Chrome Rear Brake Caliper Kit Instruction Sheet - Harley
Contents
1. HARLEY DAVIDSON J03708 INSTRUCTIONS REV 4 20 2005 Kit Numbers 42035 06 CHROME REAR BRAKE CALIPER KIT General This Chrome Rear Caliper kit is designed to fit 2006 and later Dyna model motorcycles NOTE The rear brake caliper in this kit Part No 42036 06 installs the same way as the original equipment rear brake caliper The brake pads and pad pins are not included with this kit If it is necessary to replace worn or damaged brake pads and pad pins they can be purchased separately from any Harley Davidson dealer See the Service Parts illustration for kit contents and service parts The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is available for purchase at a Harley Davidson dealer Installation Prepare the Motorcycle for Service To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 0048a 1 Follow the Service Manual instructions to disconnect the battery cables negative cable first 2 Follow the Service2. Manual instructions to remove debris deflector from motorcycle 3 Follow the Service Manual instructions to disconnect and remove exhaust pipes from motorcycle Remove Rear Brake Caliper Replace brake line gaskets Re using original gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a NOTE Place a container under the brake caliper to catch brake fluid released when removing the brake line from the caliper 1 See Figure 1 Remove the banjo bolt 1 and both steel rubber washers 2 to detach rear brake line 3 from caliper Save banjo bolt for reuse and discard washers 3 Pull axle from rear wheel Follow Service Manual instructions for Rear Wheel Removal procedure 4 Lift rear caliper away from axle and rear fork Notch 4 in caliper mount must clear tab on rear fork 5 Remove bridge bolts from caliper assembly and dis card 6 Remove pad pins and brake pads from caliper and save for future installation on new chrome caliper i06627 Banjo bolt Steel rubber washer 2 Brake line Caliper notch Figure 1 Rear Caliper Removal Inspect Pad and Pins 1 Inspect the brake pads If brake pad is worn to 1 16 in 1 6 mm or less replace the set Follow the instructions in the Service Manual 2 Inspect pad pins for wear and grooving If wear is more than 0 015 in 0 38 mm replace both pins 1 of 4 3 Inspect the brake disc and if necessar
3. cs 3of4 STO S T p ervice Parts Part No 42035 06 Date 04 05 Chrome Rear Brake Caliper Kit i07239 Description Quantity Chrome caliper assembly Steel rubber brake line gasket 2 Bridge bolt 3 Piston Kit 4 Square seal 4 Piston wiper 4 Piston 4 Crossover O ring 2 Pad Kit Not shown 8 Brake pad and holder inner 9 Brake pad and holder outer Pad Pin Kit Not shown 10 Pad pin 2 Anti Rattle Spring Kit 11 Anti rattle spring 12 Crossover O ring 2 Parts not in Kit 13 Banjo bolt 14 Brake line Part Number Not sold separately 41731 01 44193 02 44313 01 Not sold separately Not sold separately Not sold separately Not sold separately 44082 00A Not sold separately Not sold separately 44314 00 black 44324 02 silver Not sold separately 44337 00B Not sold separately Not sold separately Reference only Reference only Chrome caliper is an assembly of caliper halves pistons seals and wipers bridge bolts bleeder valve rubber bumper crossover O rings and anti rattle spring Pins and brake pads can be purchased separatety See above Piston wipers seals and crossover O rings are only available in a separate Seal Kit Part No 44315 00 J03708 4of4
4. l reservoir with the grade of brake fluid specified in the Service Manual 2 of 4 i06622 Figure 4 Fill 1 8 in 3 2 mm below Reservoir Gasket Surface a See Figure 4 Verify that fluid level is 1 8 in 3 2 mm below the gasket surface of the reservoir with the master cylinder in a level position NOTE Do not mix grades of brake fluid Different grades of brake fluid are not compatible Mixing them can cause equipment damage 3 Remove the bleeder valve cap and attach a tight fitting flexible hose to the tip of the bleeder valve Direct the end of the hose into a container 4 Press the brake pedal to apply hydraulic pressure to the brake system 5 Open the bleeder valve about 1 2 turn counterclock wise When the brake pedal has been fully depressed close the bleeder valve turn clockwise Allow the brake pedal to return to its released position 6 Repeat until all air bubbles are purged from brake line 7 Torque the bleeder valve to 80 100 in Ibs 9 0 11 3 Nm and install the bleeder valve cap 8 Verify master cylinder fluid level Fill reservoir 1 8 in 3 2 mm below gasket surface 9 Install the gasket and cover on the rear brake master cylinder reservoir Tighten cover screws to 6 8 in lbs 0 7 0 9 Nm J03708 Install the Exhaust If the exhaust system was removed to access the rear axle refer to the Service Manual for installation Install the Belt Guard and Debris Deflector Follow the inst
5. ructions in the Service Manual to reinstall the belt guard and debris deflector Return the Motorcycle to Service Awarnine Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 1 Connect battery cable to battery positive cable first 2 Follow the instructions in the Service Manual to install the seat WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a Test the Brakes 1 Turn the ignition switch ON WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 2 Pump the brake lever to verify operation of the stop lamp WARNING After servicing brakes and before moving motorcycle test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of con trol which could result in death or serious injury 00289a 3 Test ride the motorcycle at low speed If the brake feels spongy bleed the brake system again NOTE Avoid making hard stops for the first 100 miles 160 km This allows the pads to become conditioned to the brake dis
6. ue the banjo bolt to 17 22 ft lbs 23 0 29 8 Nm J03708 i06627 Banjo bolt Steel rubber washer 2 Brake line Caliper notch Figure 3 Brake line Component Installation 5 If necessary follow the instructions in the Service Manual to install new brake pads 6 If necessary install new pad pins Listen for the audible click when installing and tighten to 180 200 in Ibs 20 23 Nm Bleed the Brakes AcauTion Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye con tact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a NOTE Hydraulic brake fluid bladder type pressure equipment can be used to fill the brake master cylinder through the bleeder valve Remove the master cylinder reservoir cover to pre vent the system from pressurizing Do not use pressure bleeding equipment when the hydraulic system is sealed with the master cylinder reservoir cover and gasket in place 1 Remove the cover and gasket from the rear brake mas ter cylinder reservoir Be sure that no lubricant gets on rear tire wheel or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047b 2 Fil
7. y follow the instructions in the Service Manual to replace the brake disc Install the Chrome Rear Brake Caliper NOTE Pay close attention to all warnings cautions and torque specifications in this instruction sheet and in the service manual when installing this rear brake caliper 1 See Figure 2 Position the caliper 3 between the brake disc 5 and the rear fork 1 The weldment 2 on the fork should fit between the notch and rubber bumper 4 on the caliper Verify that the full length of the rubber bumper contacts the underside of the weldment i06649 1 Rear fork 2 Weldment 3 Rear brake caliper 4 Notch and rubber bumper 5 Rear brake disc Figure 2 Rear Wheel Axle and Caliper Assembly NOTE Apply isopropyl alcohol to the rubber bumper for ease of installation 3 Following the instructions in the Service Manual install the rear axle and check drive belt tension CAUTION Avoid leakage Be sure gaskets banjo bolts s brake line and caliper bore are clean and undamaged before assembly 0032a NOTE To prevent brake fluid loss do not re use the steel rubber gaskets removed with the banjo bolt Install the brake caliper using the new steel rubber gaskets provided in this kit 4 See Figure 3 Lubricate the new steel rubber washers 2 with the grade of brake fluid that will be used to fill reservoir Connect the rear brake line 3 to the caliper using banjo bolt 1 and two new washers 2 Torq
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