Refer to these sections of the Sportsterpedia for recommendations, change intervals and bleeding advice:
* . . . Front Master Cylinder Identification
Front Master Cylinder part numbers and bore sizes. 1) | ||||||||
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“ 2) | 45063-72 | Aug 1976 ← Dot 3 Sept 1976 → Dot 5 | 1/4”x27 NPT straight fitting | Single | 1 Banana 1 Clebrake 1.75“ 3) |
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 |
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. 4) |
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 5) | Single | 1 Semi Torque Free |
45019-85 | L1985-1986 | All Models | 5/8” | 45069-84 45072-87 | DOT 5 | Banjo Bolt 3/8“x24 | Single | 1 Semi Torque Free |
Note: OEM on 1986 and 1987 HDI models with a 3/8”x24 banjo fitting, 1989-1991 domestic models with a 7/16“x24 banjo fitting. Replacement master for '87-'88 Sportsters. Rebuild kit 45069-84 includes body, kit 45072-87 comes without body. |
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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 |
* . . . Rear Master Cylinder Identification
* . . . Rear Hydraulic Brake Assembly Pics
Rear Master Cylinder part numbers and bore sizes. 6) | |||||||
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 Large Kelsey Hayes |
42454-80 42454-80A | 1980-1981 | XL | 3/4“ | Dot 5 | Pre-made flared steel lines with no other fittings | 1 Large Kelsey Hayes |
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42453-80 42453-80A | 1980-1981 | XLS | 3/4” | Dot 5 | 1 Large Kelsey Hayes |
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42454-82 (black) | 1982 | XLS | 5/8“ | 42374-82 42374-82A 42374-82B | Dot 5 | 1 Lucas Girling |
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42453-82 42453-82A (polished) | 1982-1985 1983-1985 1986-E1987 | XL XLS, XLX All | 5/8” | Dot 5 | 1 Lucas Girling |
* . . . 1973 Front Banana Caliper Pics
* . . . 1974-1977 Front Pie Slice Caliper Pics
Caliper ID and Applications
Front Caliper
Front Brake Calipers | ||||||||
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 | |
44089-74 | 1974-1977 | XLH, XLCH | Left | 1.75” | Caliper Parts Sold Separately | DOT 5 | Caliper- AN3 Inverted Flare Threads 7) | 1/4“-28 |
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 |
Rear Calipers:
* . . . 1982-E1987 Rear Lucas Girling Caliper Pics
Caliper ID and Applications
Rear Caliper
From HD Teschnical Service Bulletin M-712 dated June 16, 1977:
Disc brake friction material can be classified as organic, semi-metallic, or metallic.
Organic material will outwear an equal section of metallic material under normal operating conditions.
An organic pad will also reduce heat transfer between the brake disc and brake fluid in the caliper.
It is also less harsh on the disc and usually leaves the disc with a polished look.
This material has two disadvantages:
Metallic friction material increases it's efficiency as temperatures increase, and water has little effect on stopping performance.
Metallic linings, in normal service, have a shorter wear life than organic.
Semi-metallic have characteristics in between the organic and metallic.
Replace pads when the thickness of the friction material has worn down to 1/16” or less on all models except those specified in the paragraph below.
We suggest that you use only the recommended Harley-Davidson pads.
1974 thru 1977 XL, XLCH, XLT, FX, FXE, FXS models have a wear indicator slot in the front brake pad friction material.
Replace pads when the friction material has worn down to 3/32“ thickness as shown in the illustration.
Motorcycle brakes operate under high temperatures and can absorb far more horsepower than the engine produces. 9)
The discs do not need a polished appearance to maintain efficiency.
A disc with a slight amount of grooving similar to a phonograph record is normal with metallic brake pads and is acceptable if the surface is smooth.
The newer stainless brake discs may appear grooved, but if you run your fingernail over the surface you find there are no grooves.
Disc runout, on the motorcycle, should not exceed .015”. If the disc becomes warped or dished beyond this specification it should be replaced.
Brake pedal travel is increased with the wave washer type of piston retraction. Caution must be used when adjusting brake pedal travel.
If the required freeplay in the plunger is adjusted away, the expanding brake fluid cannot return to the reservoir and gradual energization of the brake may occur.
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.
Disc and pad sets:
Disc, Material | Pad |
-73, mild steel | organic |
-78, hard stainless | semi-iron, black |
-79, very hard stainless | semi-iron, copper |
-84, very hard stainless 11/12“ rotor | semi-iron, copper |
-84A, 30 hole, anti symmetrical | semi-iron, copper |
-94, softer stainless | semi-iron, gray |
1980 and up: