Refer to these sections of the Sportsterpedia for recommendations, change intervals and bleeding advice:
For more information:
Refer to these threads on the XLForum:
* . . . Front Master Cylinder Identification
Front Master Cylinder part numbers and bore sizes. 2) 3) 4) | ||||||||
Master Cylinder | Year | Model | Bore | Rebuild Kit(s) | Fluid | Banjo Size | Single / Dual Discs | Caliper Pistons \ Area |
45019-85 | L1985-1986 | All Models | 5/8“ | 45069-84 45072-87 | DOT 5 | 3/8”x24 | Single | 1 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. |
||||||||
45025-87 | 1987 | All Models | 5/8“ | 45072-87 | DOT 5 | 3/8”x24 | Single | 1 Kelsey Hayes |
1988 | All Models | 5/8“ | 45072-87 | DOT 5 | 7/16”x24 | Single | 1 Kelsey Hayes |
|
45019-85 | 1989-1991 | All Models | 5/8“ | 45072-87 | DOT 5 | 7/16”x24 | Single | 1 Kelsey Hayes |
45019-85A | 1992 | All Models | 5/8“ | 45072-87 | DOT 5 | 7/16”x24 | Single | 1 Kelsey Hayes |
This version is retro for 1984-1991 Models | ||||||||
45019-93 | 1993-1995 | 883 883 Hugger 883 Deluxe 1200 | 5/8“ 5) | 45072-87 | DOT 5 | 7/16“x24 | Single | 1 Kelsey Hayes |
45013-96 45013-96D | 1996-1999 | 1200S | 11/16” | 45072-96 45072-96A 45072-96C | DOT 5 | 3/8“x24 | Dual | 2 x 39mm Kelsey Hayes |
2000 | 8 x 33mm | |||||||
45019-96 45019-96D | 1996-1999 | 883 883 Hugger 883C 1200 1200C | 9/16” | 45006-96 45006-96A 45006-96C | DOT 5 | 7/16“x24 | Single | 1 Kelsey Hayes |
2000 | 4 x 33mm | |||||||
45013-96A | 2001-2002 2002 | 1200S 883R | 11/16“ | 45072-96A | DOT 5 | 3/8”x24 | Dual | 8 x 33mm 6) Kelsey Hayes |
45019-96A | 2002 | 883 883 Hugger 883C 883R 1200 1200C | 9/16“ | 45006-96A | DOT 5 | 7/16”x24 | Single | 4 x 33mm 7) Kelsey Hayes |
45013-96B | 2003 | 883R 1200S | 11/16“ | 45072-96C | DOT 5 | 3/8”x24 | Dual | 8 Kelsey Hayes |
45019-96B | 2003 | 883 883 Hugger 883C 883R 1200 1200C | 9/16“ | 45006-96C | DOT 5 | 7/16“x24 | Single | 4 Kelsey Hayes |
45052-04 | 2004-2006 2005-2006 | 1200R 883R | 14mm 8) (.55”) | 42809-04 42809-04B | DOT 5 | 41737-04 7/16“x24 (11.1mm) | Dual | 4 x 27mm Nissin |
Parts catalog says the banjo bolt is 12mm but that's wrong. 9) | ||||||||
45146-04 | 2004-2006 2005-2006 | 883/1200C/883C 883L | 1/2” (12.7mm) | 42803-04 42803-04B | DOT 5 | M-10 | Single | 2 x 27mm 10) Nissin |
45052-07 | 2007 | 883R/1200R | 1/2“ 11) (12.7mm) | 42809-07 | DOT 4 | M-12 x 1.25 | Dual | 4 Nissin |
45146-07 | 2007 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 | 11mm | 42803-07A | DOT 4 | 41736-04 M-10×1.25 | Single | 2 Nissin |
42745-07 (black) | 2007-2012 2009-2013 2011-2013 | 1200N 883N XL1200X | 11mm | 42803-07A | DOT 4 | M-10 | Single | 2 Nissin |
45052-07A | 2008-2009 2008-2013 | 1200R 883R | 1/2” 12) (12.7mm) | 42809-07A | DOT 4 | M-12 | Dual | 4 Nissin |
42941-08 | 2009 | XR1200 | 5/8“ 13) (15.87mm) | 42736-08 | DOT 4 | M12x1.5 | Dual | 8 Nissin |
42941-10 | 2010 2010-2013 | XR1200 XR1200X | 5/8” 14) (15.87mm) | 42736-08 | DOT 4 | M-12 | Dual | 8 Nissin |
41700003 (silver) (ABS) | 2014-2017 2014-2016 2015-2017 | 883L 1200V 1200T | 14mm 15) | 41700084 | DOT 4 | M-10 | Single | 2 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“ | 41700087 | DOT 4 | M-10 | Single | 2 Nissin |
41700086 | 2014-2015 2016-2017 | 883R 1200CX | 1/2” | 41700088 | DOT 4 | M-10 | Dual | 4 Nissin |
41700099 (black (non ABS) | 2014-2017 | XL1200X 883N | 7/16“ | 41700087 | DOT 4 | M-10 | Single | 2 Nissin |
41700007 (black) (ABS) | 2014-2017 | XL1200X 883N | 14mm | 41700084 | DOT 4 | M-10 | Single | 2 Nissin |
Rear Master Cylinder part numbers and bore sizes. 16) | |||||||
Master Cylinder Assembly | Year | Model | Bore | Rebuild Kit(s) | Fluid | Brake 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 |
|
42456-84 | 1986-E1987 | All HDI | 5/8“ | 42374-82A 42374-82B | DOT 5 | 1 | |
42453-87 42453-87A 42453-87B | L1987-1990 1991 1992 | All Models | 3/4” | 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 | |
2000-2001 | All Models | 3/4” | DOT 5 | 4 | |||
42456-87C | 1998 | All Models | 3/4“ | 42382-87C | DOT 5 | 1 | |
2002-2003 | All Models | 3/4” | DOT 5 | 4 | |||
42521-04 | 2004-2007 | All Models | 42810-04 42810-04B | 1 | |||
42521-07 | 2008-2013 | All Models except XR1200/XR1200X | 42810-07A | 1 | |||
42945-08 | 2009-2010 | XR1200 | 42738-08 | 1 | |||
2010-2013 | XR1200X | ||||||
41700025 | 2014-2019 | All Models | 41700097 | 2 |
Wrench Sizes & Torque Specs
Caution the use of 6-point sockets and vise-grips will round off the bolt corners. 17)
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)
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.
Disc Part # | Material 29) |
40909-81A | Stainless Steel |
40939-79A | Stainless Steel |
40939-86 | Cast Iron |
41791-79 | Stainless Steel |
41806-72B | Stainless Steel |
41807-74 | Carbon Steel |
41813-79 | Stainless Steel |
44136-84 | Stainless Steel |
44137-77A | Stainless Steel |
44210-79 | Stainless Steel |