Question about 2004 Harley Davidson FLHT - FLHTI Electra Glide Standard

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Stuck caliper on 2003 road king classic

I replaced the rear brake pads, upon completion, the caliper piston stuck causing no rear brakes

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  • Harley Davidson Master
  • 3,506 Answers

Obviously you did something wrong. Take it apart and put it together correctly or since brakes are so important get someone who has the expertise to do it for you if you do not have the expertise yourself.

Posted on Oct 18, 2014


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Posted on Jan 02, 2017

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SOURCE: replace rear brake pads

Remove right saddlebag, pull the two caliper mounting bolts and remove the caliper. Do not open bleeder or disconnect line. You will need to push a large screwdriver between the old pads before removing them in order to push the pucks back into the caliper or the new pads will not spread enough to reinstall. Then pull the two smaller bolts from the caliper and the pads will fall out. The pads are different for inside and outside, so pay attention, and remember, after reinstalling, before riding, be sure to pump brake pedal, and it may take a few stops before brakes stop as effectively as before.

Posted on Nov 10, 2008

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SOURCE: rear brake pad change 07 streetglide

You don't have to but you should pull the caliper anyway, to clean it and check the anti-rattle spring.

Posted on Sep 08, 2009

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SOURCE: changing rear brake pads..

if the 04 is the same as my 05 ultra (and i belive it is) the rear caliper can not be removed with out pulling the axel out, and taking the 3 big star bolts out will split the caliper in half, (it is a 2 peice)

take the 2 small star bolts out, use a stiff putty knife to push the pistons back, before you pull the old pads out, make sure you take the cover off the master, slip new pads in, start with the frount and put the bolts thru to hold it then the rear

when you retighten the bolts you want the hear a "pop" that means the rear tip of the bolt is past the retaining spring, if you dont hear a pop the bolts will work there way out, (found this out the hard way, $129 new rotor, $195 new caliper)

Posted on Nov 16, 2009

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SOURCE: Rear brake light not workiing

There are two brake light switches. One is in the right handlebar switch housing. This is front brake light switch and is a simple push button type switch actuated by the front brake lever.

The other switch is a pressure switch and it is located in a Tee usually somewhere under the bike near the rear of the transmission. Follow the metal tube coming out of the rear of the master cylinder. It will go back towards the rear brake. Somewhere in that line there will be a tee with the pressure switch in it. If you jumper across this switch, the brake light should work. If it does work when you do this but not work when you depress the rear brake signal, replace the rear brake light switch.

Good luck

Posted on May 27, 2010

  • 1 Answer

SOURCE: wiring diagram for tourpak on 2003 Harley Road King Ultra Classic

i have a 2003 ultra classic my riding lights keep blowing the fuse it wont do it sitting in the garage i have gone thru the wiring harnessing looking for the short fixed many things but still have the problem the turn signals work the brake lights still work so where do i look

Posted on Jun 30, 2011

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1 Answer

How do you change the front brakes on a 2008 road king

Unbolt the caliper from front forks (2 bolts).
You'll have to move the caliper as far down as the hose will allow to clear the edge of the fender with the caliper to get it off the disc.
Remove the "hair-pin" clip on the one pad bolt, then remove the bolt.
Pop the old pads out of the caliper.
If master cylinder is almost full of brake fluid, siphon some out.
Clean off exposed pistons, then press them back into the caliper.
By hand is preferable, but you might need a "C" clamp to do this.
Install new pads, and reinstall pad pin.
Torque to 75-102 INCH lbs., and install "hair-pin" clip.
Reinstall caliper, and tighten two mounting bolts to 28-38 FOOT lbs.

Because the pistons were pushed back into the caliper (to compensate for the thicker new pads), it'll take several pumps of the brake lever before the pistons move the pads out enough to make contact with the disc.
Keep an eye on the master cylinder fluid level (don't let it get so low that air is introduced into the system), and top off with DOT 4 brake fluid.

May 07, 2014 | 2008 Harley Davidson FLHRC Road King...

1 Answer

Stuck rear brake caliper on 2003 road king after replacing brakes

Hi Anonymous, jack up bike so rear wheel is off the ground and can spin, bang the caliper on the outer half with a deadblow or rubber mallet 2 or 3 good wacks. Try and spin the wheel, if it spins check the rotor for warpage then check the brake pedal to make it works and is not locking up the rear wheel to where it won't spin freely. If it does lock up then your caliper pistons are cocked and need to be pushed all the way back into the bores and re-bleed the system. Good luck

Apr 22, 2014 | Harley Davidson FLHR Road king Motorcycles

1 Answer

Stuck rear caliper on my 2003 road king classic

Did u try bleeding the brake lines and flushing them? It just might me some dirt in there if that doesn't work you might have to replace it?

Apr 22, 2014 | 2003 Harley Davidson FLHR Road king

1 Answer

How to rebuild calipers on a 2002 road king including pistons and seals

Remove the calipers, remove the pistons and seals and if all is in great condition replace seals and pistons, re-install, bleed brake system. OFTEN may be just as cheap to replace the calipers

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2 Answers

Master cylinder 2003 road king

I would
1. Check brake pad thickness.
2. Check brake disk thickness.
3. Check and bleed the brakes, making sure you open and thighten all fittings in that system.
4. When you bleed the brakes, look for a good squirt when you hit the brakes with the top off.
5. If there isnt a squirt, rebuild the master cylinder.

I bet its one of those issues, but, do the easiest first.

Apr 28, 2012 | 2003 Harley Davidson FLHR Road king

2 Answers

Need to fit new brake pads to 2008 flhr road king

I believe there are bolts that hold caliper together 3/8 12 point socket works this was the case on my 93 fl.. the 1/2s separate which will give you access to the pads..good luck..I have found good info at

May 26, 2011 | 2008 Harley Davidson FLHR Road king

1 Answer

I need instructions for replacing the rear brakes on a 2000 Harley Davidson Road King Classic

Spray some brake cleaner into the existing pad/caliper area FIRST to wash any brake dust away.(being careful of painted surfaces) Take a thin "putty knife" and GENTLY pry the inboard and outboard brake pads away from the brake rotor/disc as far as they will go. Then with a 12pt 1/4" socket, remove the 2 pad retention pins from the caliper's face and let the pads fall out of the caliper's body, being careful to take notice of the pads themselves (they are slightly different) Slide the new pads up into the caliper body one at a time. This will require a little force as there is a spring inside the caliper body. Then you can re-insert the retention pins and snug them down firmly (do not over tighten) Double check your work, use a falshlight if necessary. Make SURE the pads are in place and you have adequate brake pedal "pressure". The bleeding of the caliper might be necessary. If you are wary of this procedure, please have qualifed persons do this critical work.

Aug 08, 2010 | 2000 Harley Davidson FLHRCI Road King...

1 Answer

How to change rear brakes on 2003 ultra classic

Take everything off the rear of the bike so you can gain access to the rear brake caliper. There are two screws that hold the brake caliper into the caliper bracket. Remove the screws. Most newer bikes have Torx head screws. Once you get the screws out, rock the caliper a bit and gently lift it up. Notice the position of the pads and the anti-rattle hardware that is in there. Some bikes have a "spirng" in there as well. Notice how it's all in there and then take it out. Replace the pads and hardware. Make sure you put the rear pad in with the fiber towards the rotor. Don't laugh, I've seen professionals put them in backwards, metal to metal.

Now, you've got to get the piston back into the bore of the caliper. I use either a large C-clamp or a large pair of slip joint pliers. Protect the paint on your caliper by wrapping it with rags or something. Compress the piston until it is all the way down into it's bore. Then, carefully put the caliper back on the bracket, insert bolts and torque them to 18-20 foot pounds.

Slowly pump the rear brake pedal until you get a full pedal. Make sure you test the brakes before you ride the bike. An improperly preformed brake job can cause serious injury or death.

Good Luck

Jul 13, 2010 | 2003 Harley Davidson FLSTC Heritage...

1 Answer

Repeat issues with drivers side front brake caliper

Were the lines to the brakes completely flushed out? If not have that done. Contaminates in the fluid id common and will bind the pistons in the brake calipers causing premature wear to the brake pads
If the pistons are sticking they will need to be removed and the inner piston wall cleaned thoroughly. Rebuilt calipers are much easier to replace if rebuilding your own is not an option you want to take

May 03, 2010 | 2003 Ford Expedition

1 Answer

How do you change the brakes on a 2008 road king classic

There are two long bolts (Torqx type bolts) that hold the rear caliper into it's bracket, Remove the two bolts and lift the caliper off the rear caliper bracket. Notice how the pads and the "anti-rattle clips" are positioned in the caliper bracket. Replace the pads and anti-rattle clips with new ones.

Now you'll need to get the piston pressed back into the caliper. Use a large C-clamp or a pair of slip joint pliers to do this with. Use a rag or something to keep from scratching your paint or scoring the piston. Once the piston is all the way back in it's bore, replace the caliper in it's bracket being careful not to disturn the pads. Pump the rear brake pedal a few times slowly until you build up pressure. Test the brakes before riding the bike. An improperly performed brake job can cause serious injury or death. Make sure everything is right before riding the bike.

Apr 19, 2010 | 2008 Harley Davidson FLHRC Road King...

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