Question about 2002 Harley Davidson FXST Softail Standard

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Stuck Brake Pad Pins

Following 02FXST HD Manual, I removed brake pads prior to removing wheel to fix a flat. Fixed flat/installed new floating break rotor. Prior to reinstalling rear wheel, I installed new inside brake pad and did tighten the pad pins just a bit. Installed wheel and now,new outside break pad will not fit. Seems the floating button on new rotor is blocking install. When I attempt to remove new inside break pad, the pins will not pull out although pins are completely loosened. Both sides of brake have pistons are fully retracted into their bores. I have not pumped or engaged the brake pedal.Thinking of reusing old brake pads (still have some life) to break in new rotor but first have to remove new inside pad. Thinking if I pump brake pedal that might unstick the pad pins, but I'm afraid of outside pistons coming out of their bore. How do I unstick the brake pad pins? Why are new brake pads not able to fit with new floating rotor?

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  • Anonymous Mar 29, 2014

    remove rear break arm

  • Anonymous Apr 01, 2014

    I am swapping the wheels on my '10 S.G. With that said, I am reusing the rear rotor but I am wondering if there is a special position on the wheel for the rivet (on the rotor)?

    Thanks

    Bill

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I suggest pulling the axle out a bit to allow the caliper assy more freedom of movement. Then see if you can get the pins out. If not, you can put something (like a piece of wood) between the pistons and the rotor on the outside and gently pump the pedal to see if that does in fact loosen the pins. But a more fundemental question: is the new floating rotor the EXACT diameter as the OEM (or whatever was on there) rotor? It sounds to me like the rotor is jammed against the pins. If it is the same size, are the new pads the same shape as the old ones (same profile on the metal backing)?

Posted on Nov 20, 2008

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1 Answer

How to replace rear brake pads 2002 softtail ?


If present, remove right saddlebag.
Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in. (3.2 mm). You may have to remove fluid to allow for this.
Loosen, but do not remove, both pad pins (12 pt/0.25 in.).
Pry the inside pad back. Use steady pressure to prevent scoring the brake disc. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Once the pistons have been fully retracted into their bores, pull pad pins part way until the inside pads drop free. Note the pad's original orientation for replacement purposes.
Install pad with two tabs on the inboard side of the rear caliper.
Install new inside brake pad using the same orientation as the pad previously removed. Curved portion of pad must face upward.
Install pad pins until the pins snap into place with an audible click. Do not fully tighten at this time.
Pump brake pedal lever to move inside pistons out until they contact inside brake pads.
Pry the outside pad back. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Verify that inside pads are captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the pad's original orientation for replacement purposes.
Install new outside brake pad using the same orientation as the pad previously removed. If the inside pad moved during the previous step, reinstall. Curved portion of pad must face upward.
Install both pad pins through holes in inner and outer
brake pads. Tighten to 180-200 in-lbs (20.3-22.6 Nm).

Jun 03, 2014 | 2003 Harley Davidson FXST Softail Standard

1 Answer

Rear brake replacement 2003 FLHT


The minimum brake disc thickness is stamped on the side of the disc. Maximum brake disc lateral runout or warpage is 0.008 inch (0.2 mm) when measured near the outside diameter.
Replace brake pads if the friction material above the backing plate on either pad is 0.04 inch (1.02 mm) thick or less.

To remove the rear brake pads begin by removing the right side saddlebag, loosen both pad pins but do not remove them or installation of the new pads will be more difficult than needs to be, remove the rear master cylinder reservoir so you can se the fluid level as you push the pads and the pistons back as the level ma rise too much when the pistons are seated fully in their bores and you may have to see this and remove excess fluid, pry the inside pad back pushing the pistons fully into their bores using a putty knife with a wide thin blade to avoid scoring or scratching the brake disc. THEN when the pistons have been fully retracted pull the pad pins part way out until the inside pad drops free and note the orientation of the pad so that you can easily install the new pad in the same orientation with the curved portion of pad necessarily facing the rear of the motorcycle, install the new pad and install but do not tighten the pad pins, then pump the rear brake pedal to move the inside pistons out until they
they contact the inside brake pad, then using a putty knife with a wide thin blade to avoid scoring or scratching the brake disc pry the outside pad back in order to push those pistons fully into their bores, verify that the inside pad is captured between the brake disc and the pistons, completely remove the pad pins to free the outside brake pad. note the orientation of the pad before it falls out and install a new outside brake pad using the same orientation with the curved portion of pad necessarily facing the rear of the motorcycle and if the inside pad moved during the previous step reinstall it. Replacing one pad at a time keeps the anti-rattle spring in place and so if you wish to replace the spring you will have to remove both pads to remove and replace it. THEN inspect the pad pins for unacceptable wear/grooving and replace if and as necessary and install the two pad pins and tighten them to 180-200 in-lbs (20.3- 22.6 Nm). THEN pump the brake pedal to extend the pistons and move the brake pads out against the brake disc. THEN check that the brake fluid is at the proper level about 1/8 inch down from the top of the reservoir and add NEW D.O.T. 5 SILICONE BRAKE FLUID, if necessary, install the master cylinder reservoir cover and tighten the cover screws to 6-8 inlbs(0.7-0.9 Nm), install the right side saddlebag, turn on the ignition/Light Key Switch and observe proper operation of the brake light, safely test ride the motorcycle and if the brakes feel soft or spongy, bleed them until you get a firm, hard pedal. Allow the new pads to properly wear in to the disc by not doing hard stops for the first 100 miles (160 km).

May 19, 2014 | 2004 Harley Davidson FLHT - FLHTI Electra...

1 Answer

Change front brake pads, 2002 FXD


For 2002 DYNA to replace front brake pads FIRST remove the front master cylinder reservoir cap because as the pistons are pushed back into the caliper the fluid level may rise and you will need to see this and may have to remove some excess fluid, the3n loosen but do not remove both (12 pt/0.25 in.) pad pins, remove both 10 mm caliper mounting bolts, detach and remove the caliper from the front forks and brake disc, pry the pads back to force all four caliper pistons fully into their bores, with the pistons retracted, remove the pad pins and brake pads. The front left, front right (if present as not present on all motorcycles) and the rear brake calipers use the same exact brake pad set. On the right side of the vehicle, the pad with the two tabs installs on the inboard side of the caliper and on the left side the pad with the two tabs installs on the outboard side of the caliper. Install new brakepads into caliper with the curved portion of the pad facing the rear of the motorcycle, loosely install the pad pins until you hear an audible click, attach the caliper to the front fork, on models with dual front calipers check the alignment of the brake discs to the calipers. Loosen the axle pinch bolt nuts, tighten the axle nut to the proper torque, insert a 7/16 in. drill bit through the hole in the axle as far as it will go so that the contact point will have the edge of the drill bit touching the edge of the fork leg, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long 12 pt/10 mm mounting bolt into the top hole on the fork leg, install the short 12 pt/10 mm mounting bolt into the bottom hole on the fork leg, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten the top mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten both pad pins to 180-200 in-lbs (20.3-22.6 Nm)., on models with dual front calipers, tighten the pinch bolt nuts while holding the slider against the 7/16 drill bit if necessary, remove the drill bit, pump the brake hand lever to move the pistons out until they contact both brake pads, verify the piston location against the pads and if the front wheel is off the ground, rotate it to check for excessive brake pad drag, check the brake fluid level in the master cylinder and fill it to the proper level if necessary using D.O.T. 5 SILICONE BRAKE FLUID, install the master cylinder reservoir cap and tighten its cap screws to 6-8 in-lbs (0.7-0.9 Nm), turn ignition switch ON pump the brake hand lever to verify operation of the brake lamp, test the brakes, test ride the motorcycle and if the brakes feel soft or spongy, bleed the system until you get a firm/hard brake lever and avoid making hard stops for the first 100 miles (160 km) to allow the new brake pads to become conditioned to the brake disc(s).

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1 Answer

How do i replace rear brake pads on my 2002 hd fxdwg


After servicing the brakes in any way and before moving the motorcycle always pump the brakes to build brake system pressure and move the pistons and pads out against the brake rotor.

First remove the rear master cylinder reservoir cap and check the fluid level because as the pistons are pushed back into the caliper the fluid level will rise and you do not want it to overflow the reservoir and spill out and to avoid this you must remove sufficient fluid.
Second, loosen, but do not remove, both pad pins with a 12 point .025 inch socket wrench.
Thirdly pry the inside pad back using steady pressure and a sturdy scraper or large screw driver or similar suitable tool, prying between the pad and the brake disc in order to push the caliper pistons back into their bores.
Fourthly, once the pistons have been fully retracted into their bores, pull the pad pins out part way only until the inside pads drop free.Do not completely pull the pad pins out from the caliper at this time because completely removing the pad pins at this time will cause you unnecessary difficulty during re-assembly. ALSO carefully note and remember each pad's original orientation for so you can put the new pads into the correct position and orientation in the caliper. Note that the front left, and the front right (if the front right is present) and all of the rear brake calipers use the same exact brake pad set. Install the pad with two tabs on the inboard side of the rear caliper.
Fifthly install the new inside brake pad using the same orientation as the pad previously removed (with the curved portion of the pad facing the rear of the motorcycle.
Sixthly install the pad pins until the pins snap into place with an audible click but do not fully tighten them at this time.
Next pump the brake pedal lever to move the inside pistons out until they contact the inside brake pads and then pry the outside pad back to push the caliper pistons back into their bores and verify that the inside pads have been captured between the brake disc and the pistons. At this point you can completely remove the pad pins to free the outside brake pad. Again note the pad's original orientation for replacement purpose and orientation
.While the pad pins are out inspect them for grooving and wear and measure the pin diameter in an unworn area, and then in the area of any grooving or wear, and if wear is more than 0.015 in. (0.38mm), replace both pins.
THEN install the new outside brake pad using the same orientation as the pad previously removed and if the inside pad moved during the previous step, reinstall it with the curved portion of the pad facing the rear of motorcycle.
THEN install both pad pins through holes in the inner and outer brake pads and tighten them to 180-200 in-lbs which is (20.3-22.6 Nm).
THEN pump the brake pedal to move the pistons out until they contact both of the brake pads and verify the correct piston location against the pads.
THEN check the brake fluid level in master cylinder and fill it up to the correct level if necessary using ONLY D.O.T. 5 SILICONE BRAKE, install the master cylinder reservoir cap and tighten the reservoir cap screws to 6-8
in-lbswhich is (0.7-0.9 Nm).
WHEN the bike is completely back together test the brakes at low speed in a safe area and also confirm that the brake light works properly and if the brakes feel at all spongy bleed them properly until a hard not spongy brake pedal is obtained. AND avoid making hard stops for the first 100 miles (160 km) to allow the new pads to condition to the brake rotors.

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1 Answer

How do i change rear brakes pads on a 2002 hd fxdwg ?


DO NOT REMOVE THE WHEEL AND DO NOT SPLIT THE CALIPER.

After servicing the brakes in any way and before moving the motorcycle always pump the brakes to build brake system pressure and move the pistons and pads out against the brake rotor.

First remove the rear master cylinder reservoir cap and check the fluid level because as the pistons are pushed back into the caliper the fluid level will rise and you do not want it to overflow the reservoir and spill out and to avoid this you must remove sufficient fluid.
Second, loosen, but do not remove, both pad pins with a 12 point .025 inch socket wrench.
Thirdly pry the inside pad back using steady pressure and a sturdy scraper or large screw driver or similar suitable tool, prying between the pad and the brake disc in order to push the caliper pistons back into their bores.
Fourthly, once the pistons have been fully retracted into their bores, pull the pad pins out part way only until the inside pads drop free.Do not completely pull the pad pins out from the caliper at this time because completely removing the pad pins at this time will cause you unnecessary difficulty during re-assembly. ALSO carefully note and remember each pad's original orientation for so you can put the new pads into the correct position and orientation in the caliper. Note that the front left, and the front right (if the front right is present) and all of the rear brake calipers use the same exact brake pad set. Install the pad with two tabs on the inboard side of the rear caliper.
Fifthly install the new inside brake pad using the same orientation as the pad previously removed (with the curved portion of the pad facing the rear of the motorcycle.
Sixthly install the pad pins until the pins snap into place with an audible click but do not fully tighten them at this time.
Next pump the brake pedal lever to move the inside pistons out until they contact the inside brake pads and then pry the outside pad back to push the caliper pistons back into their bores and verify that the inside pads have been captured between the brake disc and the pistons. At this point you can completely remove the pad pins to free the outside brake pad. Again note the pad's original orientation for replacement purpose and orientation
.While the pad pins are out inspect them for grooving and wear and measure the pin diameter in an unworn area, and then in the area of any grooving or wear, and if wear is more than 0.015 in. (0.38mm), replace both pins.
THEN install the new outside brake pad using the same orientation as the pad previously removed and if the inside pad moved during the previous step, reinstall it with the curved portion of the pad facing the rear of motorcycle.
THEN install both pad pins through holes in the inner and outer brake pads and tighten them to 180-200 in-lbs which is (20.3-22.6 Nm).
THEN pump the brake pedal to move the pistons out until they contact both of the brake pads and verify the correct piston location against the pads.
THEN check the brake fluid level in master cylinder and fill it up to the correct level if necessary using ONLY D.O.T. 5 SILICONE BRAKE, install the master cylinder reservoir cap and tighten the reservoir cap screws to 6-8
in-lbswhich is (0.7-0.9 Nm).
WHEN the bike is completely back together test the brakes at low speed in a safe area and also confirm that the brake light works properly and if the brakes feel at all spongy bleed them properly until a hard not spongy brake pedal is obtained. AND avoid making hard stops for the first 100 miles (160 km) to allow the new pads to condition to the brake rotors.

May 10, 2014 | Harley Davidson Motorcycles

1 Answer

2003 Suzuki VL 1500 Intruder LC REAR DISC RATTLE,HOW DO I REPLACE IT?


Hello Dale, this is an easy job on your bike. Use a flat head screw driver and remove the brake pad cover...it will pop off.
Remove the hairpin type clips off of the ends of the brake pad pins.... Use pliers & pull the brake pad pins out from the front of the rear brake caliper....Clean the rear brake caliper's piston with brake cleaner. Use a rag and wipe it clean...Reinsert the old brake pads into the caliper. Place a pry bar between the brake pads, then push the inner piston into the caliper body, this will allow room to install new pads.... Remove the old brake pads...Coat the brake pad pins and the new brake pads metal back plates with high-temperature grease.

Slip the new brake pads into the rear brake caliper, then push the brake pad pins halfway into the caliper. Slip the spring clips into place between the brake pads and the brake pad pins. Push the brake pad pins completely through the rear brake caliper. Push the hairpin clips back into the brake pad pin tips. Snap the brake pad cover onto the top of the rear brake caliper....

Pump the rear brake pedal until the pedal feels firm, indicating that the brake pads have closed around the brake rotor...No bleeding will be needed because the system was never opened - That's all there is to it...i hope this information is helpful & good luck with your bike.


11_23_2011_12_23_40_am.jpg

Nov 22, 2011 | 2003 Suzuki VL 1500 Intruder LC

1 Answer

How do i change front brake pads on my 2002 fxd super glide



For 2002 DYNA to replace front brake pads FIRST r
emove the front master cylinder reservoir cap because as the pistons are pushed back into the caliper the fluid level may rise and you will need to see this and may have to remove some excess fluid, the3n loosen but do not remove both (12 pt/0.25 in.) pad pins, remove both 10 mm caliper mounting bolts, detach and remove the caliper from the front forks and brake disc, pry the pads back to force all four caliper pistons fully into their bores, with the pistons retracted, remove the pad pins and brake pads. The front left, front right (if present as not present on all motorcycles) and the rear brake calipers use the same exact brake pad set. On the right side of the vehicle, the pad with the two tabs installs on the inboard side of the caliper and on the left side the pad with the two tabs installs on the outboard side of the caliper. Install new brake pads into caliper with the curved portion of the pad facing the rear of the motorcycle, loosely install the pad pins until you hear an audible click, attach the caliper to the front fork, on models with dual front calipers check the alignment of the brake discs to the calipers. Loosen the axle pinch bolt nuts, tighten the axle nut to the proper torque, insert a 7/16 in. drill bit through the hole in the axle as far as it will go so that the contact point will have the edge of the drill bit touching the edge of the fork leg, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long 12 pt/10 mm mounting bolt into the top hole on the fork leg, install the short 12 pt/10 mm mounting bolt into the bottom hole on the fork leg, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten the top mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten both pad pins to 180-200 in-lbs (20.3-22.6 Nm)., on models with dual front calipers, tighten the pinch bolt nuts while holding the slider against the 7/16 drill bit if necessary, remove the drill bit, pump the brake hand lever to move the pistons out until they contact both brake pads, verify the piston location against the pads and if the front wheel is off the ground, rotate it to check for excessive brake pad drag, check the brake fluid level in the master cylinder and fill it to the proper level if necessary using D.O.T. 5 SILICONE BRAKE FLUID, install the master cylinder reservoir cap and tighten its cap screws to 6-8 in-lbs (0.7-0.9 Nm), turn ignition switch ON pump the brake hand lever to verify operation of the brake lamp, test the brakes, test ride the motorcycle and if the brakes feel soft or spongy, bleed the system until you get a firm/hard brake lever and avoid making hard stops for the first 100 miles (160 km) to allow the new brake pads to become conditioned to the brake disc(s

Aug 12, 2011 | 2002 Harley Davidson FXD Dyna Super Glide

1 Answer

Rear brake pad installation 2006 flhx harley davidson


Do Not remove wheel.............push the pads back and remove the two pins.
Note there is a inner and outer pad on assembly, have a look at the new pads they are different

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1 Answer

How do i replace my brake pads on a 1991 dr350


You didn't specify front or rear so I will hit both.
Start with the front. Refer to this diagram:
http://216.37.204.203/Suzuki_OEM/SuzukiDB.asp?Type=13&A=91&B=43
Unbolt bracket 13 from the fork leg, then remove the 2 brake pad retaining pins #12. The brake pads can then be removed. You will have to compress the spring #5 when putting the pads back in to be able to reinstall the pins #12.
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http://216.37.204.203/Suzuki_OEM/SuzukiDB.asp?Type=13&A=91&B=49
You have one of two choices, either remove the rear wheel so you can drop the pads out by removing the brake pad retaining pins #13 or unscrew #8 from the caliper bracket then remove the caliper.

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2 Answers

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