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...