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techtalk:ih:wheels02 [2021/02/13 21:49]
hippysmack [Sub-Documents]
techtalk:ih:wheels02 [2024/01/02 16:48] (current)
hippysmack
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 ====== Disc Braking System ====== ====== Disc Braking System ======
 ====== Brake Fluid / Bleeding the System ====== ====== Brake Fluid / Bleeding the System ======
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 Refer to these sections of the Sportsterpedia for recommendations,​ change intervals and bleeding advice: \\ Refer to these sections of the Sportsterpedia for recommendations,​ change intervals and bleeding advice: \\
   * [[techtalk:​ref:​wheels03#​brake_system|Brake Fluid]]   * [[techtalk:​ref:​wheels03#​brake_system|Brake Fluid]]
   * [[techtalk:​ref:​wheels06#​bleeding_the_brake_lines|Bleeding the Brake Lines]]   * [[techtalk:​ref:​wheels06#​bleeding_the_brake_lines|Bleeding the Brake Lines]]
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 ====== Inspection ====== ====== Inspection ======
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   * Inspect the master cylinder and linkage for damage or leakage, failure to return fully when released, or sponginess when applying pressure.   * 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.     * Any problem with the master cylinder requires rebuilding or replacement.
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   * Linkage inspection: Check for damage and wear especially with non-stock parts.   * Linkage inspection: Check for damage and wear especially with non-stock parts.
   * Some amount of freeplay must exist in most brake systems.   * Some amount of freeplay must exist in most brake systems.
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 ====== Master Cylinders ====== ====== Master Cylinders ======
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 |  **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**|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))|+|**45010-73**|1973-1977|XLH \\ XLCH|3/​4"​ ((doodah man of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​167848-front-master-cylinder-rebuild-kit?​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 ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​178649-what-size-mastercylinder-plunger?​t=1919910))|
 |**43306-78**|1978-E1979|XLH \\ XLCH|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes| |**43306-78**|1978-E1979|XLH \\ XLCH|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes|
 |**45011-77**|L1979|XL \\ XLCH \\ XLS|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes| |**45011-77**|L1979|XL \\ XLCH \\ XLS|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes|
 |**45013-72**|1980-1981|XL \\ XLS|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes| |**45013-72**|1980-1981|XL \\ XLS|3/​4"​|45063-72|Dot 5|90° fitting \\ 1/​8"​-27 NPT to 3/16" \\ Inverted Flare|Dual|2 \\ Small \\ Kelsey Hayes|
-|**45013-82** \\ (black)|1982-E1984|XL \\ XLS \\ XLX|3/​4"​|45063-82|Dot 5|Banjo Bolt \\ 3/8" x 24|Dual|2 \\ Small \\ Kelsey Hayes \\ 1-3/8" ea. ((BigMek of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5846096#post5846096))|+|**45013-82** \\ (black)|1982-E1984|XL \\ XLS \\ XLX|3/​4"​|45063-82|Dot 5|Banjo Bolt \\ 3/8" x 24|Dual|2 \\ Small \\ Kelsey Hayes \\ 1-3/8" ea. ((BigMek of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​200609-front-brakes-question-dual-disc#post4433009))|
 |:::​|**45013-82A is retro for 1982-1983 Models**|||||||| |:::​|**45013-82A is retro for 1982-1983 Models**||||||||
 |**45019-84**|1984-E1985|XL \\ XLS \\ XLX|5/​8"​|45069-84 \\ 45072-87|Dot 5|Banjo Bolt \\ 7/16" x 24 ((https://​www.denniskirk.com/​v-twin-manufacturing/​chrome-12mm-banjo-bolt-kit-23-0614.p276271.prd/​276271.sku))|Single|1 \\ Semi \\ Torque Free| |**45019-84**|1984-E1985|XL \\ XLS \\ XLX|5/​8"​|45069-84 \\ 45072-87|Dot 5|Banjo Bolt \\ 7/16" x 24 ((https://​www.denniskirk.com/​v-twin-manufacturing/​chrome-12mm-banjo-bolt-kit-23-0614.p276271.prd/​276271.sku))|Single|1 \\ Semi \\ Torque Free|
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 |42454-82 \\ (black)|1982|XLS|5/​8"​|42374-82 \\ 42374-82A \\ 42374-82B|Dot 5|:::|1 \\ Lucas Girling| |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 \\ 1986-E1987|XL \\ XLS, XLX \\ All|5/​8"​|:::​|Dot 5|:::|1 \\ Lucas Girling| |42453-82 \\ 42453-82A \\ (polished)|1982-1985 \\ 1983-1985 \\ 1986-E1987|XL \\ XLS, XLX \\ All|5/​8"​|:::​|Dot 5|:::|1 \\ Lucas Girling|
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 ====== Calipers ====== ====== Calipers ======
 \\ \\
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 ===== Front ===== ===== Front =====
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 ==== Sub-Documents ==== ==== Sub-Documents ====
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 * . . . [[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]] \\
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 |Caliper \\ Assembly|Year|Model|Position|Bore|Rebuild Kit(s)|Fluid|Brake Line \\ Fitting / Threads|Bleeder \\ Threads| |Caliper \\ Assembly|Year|Model|Position|Bore|Rebuild Kit(s)|Fluid|Brake Line \\ Fitting / Threads|Bleeder \\ Threads|
 |44104-72A|1973|XLH,​ XLCH|Left| ​ |45063-72|Aug 1976 ← \\ DOT 3 \\ Sept 1976 → \\ DOT 5|Caliper- \\ - \\ Fitting- \\ Inverted Flare Fitting|1/​4"​-28| |44104-72A|1973|XLH,​ XLCH|Left| ​ |45063-72|Aug 1976 ← \\ DOT 3 \\ Sept 1976 → \\ DOT 5|Caliper- \\ - \\ Fitting- \\ Inverted Flare Fitting|1/​4"​-28|
-|44089-74|1974-1977|XLH,​ XLCH|Left|1.75"​|Caliper Parts \\ Sold Separately|DOT 5|Caliper- \\ AN3 Inverted Flare Threads ((4th of July of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1923879&​page=2))|1/​4"​-28|+|44089-74|1974-1977|XLH,​ XLCH|Left|1.75"​|Caliper Parts \\ Sold Separately|DOT 5|Caliper- \\ AN3 Inverted Flare Threads ((4th of July of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​179040-brake-caliper-threads-stripped-76-sporty/​page2?​t=1923879&​page=2))|1/​4"​-28|
 |44117-77|1978- |XLH, XLCH|Left| ​ |:::|DOT 5|Caliper- \\ 3/​8"​-24 Inverted Flare |3/​8"​-24| |44117-77|1978- |XLH, XLCH|Left| ​ |:::|DOT 5|Caliper- \\ 3/​8"​-24 Inverted Flare |3/​8"​-24|
 |44116-77|1978- |XLH, XLCH|Right| ​ |:::|DOT 5|Caliper- \\ 3/​8"​-24 Inverted Flare|3/​8"​-24| |44116-77|1978- |XLH, XLCH|Right| ​ |:::|DOT 5|Caliper- \\ 3/​8"​-24 Inverted Flare|3/​8"​-24|
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 If there is any doubt concerning this freeplay or other proper operation of the master cylinder; \\ If there is any doubt concerning this freeplay or other proper operation of the master cylinder; \\
 The master cylinder cap should be removed and the pedal depressed several times. A squirt of fluid each time will verify proper operation. \\ The master cylinder cap should be removed and the pedal depressed several times. A squirt of fluid each time will verify proper operation. \\
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 **Disc and pad sets**: **Disc and pad sets**:
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 |-84A, 30 hole, anti symmetrical|semi-iron,​ copper| |-84A, 30 hole, anti symmetrical|semi-iron,​ copper|
 |-94, softer stainless|semi-iron,​ gray| |-94, softer stainless|semi-iron,​ gray|
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 ===== Rear Brake Clevis Rod ===== ===== Rear Brake Clevis Rod =====
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 **1980 and up**: **1980 and up**: