hose. Check the

crimped clamp for looseness or damage.

b. Check the flexible hose portion for swelling,

cracks or other damage.

c. If any wear or damage is found, replace the

brake hose.

12. If necessary, remove the stoplight switch (B,

Figure 130) from the rear brake hose fitting. Re-

verse to install the switch. Tighten the switch se-

curely.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

492

CHAPTER TWELVE

131

132

13. Install the brake hose in the reverse order of re-

moval while noting the following:

a. Install new sealing washers against the side of

each hose fitting.

b. Carefully install the clips and guides to hold

the brake hose in place.

c. Tighten the banjo bolts to the specification in

Table 2.

d. Refill the master cylinder with clean brake

133

fluid clearly marked DOT 5. Bleed the rear

brake system as described in this chapter.

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.

BRAKE DISC

The brake discs are separate from the wheel hubs

discs are thin, and grinding will only reduce their

and can be removed once the wheel is removed

thickness, causing them to warp quite rapidly. If the

from the motorcycle.

disc is warped, the brake pads may be dragging on

the disc due to a faulty caliper and causing the disc

to overheat. Overheating can also be caused when

Inspection

there is unequal pad pressure on both sides of the

disc.

It is not necessary to remove the disc from the

wheel to inspect it. Small nicks and marks on the

Three main causes of unequal brake pad pressure

disc are not important, but radial scratches deep

are:

enough to snag a fingernail reduce braking effec-

a. The brake caliper piston seals are worn or

tiveness and increase brake pad wear. If these

damaged.

grooves are evident, and the brake pads are wearing

rapidly, the disc should be replaced.

b. The small master cylinder relief port is

The minimum (MIN) disc thickness is stamped

plugged.

on the disc.

When servicing the brake discs, do not have the

c. The primary cup on the master cylinder pis-

discs surfaced to compensate for any warp. The

ton is worn or damaged.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

493

4. Clean the disc of any rust or corrosion and wipe

134

clean with lacquer thinner. Never use an oil-based

solvent that may leave an oil residue on the disc.

Removal/Installation

1. Remove the front or rear wheel as described in

Chapter Nine.

NOTE

On dual disc models, the disc is

marked with a LEFT or RIGHT (Fig-

ure

133). The disc must be rein-

stalled on the correct side of the

135

wheel.

2. Remove the Torx bolts (Figure 134) securing

the brake disc to the hub and remove the disc.

3. Check the brake disc bolts for thread damage.

Replace worn or damaged fasteners.

4. Check the brake disc threaded bolt holes in the

wheel hub for thread damage. Clean out with a tap if

necessary.

5. Clean the disc and the disc mounting surface

thoroughly with brake cleaner or contact cleaner.

Allow the surfaces to dry before installation.

6A. On 1999 models, to install the front brake

NOTE

not

necessary to

remove

the

disc(s) perform the following:

wheel to

measure the

disc thick-

a. Install the disc onto the correct side of the

ness. The measurement can be per-

wheel hub, aligning the notch in the brake

formed with the wheel installed or

disc with the 1/4 in. (6.3 mm) blind hole in the

removed.

hub (Figure 135).

b. Apply a drop of ThreeBond TB1342 or an

equivalent to each bolt thread prior to installa-

1. Measure the thickness of the disc at several lo-

tion.

cations around the disc with a vernier caliper or a

c. Install new Torx bolts and tighten to the speci-

micrometer (Figure 131). The disc must be re-

fication in Table 2.

placed if the thickness in any area is less than the

6B. On 2000-on models, to install the front brake

marked MIN dimension on the disc.

disc(s) perform the following:

2. Make sure the disc mounting bolts are tight prior

a. Install the disc onto the correct side of the

to running this check. Check the disc runout with a

wheel hub.

dial indicator as shown in Figure 132.

b. Apply a drop of ThreeBond TB1342 or an

equivalent to each bolt thread prior to installa-

NOTE

tion.

When checking the front disc, turn the

c. Install new Torx bolts and tighten to the speci-

handlebar all the way to one side,

fication in Table 2.

then to the other side.

7. To install the rear brake disc, perform the follow-

ing:

3. Slowly rotate the wheel and watch the dial indi-

a. Apply a drop of ThreeBond TB1342 or an

cator. If the runout exceeds that listed in Table 1, re-

equivalent to each bolt thread prior to installa-

place the disc(s).

tion.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

494

CHAPTER TWELVE

b. Install new Torx bolts and tighten to the speci-

fication in Table 2.

136

BLEEDING THE SYSTEM

If air enters the brake system, the brake will feel soft

or spongy, greatly reducing braking pressure. If this

happens, the system must be bled to remove the air.

Air can enter the system if there is a leak in the system,

the brake fluid level in a master cylinder runs low, a

brake line is opened, or the brake fluid is replaced.

When bleeding the brakes, two different methods

can be used—with a brake bleeder or manually.

This section describes both procedures separately.

137

Before bleeding the brake system, observe the

following conditions:

1. Check the brake lines to make sure that all fit-

tings are tight.

2. Check that the caliper piston does not stick or

bind in its bore.

3. Check piston movement in each master cylinder.

Operate the lever or brake pedal, making sure there

is no binding or other abnormal conditions present.

Brake Bleeder Process

Leave the cover in place during this procedure to

This procedure uses the Mityvac hydraulic brake

prevent the entry of dirt.

bleeding kit (Figure 136) that is available from au-

tomotive or motorcycle supply stores or from mail

WARNING

order outlets.

Use brake fluid clearly marked DOT 5

from a sealed container. Other types

NOTE

may vaporize and cause brake failure.

This procedure is shown on the rear

Always use the same brand name; do

wheel and relates to the front wheel as

not intermix, as many brands are not

well.

compatible. Do not intermix DOT 3,

DOT 4 or DOT 5.1 brake fluid, as it

1. Remove the dust cap from the caliper bleed

can cause brake component damage

valve.

leading to brake system failure.

2. Place a clean shop cloth (A, Figure 137) over the

caliper to protect it from accidental brake fluid spills.

8. Operate the pump several times to create a vac-

3. Open the bleed screw approximately 1/2 turn (B,

uum in the line. Brake fluid will quickly flow from

Figure 137).

the caliper into the pump’s reservoir. Tighten the

4. Assemble the brake bleeder according to its

caliper bleed valve before the fluid stops flowing

manufacturer’s instructions. Secure it to the caliper

through the hose. To prevent air from being drawn

bleed valve (Figure 138).

through the master cylinder, add fluid to maintain

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

its level at the top of the reservoir.

6. Remove the screws securing the master cylinder

top cover and remove the cover and rubber dia-

NOTE

phragm.

Do not allow the master cylinder res-

7. Fill the reservoir almost to the top with DOT5

ervoir to empty during the bleeding

brake fluid and reinstall the diaphragm and cover.

operation or more air will enter the

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

495

correctly with full hydraulic advan-

138

tage.

15. Test ride the motorcycle slowly at first to make

sure that the brakes are operating properly.

Without a Brake Bleeder

NOTE

Before bleeding the brake, check that

all brake hoses and lines are tight.

1. Connect a length of clear tubing to the bleed

system. If this occurs, the procedure

valve on the caliper. Place the other end of the tube

must be repeated.

into a clean container. Fill the container with

enough clean DOT 5 brake fluid to keep the end of

9. Continue the bleeding process until the fluid

the tube submerged. The tube must be long enough

drawn from the caliper is bubble free. If bubbles are

so that a loop can be made higher than the bleeder

withdrawn with the brake fluid, more air is trapped

valve to prevent air from being drawn into the cali-

in the line. Repeat Step 8, making sure to refill the

per during bleeding.

master cylinder to prevent air from being drawn into

2. Clean the top of the master cylinder of all de-

the system.

bris.

10. When the brake fluid is free of bubbles, tighten

3. Remove the screws securing the master cylinder

the bleed valve and remove the brake bleeder as-

top cover. Remove the cover and diaphragm.

sembly. Reinstall the bleed valve dust cap.

4. Fill the reservoir almost to the top with DOT5

brake fluid and reinstall the diaphragm and cover.

NOTE

Leave the cover in place during this procedure to

Dispose of the brake fluid expelled

prevent the entry of dirt.

during the bleeding process. Do not

reuse the brake fluid.

WARNING

Use brake fluid clearly marked DOT

11. If necessary, add fluid to correct the level in the

5 from a sealed container. Other

master cylinder reservoir. When topping off the

types may vaporize and cause brake

front master cylinder, turn the handlebar until the

failure. Always use the same brand

reservoir is level; add fluid until it is level with the

name; do not intermix, as many

reservoir gasket surface. The fluid level in the rear

brands are not compatible. Do not

master cylinder must be slightly below the upper

intermix DOT 3, DOT 4 or DOT 5.1

gasket surface.

brake fluid, as it can cause brake

component damage leading to brake

12. On front dual-disc models, repeat steps 1-9 for

system failure.

the other caliper.

13. Reinstall the reservoir diaphragm and cover.

NOTE

Install the screws and tighten securely.

During this procedure, it is important

14. Test the feel of the brake lever or pedal. It must

to check the fluid level in the master

be firm and offer the same resistance each time it is

cylinder reservoir often. If the reser-

operated. If it feels spongy, it is likely that there is

voir runs dry, air will enter the sys-

still air in the system and it must be bled again. After

tem.

bleeding the system, check for leaks and tighten all

5. Slowly apply the brake lever several times. Hold

fittings and connections as necessary.

the lever in the applied position and open the bleed

WARNING

valve about 1/2 turn. Allow the lever to travel to its

Do not ride the motorcycle until the

limit. When the limit is reached, tighten the bleed

front and/or rear brake are operating

valve, then release the brake lever. As the brake

-------------------------------------------------------------------------------------------------------------------------------------------------------------

496

CHAPTER TWELVE

139

REAR BRAKE PEDAL

1. Nut

2. Pushrod

3. Clevis pin

4. Acorn nut

5. Washer

6. Brake pedal

7. Washer

8. Footrest and

brake pedal

bracket

9. Bolt

10. Washer

11. Cotter pin

12. Bolt

13. Pad

FXDWG MODELS*

1. Nut

2. Pushrod

3. Spring washer

4. Brake pedal

5. Snap ring

6. Cotter pin

7. Pivot pin

*For 2003 models

FXDWL, FXDX, FXD, FXDS-CON, FXDXT, AND FXDP MODELS

see Supplement

fluid enters the system, the level will drop in the

NOTE

master cylinder reservoir. Maintain the level at the

Dispose of the brake fluid expelled

top of the reservoir to prevent air from being drawn

during the bleeding process. Do not

reuse the brake fluid.

into the system.

6. Continue the bleeding process until the fluid

8. If necessary, add fluid to correct the level in the

emerging from the hose is completely free of air

master cylinder reservoir. When topping off the

bubbles. If the fluid is being replaced, continue until

front master cylinder, turn the handlebar until the

the fluid emerging from the hose is clean.

reservoir is level; add fluid until it is level with the

reservoir gasket surface. The fluid level in the rear

NOTE

master cylinder must be slightly below the upper

If bleeding is difficult, allow the

gasket surface.

fluid to stabilize for a few hours. Re-

9. On front dual-disc models, repeat steps 1-9 for

peat the bleeding procedure when

the other caliper.

the tiny bubbles in the system settle

10. Install the diaphragm and top cover and tighten

out.

the screws securely.

11. Test the feel of the brake lever or pedal. It must

7. Hold the lever in the applied position and tighten

be firm and offer the same resistance each time it is

the bleed valve. Remove the bleed tube and install

operated. If it feels spongy, it is likely that there is

the bleed valve dust cap.

still air in the system and it must be bled again. After

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BRAKES

497

1. Remove the exhaust system as described in

140

Chapter Seven.

2. Remove the bolts (A, Figure 140) securing the

brake pedal bracket to the frame.

3. Remove the bracket (B, Figure 140) and pedal

assembly.

4. Disconnect the push rod from the pedal assembly.

5A. On FXDWG models, remove the bolt, washers

and acorn nut securing the pedal to the mounting

bracket. Remove the pedal.

5B. On all models except FXDWG models, remove

the snap ring securing the pedal to the mounting

bracket. Remove the pedal.

bleeding the system, check for leaks and tighten all

6. Inspect the brake pedal for fractures or damage

fittings and connections as necessary.

and replace if necessary.

7. On FXDWG models, perform the following:

WARNING

a. Inspect the bushing within the pedal for wear.

Do not ride the motorcycle until the

Replace if necessary.

front and/or rear brake are operating

b. Inspect the shoulder on the bracket where the

correctly with full hydraulic advan-

tage.

pedal rides for wear.

c. Lubricate the bushing and bracket shoulder

12. Test ride the motorcycle slowly at first to make

with waterproof grease.

sure that the brakes are operating properly.

8. Install the pedal by reversing these removal

steps while noting the following:

a. Tighten the special bolt securely.

REAR BRAKE PEDAL

b. Install a new cotter pin and bend the ends over

completely.

Removal/Lubrication/Installation

c. Adjust the rear brake pedal height as de-

Refer to Figure 139.

scribed in Chapter Three.

Table 1 BRAKE SYSTEM SPECIFICATIONS

Brake fluid

DOT 5 silicone base

Brake pad minimum thickness

1999 models

1/16 in. (1.6 mm)

2000 and later

0.04 in. (1.02 mm)

Brake disc

Thickness

Stamped on disc

Runout

0.008 in. (0.20 mm)

Table 2 BRAKE SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Bleed valves

80-100

9-11

Caliper bridge bolts

(front and rear)

28-38

38-51

Brake disc bolts

Front wheel

16-24

22-32

Rear wheel

30-45

41-61

Brake pad pins (2000-on)

Front and rear calipers

180-200

20-23

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CHAPTER THIRTEEN

BODY

SEAT

6. Make sure the nylon retaining clip is in place,

then install the bolt securing the rear of the seat to

Removal/Installation

the fender bracket. Tighten the bolt securely.

7. Pull up on the front of the seat to ensure the seat

1. Remove the bolt (A, Figure 1) securing the rear

front hook is secured in place on the frame bracket.

of the seat to the fender bracket. Do not lose the ny-

lon retaining clip between the bracket and the rear

WINDSHIELD

fender.

2. Pull the seat toward the rear to release the seat

Removal/Installation

front hook from the frame bracket.

(FXDS-CONV)

3. Carefully slide the seat forward and out of the

1. Place the motorcycle on level ground on the jiffy

seat strap (B, Figure 1). Remove the seat.

stand.

4. Install the strap under the seat.

2. Loosen, but do not remove, the two screws on

5. Slide the seat forward and insert the front hook

each side securing the windshield and bracket to the

under the frame bracket (Figure 2).

mounting brackets on the forks.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 25