Info

Figure 2-65. Disc Brake - Exploded View, 1972 and Later FL/FLH Front and Rear, 1973 FX Front and Rear, 1974 FX/FXE/FXS Rear Only

With hydraulic system connected to outer caliper half assembly (3), use a dial indicator to check piston retraction. Mount dial indicator on back of outer caliper with indicator plunger on the piston face. Apply brake. Set dial indicator on zero. Release brake. Front brake piston (stamped "F") should retract .020 to .025 in. Rear brake piston (stamped "R") should retract .033 to .038 in. If it does not, replace piston assembly (8A). Do not remove piston assembly unless there are signs of hydraulic fluid leakage or if piston is not operating properly.

To remove piston (8 or 8A), pump brake hand lever until piston will move no farther. Remove hydraulic line (9). Push piston boot (10) back from groove in piston and pull piston the rest of the way out.

Remove the retaining ring (11, if used) using external retaining ring pliers, Harley-Davidson Part No. 95017-61. Backing plate (12), wave spring (13), adjusting ring (14), and O-ring (15) may now be removed. Remove bleeder valve (16). Clean all parts in solvent and inspect. Replace any parts that are worn, or damaged. Inspect cylinder bore. If it is badly scored replace outer caliper half (3). When reassembling use new O-ring (15) and adjusting ring (14).

Inspect the brake disc (20). If it is warped, or badly scored it must be replaced. If disc is worn excessively, it must be replaced. See "Removing and Installing Brake Disc." Minimum brake disc thickness is stamped on side of disc.

Clean and inspect bushings (17) and (18) in fork slider or caliper mounting bracket. Install new bushings if worn or damaged. Coat inside of bushings with Harley-Davidson "Anti-Seize" before installing caliper.

Riveted type mounting pin can be replaced with threaded type (25) if loose or damaged.

REASSEMBLING DISC BRAKE CALIPERS - 1972 AND LATER FL/FLH FRONT AND REAR, 1973 FX FRONT AND REAR, 1974 AND LATER FX/FXE/FXS REAR ONLY (Figure 2-65)

Reassembly is basically the reverse of disassembly. Make sure all parts are clean and in good condition before assembly. Dip the piston assembly (items 8 or 8A, 11, 12, 13, 14 and 15) and piston boot (10) in hydraulic fluid.

Assemble piston boot to caliper bore. Piston boot has a small hole in it to allow drainage of accumulated moisture. Assemble boot so that hole will point downward when caliper is assembled to motorcycle. Press piston assembly into caliper bore keeping it square to avoid scoring the bore. Push it firmly all the way in.

CAUTION — Be careful not to get brake fluid on brake light switch contacts. If brake fluid contaminates contacts. switch failure may occur.

0 0

Post a comment