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techtalk:ih:wheels02 [2020/06/23 05:46] hippysmack [Sub-Documents] |
techtalk:ih:wheels02 [2020/06/24 18:03] hippysmack [Cleaning The Master Cylinder] |
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| ====== Disc Braking System ====== | ====== Disc Braking System ====== | ||
| + | ====== Inspection ====== | ||
| + | |||
| + | * Inspect the master cylinder and linkage for damage or leakage, failure to return fully when released, or sponginess when applying pressure. | ||
| + | * 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. | ||
| + | * Check the brake fluid for contamination and proper level. \\ Any problem with the master cylinder requires rebuilding or replacement. \\ The fluid change level should be 1/8” from top (with reservoir level). | ||
| + | * Linkage inspection: Check for damage and wear especially with non-stock parts. | ||
| + | * Some amount of freeplay must exist in most brake systems. | ||
| + | |||
| ====== Brake Fluid ====== | ====== Brake Fluid ====== | ||
| + | |||
| [[techtalk:ref:wheels03#brake_fluid|Brake Fluid - recommendations, change intervals and bleeding advice]]. | [[techtalk:ref:wheels03#brake_fluid|Brake Fluid - recommendations, change intervals and bleeding advice]]. | ||
| ====== Front Master Cylinder ====== | ====== Front Master Cylinder ====== | ||
| \\ | \\ | ||
| ==== Sub-Documents ==== | ==== Sub-Documents ==== | ||
| - | * . . . [[techtalk:ih:wheels02H|Front Master Cylinder Identification]] \\ | + | * . . . [[techtalk:ih:wheels02h|Front Master Cylinder Identification]] \\ |
| - | + | * 1981 and earlier front master cylinders should have some free play. | |
| - | * Kelsey Hayes front master cylinder: | + | * 1982 and later do not. The internals are held in place by a seal ring. |
| - | * The Kelsey Hayes master has no freeplay. The internals are held in place by a seal ring. | + | |
| - | * There were 5 bore sizes on HD motorcycles according to 2000 MMI documentation: | + | |
| - | * 1982 (only) had a 3/4” bore. | + | |
| - | * 1983-1995 had 5/8” bore on a single disc and 11/16" on dual discs. | + | |
| - | * 1996 and up had 9/16” on singles and 13/16" on duals (however, 1996-2003 S models had a 11/16" bore). | + | |
| - | * This information has been repeated around many forums and it's not clear exactly which HD models the MMI information refers to. \\ However, the information below was taken from period specific Sportster parts catalogs. | + | |
| | **Front Master Cylinder part numbers and bore sizes**. ((1976-up Sportster Parts Catalogs)) ||||||||| | | **Front Master Cylinder part numbers and bore sizes**. ((1976-up Sportster Parts Catalogs)) ||||||||| | ||
| |Master \\ Cylinder \\ Assembly|Year|Model|Bore|Rebuild \\ Kit(s)|Fluid|Brake Line \\ Fitting / \\ Threads|Single / \\ Dual \\ Discs|Caliper \\ Pistons \ \\ Area| | |Master \\ Cylinder \\ Assembly|Year|Model|Bore|Rebuild \\ Kit(s)|Fluid|Brake Line \\ Fitting / \\ Threads|Single / \\ Dual \\ Discs|Caliper \\ Pistons \ \\ Area| | ||
| - | |45010-73|1973-1977|XLH \\ XLCH|3/4" ((doodah man of the XLFORUM http://xlforum.net/forums/showthread.php?t=1802284))|45063-72|Dot 5|1/4"x27 NPT \\ straight fitting|Single|Banana \\ Clebrake \\ 1.75" ((sagebrush of the XLFORUM http://xlforum.net/forums/showthread.php?t=1919910))| | + | |45010-73|1973-1977|XLH \\ XLCH|3/4" ((doodah man of the XLFORUM http://xlforum.net/forums/showthread.php?t=1802284))|45063-72|Aug 1976 ← \\ Dot 3 \\ Sept 1976 → \\ Dot 5|1/4"x27 NPT \\ straight fitting|Single|1 \\ Banana \\ 1 \\ Clebrake \\ 1.75" ((sagebrush of the XLFORUM http://xlforum.net/forums/showthread.php?t=1919910))| |
| - | |43306-78|1978-E1979|XLH \\ XLCH|3/4"|45063-72|Dot 5|90° fitting|Dual|Kelsey Hayes| | + | |43306-78|1978-E1979|XLH \\ XLCH|3/4"|45063-72|Dot 5|90° fitting|Dual|2 \\ Small \\ Kelsey Hayes| |
| - | |45011-77|L1979|XL \\ XLCH \\ XLS|3/4"|45063-72|Dot 5|90° fitting|Dual|Kelsey Hayes| | + | |45011-77|L1979|XL \\ XLCH \\ XLS|3/4"|45063-72|Dot 5|90° fitting|Dual|2 \\ Small \\ Kelsey Hayes| |
| - | |4501372|1980-1981|XL \\ XLS|3/4"|45063-72|Dot 5|90° fitting|Dual|Kelsey Hayes| | + | |45013-72|1980-1981|XL \\ XLS|3/4"|45063-72|Dot 5|90° fitting|Dual|2 \\ Small \\ Kelsey Hayes| |
| - | |45013-82 \\ (black)|1982-1983|XL \\ XLS \\ XLX|3/4"|45063-82|Dot 5| |Dual|Kelsey Hayes| | + | |45013-82 \\ (black)|1982-1983|XL \\ XLS \\ XLX|3/4"|45063-82|Dot 5| |Dual|2 \\ Small \\ Kelsey Hayes| |
| - | |45019-84|1984-E1985|XL \\ XLS \\ XLX|5/8"|45069-84 \\ 45072-87|Dot 5| |Single|Kelsey Hayes| | + | |45019-84|1984-E1985|XL \\ XLS \\ XLX|5/8"|45069-84 \\ 45072-87|Dot 5| |Single|1 \\ Semi \\ Torque Free| |
| - | |45019-85|L1985 \\ 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 5|86-E90 \\ 3/8"x24 \\ L90-91 \\ 7/16"x24|Single|1 \\ Kelsey Hayes| | + | |45019-85|L1985 \\ 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 5|86-E90 \\ 3/8"x24 \\ L90-91 \\ 7/16"x24|Single|1 \\ Semi \\ Torque Free| |
| |:::|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.|||||||| | |:::|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.|||||||| | ||
| ====== Rear Master Cylinder ====== | ====== Rear Master Cylinder ====== | ||
| + | ==== Sub-Documents ==== | ||
| + | * . . . [[techtalk:ih:wheels02j|Rear Master Cylinder Identification]] \\ | ||
| | **Rear Master Cylinder part numbers and bore sizes**. ((1979-up Sportster Parts Catalogs)) |||||||| | | **Rear Master Cylinder part numbers and bore sizes**. ((1979-up Sportster Parts Catalogs)) |||||||| | ||
| |Master \\ Cylinder \\ Assembly|Year|Model|Bore|Rebuild \\ Kit(s)|Fluid|Brake Line \\ Fitting / \\ Threads|Caliper \\ Pistons \ \\ Area| | |Master \\ Cylinder \\ Assembly|Year|Model|Bore|Rebuild \\ Kit(s)|Fluid|Brake Line \\ Fitting / \\ Threads|Caliper \\ Pistons \ \\ Area| | ||
| - | |42415-79|1979-1981|XL, XLCH, XLS|3/4"|42374-77 \\ 42374-77A \\ 42374-77B|Dot 5|43307-78 \\ 90° Fitting|1| | + | |42415-79|1979-1981|XL, XLCH, XLS|3/4"|42374-77 \\ 42374-77A \\ 42374-77B|Dot 5|43307-78 \\ 90° Fitting|1 \\ Large \\ Kelsey Hayes| |
| - | |42454-80 \\ 42454-80A|1980-1981|XL|3/4"|:::|Dot 5|Pre-made \\ flared steel \\ lines with \\ no other \\ fiitings|1| | + | |42454-80 \\ 42454-80A|1980-1981|XL|3/4"|:::|Dot 5|Pre-made \\ flared steel \\ lines with \\ no other \\ fittings|1 \\ Large \\ Kelsey Hayes| |
| - | |42453-80 \\ 42453-80A|1980-1981|XLS|3/4"|:::|Dot 5|:::|1| | + | |42453-80 \\ 42453-80A|1980-1981|XLS|3/4"|:::|Dot 5|:::|1 \\ Large \\ Kelsey Hayes| |
| - | |42454-82 \\ (black)|1982|XLS|5/8"|42374-82 \\ 42374-82A \\ 42374-82B|Dot 5|:::|1| | + | |42454-82 \\ (black)|1982|XLS|5/8"|42374-82 \\ 42374-82A \\ 42374-82B|Dot 5|:::|1 \\ Lucas Girling| |
| - | |42453-82 \\ 42453-82A \\ (polished)|1982-1985 \\ 1983-1985|XL \\ XLS, XLX|5/8"|:::|Dot 5|:::|1| | + | |42453-82 \\ 42453-82A \\ (polished)|1982-1985 \\ 1983-1985 \\ 1986-E1987|XL \\ XLS, XLX \\ All|5/8"|:::|Dot 5|:::|1 \\ Lucas Girling| |
| - | ===== Cleaning The Master Cylinder ===== | ||
| - | |||
| - | * For use with DOT 5 brake fluid: Always clean brake system rubber parts by washing in denatured alcohol or DOT 5 brake fluid. Do not use mineral base cleaning solvents such as gasoline or paint thinner. These cause deterioration of non-metallic parts which would continue to deteriorate after assembly, possibly resulting in component failure. ((HD Service Bulletin #M-785 dated June 10, 1980)) | ||
| ====== Calipers ====== | ====== Calipers ====== | ||
| \\ | \\ | ||
| ==== Sub-Documents ==== | ==== Sub-Documents ==== | ||
| + | **Front Calipers**: \\ | ||
| + | |||
| * . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ | * . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ | ||
| * . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ | * . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ | ||
| + | |||
| + | **Rear Calipers**: \\ | ||
| + | |||
| + | * . . . [[techtalk:ih:wheels02q|1982-E1987 Rear Lucas Girling Caliper Pics]] \\ | ||
| ===== Caliper ID and Applications ===== | ===== Caliper ID and Applications ===== | ||
