* . . . Rear Drum Fitting Issues with a Rigid Frame

• On 1963-1978 XLH/XLCH Models, a bearing spacer washer HD part #41195-63 (or V-Twin part number 44-0395 ¹⁾) is placed between the two bearings on the right hub (brake side). This spacer washer is reportedly not installed at the factory but is a service part for alignment where the aluminum back plate butts to the bearing inner race due to wear. The race will plow right into the soft back plate when the axle flexes ²⁾.
  • Approximate dimensions of this spacer are: ID -.737“, OD - 1.008”, Thickness .018“. ³⁾
• This is not a grease shield for the bearing. The grease shield used on the brake side →'62 was no longer in use by '63 and up models.
• This small washer has a lip, its very thin, and is not a regular flat washer. It goes in between the right side bearings in the hub, and pushes/holds the outer bearing flush with the hub where it goes up against the inside of the brake backing plate. Others have also said it is OK to use a second one in between the backing pate and the outer bearing if you need a little clearance so the backing plate wont rub, but if you need more than those 2, you should look inside your hub for issues… ⁴⁾

Brake Fluid - recommendations, change intervals and bleeding advice.

• 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. ⁵⁾

1980 and up:

• If the motorcycle should fall on it's right side or the muffler and bracket should hit the curb, the brake stop bracket could be inadvertently bent. This could then allow the brake pedal to travel past it's stop and could result in the distort­ing or bending of the clevis rod end (42445-80). Although the bend in the clevis rod end will not adversely affect the brake function, it could allow increased brake pedal free play. This condition would cause the brake pedal to travel further when applying the brake. ⁶⁾
  • Inspection:
    • Inspect brake stop bracket (welded to muffler) for the correct bend periodically.
    • The bracket should form a 90° angle out from the muffler. If it is bent in either direction, tap it with a ball peen hammer to straighten it.
    • Check the rear brake pedal adjustment. Work the rear brake pedal back and forth by hand to determine the amount of free play before the pushrod contacts the piston in the master cylinder. Free play measured at the pushrod should be app. 1/16”.
  • Correction:
    • If free play is excessive, inspect the clevis rod end (42445-80) for signs of distortion. If it is bent at the end, replace it.
    • If free play is incorrect, loosen the jamnut and turn the ad­justing screw in (clockwise) to increase free play, or out (counterclockwise) to decrease free play.
  • When proper free play is achieved , apply Harley­ Davidson Lock 'N Seal (99625-77) to the threads and then tighten the jamnut to 12-15 ft-lbs. while holding the screw in position.
  • When properly adjusted, the brake pedal should be parallel to the ground when bottomed against brake pedal stop.