EVO: Wheels, Brakes & Tires


Brake System

Brake Fluid / Bleeding the System

Refer to these sections of the Sportsterpedia for recommendations, change intervals and bleeding advice:

For more information:

Refer to these threads on the XLForum:

Inspection

  • Inspect the master cylinder and linkage for damage or leakage, failure to return fully when released, or sponginess when applying pressure.
    • Any problem with the master cylinder requires rebuilding or replacement.
  • Brake Fluid Leakage:
    • Any fluid leakage in the brake system should be a signal for replacement of the particular component causing leakage.
    • On an older systems, pay special attention to hoses, looking for cracked or cut surfaces which could develop leakage.
  • Check the brake fluid for contamination and proper level.
    • The fluid change level should be 1/8” from top (with reservoir level).
  • Perform a stationary test:
    • Squeeze the lever or depress the pedal as hard as possible to make sure the system will not leak or fail.
      Make sure the system releases and the wheel turns freely.
  • Linkage inspection: Check for damage and wear especially with non-stock parts.
  • Some amount of freeplay must exist in most brake systems.


Master Cylinders


Front

Sub-Documents

* . . . Front Master Cylinder Identification

  • 1981 and earlier front master cylinders should have some free play.
  • 1982 and later do not. The internals are held in place by a seal ring.
  • Prior to 2004, there were only two thread pitches for EVO / TC88 models. 1)
    They were 3/8“-24, commonly known as 10mm, and 7/16”-24, commonly known as 12mm.
    (12mm is symbolic only, actual bore size is 11.2mm)
    With the introduction of the 2004 XLH (Sportster) models things changed.
    XL883, XL883C, and XL1200C models use 10mm x 1.25thread on both the front and rear master cylinders and calipers.
    The XL1200R uses a 12mm x 1.5 thread on the front master cylinder and 10mm x 1.25 on the rear master cylinder, and front and rear calipers.
    Only 2004-2006 models use true metric bolts. All other models have not changed.
Front Master Cylinder part numbers and bore sizes. 2) 3) 4)
Master
Cylinder
YearModelBoreRebuild
Kit(s)
FluidBanjo
Size
Single /
Dual
Discs
Caliper
Pistons \
Area
45019-85L1985
1986-1991
1986-1991
1986-1991
1986-1987
1988-1991
XL, XLS, XLX
883
883 Hugger
883 Deluxe
1100
1200
5/8“45069-84
45072-87
DOT 586-E90
3/8”x24
L90-91
7/16“x24
Single1
Kelsey Hayes
Note: OEM on 1986, 1989-1991 domestic models and 1987 HDI models.
Replacement master for '87-'88 Sportsters.
Rebuild kit 45069-84 includes body, kit 45072-87 comes without body.
45025-871987-1988
1987-1988
1987-1988
1987
1988
883
883 Hugger
883 Deluxe
1100
1200
5/8”45072-87DOT 53/8“x24Single1
Kelsey Hayes
45019-85A1992883
883 Hugger
883 Deluxe
1200
5/8”45072-87DOT 57/16“x24Single1
Kelsey Hayes
45019-931993-1995883
883 Hugger
883 Deluxe
1200
5/8” 5)45072-87DOT 57/16“x24Single1
Kelsey Hayes
45013-96

45013-96D
1996-19991200S11/16“45072-96
45072-96A
45072-96C
DOT 53/8”x24Dual2 x 39mm
Kelsey Hayes
20008 x 33mm
45019-96

45019-96D
1996-1999883
883 Hugger
883C
1200
1200C
9/16“45006-96
45006-96A
45006-96C
DOT 57/16“x24Single1
Kelsey Hayes
20004 x 33mm
45013-96A2001-2002
2002
1200S
883R
11/16”45072-96ADOT 53/8“x24Dual8 x 33mm 6)
Kelsey Hayes
45019-96A2002883
883 Hugger
883C
883R
1200
1200C
9/16”45006-96ADOT 57/16“x24Single4 x 33mm 7)
Kelsey Hayes
45013-96B2003883R
1200S
11/16”45072-96CDOT 53/8“x24Dual8
Kelsey Hayes
45019-96B2003883
883 Hugger
883C
883R
1200
1200C
9/16”45006-96CDOT 57/16“x24Single4
Kelsey Hayes
45052-042004-2006
2005-2006
1200R
883R
14mm 8)
(.55“)
42809-04
42809-04B
DOT 541737-04
7/16”x24
(11.1mm)
Dual4 x 27mm
Nissin
Parts catalog says the banjo bolt is 12mm but that's wrong. 9)
45146-042004-2006
2005-2006
883/1200C/883C
883L
1/2“
(12.7mm)
42803-04
42803-04B
DOT 5M-10Single2 x 27mm 10)
Nissin
45052-072007883R/1200R1/2” 11)
(12.7mm)
42809-07DOT 4M-12 x 1.25Dual4
Nissin
45146-072007
2007-2009
2007-2010
2007-2013
2007-2013
2007-2011
2011-2013
2013
2013
2013
2013
XL50
883
883C
1200C
883L
1200L
1200CP
1200C Anv
1200V
1200CA
1200CB
11mm42803-07ADOT 441736-04
M-10×1.25
Single2
Nissin
42745-07
(black)
2007-2012
2009-2013
2011-2013
1200N
883N
XL1200X
11mm42803-07ADOT 4M-10Single2
Nissin
45052-07A2008-2009
2008-2013
1200R
883R
1/2“ 12)
(12.7mm)
42809-07ADOT 4M-12Dual4
Nissin
42941-082009XR12005/8” 13)
(15.87mm)
42736-08DOT 4M12x1.5Dual8
Nissin
42941-102010
2010-2013
XR1200
XR1200X
5/8“ 14)
(15.87mm)
42736-08DOT 4M-12Dual8
Nissin
41700003
(silver)
(ABS)
2014-2017
2014-2016
2015-2017
883L
1200V
1200T
14mm 15)41700084DOT 4M-10Single2 x 34mm
Nissin
41700085
(silver)
(non-ABS)
2014-2017
2014-2017
2014-2016
2014-2016
2014-2016
2014-2017
2015-2017
883L
1200C
1200V
1200CP
1200CA
1200CB
1200T
7/16”41700087DOT 4M-10Single2
Nissin
417000862014-2015
2016-2017
883R
1200CX
1/2“41700088DOT 4M-10Dual4
Nissin
41700099
(black
(non ABS)
2014-2017XL1200X
883N
7/16”41700087DOT 4M-10Single2
Nissin
41700007
(black)
(ABS)
2014-2017XL1200X
883N
14mm41700084DOT 4M-10Single2
Nissin

Rear

Sub-Documents

  • 1982-E1987 master cylinders have aluminum bodies and require a minimum of 1/32” free play.
    They all had a 5/8“ bore.
  • L1987-2003 master cylinders have built-in free play and use replaceable cartridge type internals that rarely need replacing.
    They all came with a 3/4” bore.
    The replacement body (42472-87), one piece bore/bowl, is the same part number from L1987-2003.
Rear Master Cylinder part numbers and bore sizes. 16)
Master
Cylinder
Assembly
YearModelBoreRebuild
Kit(s)
FluidBrake Line
Fitting /
Threads
Caliper
Pistons \
Area
42453-82
42453-82A
(polished)
1982-1985
1983-1985
1986-E1987
XL
XLS, XLX
All
5/8“42374-82
42374-82A
42374-82B
DOT 5 1
Lucas Girling
42456-841986-E1987All HDI5/8”42374-82A
42374-82B
DOT 5 1
42453-87
42453-87A
42453-87B
L1987-1990
1991
1992
All Models3/4“42382-87
42382-87A
DOT 5 1
42456-87A
42456-87B
1991
1992
1993-97
1999
All HDI
All HDI
All Domestic
3/4”42382-87
42382-87A
42382-87B
DOT 5 1
2000-2001All Models3/4“DOT 5 4
42456-87C1998All Models3/4”42382-87CDOT 5 1
2002-2003All Models3/4“DOT 5 4
42521-042004-2007All Models 42810-04
42810-04B
1
42521-072008-2013All Models except
XR1200/XR1200X
42810-07A 1
42945-082009-2010XR1200 42738-08 1
2010-2013XR1200X
417000252014-2019All Models 41700097 2

Calipers


Front

Rear

Sub-Documents

2001 Front Style Caliper

Wrench Sizes & Torque Specs

Caution the use of 6-point sockets and vise-grips will round off the bolt corners. 17)

  • Changing pads:
  • Caliper to fork mounting bolts (2) (rectangles in pic below):
    • Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38-51.5 Nm). 18)
  • Brake Pad Slide Pins (2) (five sided box below):
    • The small bolts on the caliper need to be removed in order to change the pads. 19)
      They will give an audible click when inserted into the housing. 20)
    • Wrench (1/4” 12-point), Torque (180-200 in/lbs / 20.3-22.6 Nm). 21)
  • Bleeder valve:
    • Torque (80-100 in/lbs / 9.0-11.3 Nm) 22)
  • Banjo bolt on caliper (six sided box below):
    • Wrench (3/8“ 12-point)
  • Banjo bolt at M/C:
    • Wrench (7/16 12-point)
  • Disassembling the caliper:
  • Bridge bolts (2) (rectangles in pic below):
  • The 2 larger bolts to the right on the caliper.
    These hold the caliper halves together and shouldn't need to be removed unless you are rebuilding the caliper. 23)
    • Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38.0-51.5 Nm). 24)
02 Caliper 25)


Alternative Calipers:

The 2000 and newer bikes have a completely different mounting boss for the brakes. If you want to upgrade to Brembo calipers you're going to need the lowers from a 2000 and newer model. The stock aluminum style is the same price as the chrome version (at retail) so if you like chrome, it's definitely the way to go. 26)

2004 Rear Style Caliper

When removing the rear caliper pin bolt (44184-04) and raising the caliper, the brake pads will rotate and come out of the retention clip. 27)
During reassembly you must be certain to visually check that the brake pads are properly reinserted into the retention clip.
If the pads are not positioned properly you will cross thread the pin bolt in the aluminum caliper during reassembly.
A cross-threaded caliper pin bolt may permit the caliper to rock side to side on the bracket when the brake is applied causing drag and noise.

Brake Pads


Brake Disc (rotor)

Disc Part #Material 28)
40909-81AStainless Steel
40939-79AStainless Steel
40939-86Cast Iron
41791-79Stainless Steel
41806-72BStainless Steel
41807-74Carbon Steel
41813-79Stainless Steel
44136-84Stainless Steel
44137-77AStainless Steel
44210-79Stainless Steel

Rear

Rear Brake Rotor (41833-08) 29)


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