For more information:

Refer to these threads:

• 2005 Rear Master Cylinder Re-build
• - http://xlforum.net/forums/showthread.php?t=75157
• 2006 vs 2007 1200L Front Brake Caliper
• - http://xlforum.net/forums/showthread.php?threadid=2057183

Refer to the Reference Section:

• on Brakes (Fluid): brake_system
  

Wrench Sizes & Torque Specs

Caution the use of 6-point sockets and vise-grips will round off the bolt corners. ¹⁾

• 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). ²⁾
• 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. ³⁾
    They will give an audible click when inserted into the housing. ⁴⁾
  • Wrench (1/4“ 12-point), Torque (180-200 in/lbs / 20.3-22.6 Nm). ⁵⁾
• Bleeder valve:
  • Torque (80-100 in/lbs / 9.0-11.3 Nm) ⁶⁾
• 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. ⁷⁾
  • Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38.0-51.5 Nm). ⁸⁾

02 Caliper 9)

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. ¹⁰⁾