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techtalk:ih:wheels02 [2021/01/22 02:18] 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 \\ 45013-82A \\ (updated)\\ (black)|1982-1983|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))| |
| - | |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| | + | |:::|**45013-82A is retro for 1982-1983 Models**|||||||| |
| - | |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|Banjo Bolt \\ 3/8"x24|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| |
| - | |:::|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.|||||||| | + | |**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.|||||||| | ||
| + | |**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 ===== | ===== Rear ===== | ||
| ==== Sub-Documents ==== | ==== Sub-Documents ==== | ||
| * . . . [[techtalk:ih:wheels02j|Rear Master Cylinder Identification]] \\ | * . . . [[techtalk:ih:wheels02j|Rear Master Cylinder Identification]] \\ | ||
| + | * . . . [[techtalk:ih:wheels02k|Rear Hydraulic Brake Assembly Pics]] \\ | ||
| | **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)) |||||||| | ||
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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 ====== | ||
| \\ | \\ | ||
| + | ===== Front ===== | ||
| + | \\ | ||
| + | ==== Sub-Documents ==== | ||
| + | * . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ | ||
| + | * . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ | ||
| + | \\ | ||
| Caliper ID and Applications \\ | Caliper ID and Applications \\ | ||
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| * 1984-up All models except FLH | * 1984-up All models except FLH | ||
| * 1985 All models | * 1985 All models | ||
| + | |||
| + | | **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 ((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| | ||
| + | |44116-77|1978- |XLH, XLCH|Right| |:::|DOT 5|Caliper- \\ 3/8"-24 Inverted Flare|3/8"-24| | ||
| + | |||
| + | ===== Rear ===== | ||
| + | |||
| + | ==== Sub-Documents ==== | ||
| + | |||
| + | **Rear Calipers**: \\ | ||
| + | |||
| + | * . . . [[techtalk:ih:wheels02q|1982-E1987 Rear Lucas Girling Caliper Pics]] \\ | ||
| + | |||
| + | Caliper ID and Applications \\ | ||
| + | |||
| **Rear Caliper** | **Rear Caliper** | ||
| * Banana | * Banana | ||
| Line 112: | Line 133: | ||
| * 1984-E1987 FXST | * 1984-E1987 FXST | ||
| * 1983-1984 and 1987 FLHS | * 1983-1984 and 1987 FLHS | ||
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| - | ===== Front ===== | ||
| - | |||
| - | ==== Sub-Documents ==== | ||
| - | |||
| - | * . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ | ||
| - | * . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ | ||
| - | |||
| - | ===== Rear ===== | ||
| - | |||
| - | ==== Sub-Documents ==== | ||
| - | |||
| - | **Rear Calipers**: \\ | ||
| - | |||
| - | * . . . [[techtalk:ih:wheels02q|1982-E1987 Rear Lucas Girling Caliper Pics]] \\ | ||
| ====== Brake Disc and Pads ====== | ====== Brake Disc and Pads ====== | ||
| Line 162: | Line 168: | ||
| 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**: | ||
| Line 172: | Line 177: | ||
| |-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**: | ||
