INSTRUCTIONS - HARLEY-DAVIDSON Rostock GmbH
Contents
1. HARLEY DAVIDSON J02502 INSTRUCTIONS REV 10 21 2004 Kit Number 44539 02A CHROME REAR BRAKE CALIPER KIT General The Chrome Rear Brake Caliper Kit fits the following mod els 2000 and later Softail models Except FXSTD and models with Wide Tire Kit Part No 43685 00 or 44490 00 2002 2004 V Rod models Brake pad anti rattle spring piston and pad pins are not included with this kit If it is necessary to replace worn or damaged parts kits which include these parts are available for purchase separately from your Harley Davidson dealer See the Service Parts illustration See the Service Parts illustration for kit contents The rider s safety depends upon the correct installation of this kit 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 00308a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is available for purchase at your Harley Davidson dealer Installation Prepare the Motorcycle for Service 1 For all models except V Rod Follow the Service Manual instructions to remove the seat To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 For all models excep2. 00204a 2 Fill reservoir with the grade of brake fluid specified in the Service Manual a For all models except V Rod See Figure 6 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 b For V Rod See Figure 7 Verify that the fluid level is 1 2 in 12 7 mm below gasket surface of reservoir NOTE Do not mix D O T 5 silicone hydraulic brake fluid with other grades of fluid as they are not compatible and could 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 J02502 i06622 Figure 6 Fill 1 8 in 3 2 mm below Reservoir Gasket Surface Softail Figure 7 Fill 1 2 in 12 7 mm below Reservoir Gasket Surface V Rod Figure 8 Rear Brake Bleeder Valve 4 of 6 Be sure the master cylinder relief port is not plugged A plugged relief port can cause brake drag or lockup and loss of vehicle control which could result in death or serious injury 00317a 7 To v
3. 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 J02502 Test the Brakes 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 1 Turn the ignition switch ON 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 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 discs 4 For models equipped with saddlebags install the right side saddlebag on models Refer to the SADDLE BAGS section of the Service Manual for installation and torque details 5 of 6 CANY e Service Parts Part No 44539 02A Date 07 04 Chrome Rear Brake Caliper Kit i06620 Item Description Quantity Chrome Rear Brake Caliper Kit 1 Chrome caliper assembly 2 Steel rubber brake line gasket 2 Piston Kit Square seal 4 Piston wiper 4 Piston 4 Crossover O ring 2 Pad Kit 7 Brake pad a
4. install new pad pins Listen for the audible click when installing and tighten to 180 200 in Ibs 20 23 Nm 3 of 6 Bleed the Brakes AcauTIon Direct contact of D O T 5 brake fluid with eyes can cause eye irritation swelling and redness Avoid eye contact in case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 5 brake fluid can cause digestive dis comfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF THE REACH OF CHILDREN 00144a 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 For V Rod To locate reservoir remove right side radi ator cover WARNING 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 CAUTION D O T 5 silicone hydraulic brake fluid is used in the hydraulic clutch Do not use other types of fluids as they are not compatible and could cause equipment damage
5. erify proper operation of the master cylinder relief port actuate the brake lever with the reservoir cover and gasket removed A slight spurt of fluid will break the surface if internal components are working properly 8 Torque the bleeder valve to 80 100 in Ibs 9 0 11 3 Nm and install the bleeder valve cap 9 Verify master cylinder fluid level For all models except V Rod See Figure 5 Fill reser voir 1 8 in 3 2 mm below gasket surface For V Rod See Figure 6 Fill reservoir 1 5 in 12 7 mm below gasket surface 10 Install the gasket and cover on the rear brake master cylinder reservoir For all models except V Rod Tighten cover screws to 6 8 in Ibs 0 7 0 9 Nm For V Rod Tighten cover screws to 0 7 0 9 Nm 6 8 in Ibs 11 For V Rod only Replace the right side radiator cover 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 instructions in the Service Manual to reinstall the belt guard and debris deflector Return the Motorcycle to Service 1 For all models except V Rod Connect negative bat tery cable to battery For V Rod Connect negative battery cable to battery and install left side cover Install maxi fuse and right side cover 2 For all models except V Rod Follow the instructions in the Service Manual to install the seat Awarnine After installing seat
6. he brake line from the caliper 3 See Figure 4 Remove the banjo bolt 2 fastening the rear brake line 3 to the stock rear brake caliper Save the banjo bolt for brake caliper installation and discard the steel rubber gaskets 1 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 3 Inspect the brake disc and if necessary follow the instructions in the Service Manual to replace the brake disc J02502 1 Rear axle adjusting screw 2 Rear axle adjusting nut 3 Spacer washer 4 Left rear axle spacer 5 Castle nut 6 Retaining pin Figure 2 Softail Rear Axle Figure 3 V Rod Rear Axle left side axle nut welded to eccentric and axle i06627 1 Steel rubber gaskets 2 Banjo bolt 3 Rear brake line 4 Bumper Figure 4 Rear Brake Caliper Removal 2 of 6 i06625 1 Rear fork 2 Weldment 3 Rear brake caliper 4 Notch and rubber bumper 5 Rear brake disc Figure 5 Rear Wheel Axle and Caliper Assembly Softail left V Rod right 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 4 Position the ca
7. liper 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 NOTE Apply isopropyl alcohol to the rubber bumper for ease of installation 2 Following the instructions in the Service Manual install the rear axle and check drive belt tension For all models except V Rod Final tighten axle nut to 60 65 ft lbs 82 88 Nm For V Rod Final tighten axle nut to 129 142 Nm 95 105 ft lbs J02502 CAUTION Avoid leakage Be sure gaskets banjo bolts s brake line and caliper bore are clean and undamaged before assembly 00032a 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 3 See Figure 3 Lubricate the new steel rubber gaskets 1 with the grade of brake fluid specified in the Service Manual Connect the rear brake line 3 to the caliper using banjo bolt 2 and two new gaskets 1 Torque the banjo bolt to 17 22 ft lbs 23 0 29 8 Nm 4 If necessary follow the instructions in the Service Manual and the individual kits to install new brake pads 5 If necessary follow the instructions in the Service Manual and the individual kits to install new anti rattle springs and crossover O rings 6 If necessary
8. nd holder inner 8 Brake pad and holder outer Pad Pin Kit 9 Pad pin 2 Anti Rattle Spring Kit 10 Anti rattle spring 11 Crossover O ring 2 Part Number 44539 02A Not sold separately 41731 01 44313 01 44329 00 44330 00 44335 01 44336 00 44082 00A Not sold separately Not sold separately 44314 00 black 44324 02 silver Not sold separately 44337 00B Not sold separately 44336 00 Chrome caliper is an assemlby of caliper halves pistons seals and wipers bridge bolts bleeder valve rubber bumper crossover O rings and anti rattle spring Piston wipers seals and crossover O rings only are available in a separate Seal Kit Part No 44315 00 J02502 6 of 6
9. rear wheel CAUTION Support the rear wheel from underneath during axle removal Failure to support the rear wheel may cause damage to the motorcycle as the axle is removed 2 For all models except V Rod See Figure 2 Remove the rear axle a Loosen the rear axle adjusting nut 2 and retract the axle adjusting screw 1 b Remove the retaining pin 6 castle nut 5 spacer washer 3 and left rear axle spacer 4 from the left side of the axle c Tap the axle toward the right side and remove the axle The wheel and the wheel spacer will fall loose as the axle is removed For V Rod See Figure 3 Remove the rear axle a Remove snap ring axle nut and adjustment eccentric from the right side b Release belt tension with left side eccentric and tap axle towards left side until axle is free The wheel and spacer will fall loose as the axle is removed NOTE Do not operate the rear brake with the rear wheel removed or the caliper pistons may be forced out of the piston bores Reseating the pistons requires caliper disassembly Remove the Stock Rear Brake Caliper 1 See Figure 4 Apply isopropyl alcohol to the rubber bumper 4 on the brake caliper to ease removal 2 See Figure 5 Lift the stock rear brake caliper toward the front of the motorcycle The notch in the caliper must clear the weldment 2 on the swing arm NOTE Place a container under the brake caliper to catch brake fluid released when removing t
10. t V Rod Follow the Service Manual instructions to disconnect the negative battery cable For V Rod Remove the right side cover and remove the maxi fuse Remove the left side cover and disconnect the negative battery cable Remove Rear Brake Caliper Remove the Brake Pads 1 For models equipped with saddlebags Remove the right side saddlebag Refer to the SADDLEBAGS sec tion of the Service Manual 2 Remove the rear master cylinder reservoir cover 3 Pry both the inside and outside pads away from the brake disc and toward the caliper assembly to push the caliper pistons back into their bores Use steady pres sure to prevent scoring the brake disc Pry between the pads and the brake disc 4 See Figure 1 When the pistons are fully retracted into their bores pull the pad pins out to allow the pads to drop from the caliper assembly Note the pads original orientation for installation 5 Install the cover on the rear master cylinder reservoir i06619 f Figure 1 Rear Caliper Pad Pins Softail shown Remove the Belt Guard and Debris Deflector Follow the instructions in the Service Manual to remove the belt guard and debris deflector Remove the Exhaust System If exhaust system removal is necessary follow the instruc tions in the Service Manual to remove the exhaust system 1 of 6 Remove the Rear Axle 1 Block the motorcycle under the frame to remove the weight of the motorcycle from the
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