Differences

This shows you the differences between two versions of the page.

--- techtalk:evo:wheels02 [2020/06/24 23:46]
hippysmack [Sub-Documents]
+++ techtalk:evo:wheels02 [2024/01/09 03:06] (current)
hippysmack
@@ Line 17: / Line 17: @@
 Refer to these threads on the XLForum:
   * 2005 Rear Master Cylinder Re-build
-  *  - http://xlforum.net/forums/showthread.php?t=75157
+  *  - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/37937-my-rear-master-cylinder-re-build?t=75157
   * 2006 vs 2007 1200L Front Brake Caliper
-  *  - http://xlforum.net/forums/showthread.php?threadid=2057183
+  *  - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/192254-2007-1200l-front-brake-caliper-question-oddity?threadid=2057183
 ====== Inspection ======
@@ Line 34: / Line 34: @@
   * Linkage inspection: Check for damage and wear especially with non-stock parts.
   * Some amount of freeplay must exist in most brake systems.
 \\
@@ Line 50: / Line 47: @@
   * 1982 and later do not. The internals are held in place by a seal ring.
-|  Front Master Cylinder part numbers and bore sizes. ((whittlebeast of the XLFORUM http://xlforum.net/forums/showthread.php?p=1340667#post1340667)) ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=847430)) ((1986-up Sportster Parts Catalogs))  |||||||||
+  * Prior to 2004, there were only two thread pitches for EVO / TC88 models. ((psycho69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/97590-banjo-bolt-size-for-master-cylinder?t=824722)) \\ They were 3/8"-24, commonly known as 10mm, and 7/16"-24, commonly known as 12mm. \\ (12mm is symbolic only, actual bore size is 11.2mm) \\ With the introduction of the 2004 XLH (Sportster) models things changed. \\ XL883, XL883C, and XL1200C models use 10mm x 1.25thread on both the front and rear master cylinders and calipers. \\ The XL1200R uses a 12mm x 1.5 thread on the front master cylinder and 10mm x 1.25 on the rear master cylinder, and front and rear calipers. \\ Only 2004-2006 models use true metric bolts. All other models have not changed.
+|  Front Master Cylinder part numbers and bore sizes. ((whittlebeast of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/31075-installing-a-dyna-caliper-on-a-single-disc-2007/page12#post1122959)) ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99136-1-2-bore-front-master-cylinder?t=847430)) ((1986-up Sportster Parts Catalogs))  |||||||||
 |Master \\ Cylinder|Year|Model|Bore|Rebuild \\ Kit(s)|Fluid|Banjo \\ Size|Single / \\ Dual \\ Discs|Caliper \\  Pistons \ \\ Area|
-|**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|All Models|5/8"|45069-84 \\ 45072-87|DOT 5|3/8"x24|Single|1 \\ Kelsey Hayes|
 |:::|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.||||||||
-|**45025-87**|1987-1988 \\ 1987-1988 \\ 1987-1988 \\ 1987 \\ 1988|883 \\ 883 Hugger \\ 883 Deluxe \\ 1100 \\ 1200|5/8"|45072-87|DOT 5|3/8"x24|Single|1 \\ Kelsey Hayes|
+|**45025-87**|1987|All Models|5/8"|45072-87|DOT 5|3/8"x24|Single|1 \\ Kelsey Hayes|
-|**45019-85A**|1992|883 \\ 883 Hugger \\ 883 Deluxe \\ 1200|5/8"|45072-87|DOT 5|7/16"x24|Single|1 \\ Kelsey Hayes|
+|:::|1988|All Models|5/8"|45072-87|DOT 5|7/16"x24|Single|1 \\ Kelsey Hayes|
-|**45019-93**|1993-1995|883 \\ 883 Hugger \\ 883 Deluxe \\ 1200|5/8" ((fourteen of the XLFORUM http://xlforum.net/forums/showthread.php?s=8aae2a12442e258eb794f3891014d30e&t=857371&page=3))|45072-87|DOT 5|7/16“x24|Single|1 \\ Kelsey Hayes|
+|**45019-85**|1989-1991|All Models|5/8"|45072-87|DOT 5|7/16"x24|Single|1 \\ Kelsey Hayes|
-|**45013-96** \\ \\ **45013-96D**|1996-2000|1200S|11/16"|45072-96 \\ 45072-96A \\ 45072-96C|DOT 5|3/8"x24|Dual|2 x 39mm \\ Kelsey Hayes|
+|**45019-85A**|1992|All Models|5/8"|45072-87|DOT 5|7/16"x24|Single|1 \\ Kelsey Hayes|
-|:::|:::|:::|:::|:::|:::|:::|:::|8 x 33mm|
+|:::|**This version is retro for 1984-1991 Models**||||||||
-|**45019-96** \\ \\ **45019-96D**|1996-2001|883 \\ 883 Hugger \\ 883C \\ 1200 \\ 1200C|9/16"|45006-96 \\ 45006-96A \\ 45006-96C|DOT 5|7/16“x24|Single|1 \\ Kelsey Hayes|
+|**45019-93**|1993-1995|883 \\ 883 Hugger \\ 883 Deluxe \\ 1200|5/8" ((fourteen of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99872-front-brake-upgrade/page3?s=8aae2a12442e258eb794f3891014d30e&t=857371&page=3))|45072-87|DOT 5|7/16“x24|Single|1 \\ Kelsey Hayes|
-|:::|:::|:::|:::|:::|:::|:::|:::|4 x 33mm|
+|**45013-96** \\ \\ **45013-96D**|1996-1999|1200S|11/16"|45072-96 \\ 45072-96A \\ 45072-96C|DOT 5|3/8"x24|Dual|2 x 39mm \\ Kelsey Hayes|
-|**45013-96A**|2001-2002 \\ 2002|1200S \\ 883R|11/16"|45072-96A|DOT 5|3/8"x24|Dual|8 x 33mm ((Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?t=1815643)) \\ Kelsey Hayes|
+|:::|2000|:::|:::|:::|:::|:::|:::|8 x 33mm|
-|**45019-96A**|2002|883 \\ 883 Hugger \\ 883C \\ 883R \\ 1200 \\ 1200C|9/16"|45006-96A|DOT 5|7/16"x24|Single|4 x 33mm ((Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?t=1815643)) \\ Kelsey Hayes|
+|**45019-96** \\ \\ **45019-96D**|1996-1999|883 \\ 883 Hugger \\ 883C \\ 1200 \\ 1200C|9/16"|45006-96 \\ 45006-96A \\ 45006-96C|DOT 5|7/16“x24|Single|1 \\ Kelsey Hayes|
+|:::|2000|:::|:::|:::|:::|:::|:::|4 x 33mm|
+|**45013-96A**|2001-2002 \\ 2002|1200S \\ 883R|11/16"|45072-96A|DOT 5|3/8"x24|Dual|8 x 33mm ((Randy_rots of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/169230-master-cylinder-size-w-4-piston-caliper?t=1815643)) \\ Kelsey Hayes|
+|**45019-96A**|2002|883 \\ 883 Hugger \\ 883C \\ 883R \\ 1200 \\ 1200C|9/16"|45006-96A|DOT 5|7/16"x24|Single|4 x 33mm ((Randy_rots of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/169230-master-cylinder-size-w-4-piston-caliper?t=1815643)) \\ Kelsey Hayes|
 |**45013-96B**|2003|883R \\ 1200S|11/16"|45072-96C|DOT 5|3/8"x24|Dual|8 \\ Kelsey Hayes|
 |**45019-96B**|2003|883 \\ 883 Hugger \\ 883C \\ 883R \\ 1200 \\ 1200C|9/16"|45006-96C|DOT 5|7/16“x24|Single|4 \\ Kelsey Hayes|
-|**45052-04**|2004-2006 \\ 2005-2006| 1200R \\ 883R|14mm ((XLdaveR of the XLFORUM http://xlforum.net/forums/showthread.php?t=786022)) \\ (.55")|42809-04 \\ 42809-04B|DOT 5|41737-04 \\ 7/16"x24 \\ (11.1mm)|Dual|4 x 27mm \\ Nissin|
+|**45052-04**|2004-2006 \\ 2005-2006| 1200R \\ 883R|14mm ((XLdaveR of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/94666-question-about-master-cylinders?t=786022)) \\ (.55")|42809-04 \\ 42809-04B|DOT 5|41737-04 \\ 7/16"x24 \\ (11.1mm)|Dual|4 x 27mm \\ Nissin|
-|:::|Parts catalog says the banjo bolt is 12mm but that's wrong. ((http://xlforum.net/forums/showthread.php?s=8aae2a12442e258eb794f3891014d30e&t=580402&page=3))|||||||
+|:::|Parts catalog says the banjo bolt is 12mm but that's wrong. ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/79722-frustrated-banjo-bolt-size-1200r-master-cylinder/page3?s=8aae2a12442e258eb794f3891014d30e&t=580402&page=3))|||||||
-|**45146-04**|2004-2006 \\ 2005-2006|883/1200C/883C \\ 883L|1/2" \\ (12.7mm)|42803-04 \\ 42803-04B|DOT 5|M-10|Single|2 x 27mm ((goblin_dust of the XLFORUM http://xlforum.net/forums/showthread.php?t=2006045)) \\ Nissin|
+|**45146-04**|2004-2006 \\ 2005-2006|883/1200C/883C \\ 883L|1/2" \\ (12.7mm)|42803-04 \\ 42803-04B|DOT 5|M-10|Single|2 x 27mm ((goblin_dust of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/188307-front-caliper-pistons-06-vs-07?t=2006045)) \\ Nissin|
-|**45052-07**|2007|883R/1200R|1/2" ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=847430)) \\ (12.7mm)|42809-07|DOT 4|M-12 x 1.25|Dual|4 \\ Nissin|
+|**45052-07**|2007|883R/1200R|1/2" ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99136-1-2-bore-front-master-cylinder?t=847430)) \\ (12.7mm)|42809-07|DOT 4|M-12 x 1.25|Dual|4 \\ Nissin|
 |**45146-07**|2007 \\ 2007-2009 \\ 2007-2010 \\ 2007-2013 \\ 2007-2013 \\ 2007-2011 \\ 2011-2013 \\ 2013 \\ 2013 \\ 2013 \\ 2013|XL50 \\ 883 \\ 883C \\ 1200C \\ 883L \\ 1200L \\ 1200CP \\ 1200C Anv \\ 1200V \\ 1200CA \\ 1200CB|11mm|42803-07A|DOT 4|41736-04 \\ M-10x1.25|Single|2 \\ Nissin|
 |**42745-07** \\ (black)|2007-2012 \\ 2009-2013 \\ 2011-2013|1200N \\ 883N \\ XL1200X|11mm|42803-07A|DOT 4|M-10|Single|2 \\ Nissin|
-|**45052-07A**|2008-2009 \\ 2008-2013|1200R \\ 883R|1/2" ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=847430)) \\ (12.7mm)|42809-07A|DOT 4|M-12|Dual|4 \\ Nissin|
+|**45052-07A**|2008-2009 \\ 2008-2013|1200R \\ 883R|1/2" ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99136-1-2-bore-front-master-cylinder?t=847430)) \\ (12.7mm)|42809-07A|DOT 4|M-12|Dual|4 \\ Nissin|
-|**42941-08**|2009|XR1200|5/8" ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=847430)) \\ (15.87mm)|42736-08|DOT 4|M12x1.5|Dual|8 \\ Nissin|
+|**42941-08**|2009|XR1200|5/8" ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99136-1-2-bore-front-master-cylinder?t=847430)) \\ (15.87mm)|42736-08|DOT 4|M12x1.5|Dual|8 \\ Nissin|
-|**42941-10**|2010 \\ 2010-2013|XR1200 \\ XR1200X|5/8" ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=847430)) \\ (15.87mm)|42736-08|DOT 4|M-12|Dual|8 \\ Nissin|
+|**42941-10**|2010 \\ 2010-2013|XR1200 \\ XR1200X|5/8" ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/99136-1-2-bore-front-master-cylinder?t=847430)) \\ (15.87mm)|42736-08|DOT 4|M-12|Dual|8 \\ Nissin|
-|**41700003** \\ (silver) \\ (ABS)|2014-2017 \\ 2014-2016 \\ 2015-2017|883L \\ 1200V \\ 1200T|14mm ((spacetiger of the  XLFORUM http://xlforum.net/forums/showthread.php?t=1880028))|41700084|DOT 4|M-10|Single|2 x 34mm \\ Nissin|
+|**41700003** \\ (silver) \\ (ABS)|2014-2017 \\ 2014-2016 \\ 2015-2017|883L \\ 1200V \\ 1200T|14mm ((spacetiger of the  XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/175266-single-front-brake-upgrade-2014-xl1200t?t=1880028))|41700084|DOT 4|M-10|Single|2 x 34mm \\ Nissin|
 |**41700085** \\ (silver) \\ (non-ABS)|2014-2017 \\ 2014-2017 \\ 2014-2016 \\ 2014-2016 \\ 2014-2016 \\ 2014-2017 \\ 2015-2017|883L \\ 1200C \\ 1200V \\ 1200CP \\ 1200CA \\ 1200CB \\ 1200T|7/16"|41700087|DOT 4|M-10|Single|2 \\ Nissin|
 |**41700086**|2014-2015 \\ 2016-2017|883R \\ 1200CX|1/2"|41700088|DOT 4|M-10|Dual|4 \\ Nissin|
@@ Line 84: / Line 86: @@
 ==== Sub-Documents ====
   * [[techtalk:evo:wheels02l|Rear Master Cylinder Identification]]
-  * [[techtalk:evo:wheels02r|Known issues with the 2004-2007 Style Master Cylinder]] \\ \\
+  * [[techtalk:evo:wheels02r|Known issues with the 2004-2007 Style Rear Master Cylinder]] \\ \\
   * 1982-E1987 master cylinders have aluminum bodies and require a minimum of 1/32” free play. \\ They all had a 5/8" bore.
@@ Line 118: / Line 120: @@
 ===== 2001 Front Style Caliper =====
-**Wrench Sizes & Torque Specs** \\ \\ **Caution** the use of 6-point sockets and vise-grips will round off the bolt corners. ((Jheitt of the XLFORUM http://xlforum.net/forums/showthread.php?p=5667519#post5667519))
+**Wrench Sizes & Torque Specs** \\ \\ **Caution** the use of 6-point sockets and vise-grips will round off the bolt corners. ((Jheitt of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/191119-send-a-note-to-sportsterpedia-admin/page3#post4187744))
@@ Line 125: / Line 127: @@
     * Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38-51.5 Nm). ((2000 HD XLH FSM pg 2-46))
   * Brake Pad Slide Pins (2) (five sided box below):
-    * The small bolts on the caliper need to be removed in order to change the pads. ((Jheitt of the XLFORUM http://xlforum.net/forums/showthread.php?p=5667519#post5667519)) \\ They will give an audible click when inserted into the housing. ((2000 HD XLH FSM pg 2-45))
+    * The small bolts on the caliper need to be removed in order to change the pads. ((Jheitt of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/191119-send-a-note-to-sportsterpedia-admin/page3#post4187744)) \\ They will give an audible click when inserted into the housing. ((2000 HD XLH FSM pg 2-45))
     * Wrench (1/4" 12-point), Torque (180-200 in/lbs / 20.3-22.6 Nm). ((2000 HD XLH FSM pg 2-45))
   * Bleeder valve:
@@ Line 136: / Line 138: @@
   * **Disassembling the caliper**:
   * Bridge bolts (2) (rectangles in pic below):
-  * The 2 larger bolts to the right on the caliper. \\ These hold the caliper halves together and shouldn't need to be removed unless you are rebuilding the caliper. ((Jheitt of the XLFORUM http://xlforum.net/forums/showthread.php?p=5667519#post5667519))
+  * The 2 larger bolts to the right on the caliper. \\ These hold the caliper halves together and shouldn't need to be removed unless you are rebuilding the caliper. ((Jheitt of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/191119-send-a-note-to-sportsterpedia-admin/page3#post4187744))
     * Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38.0-51.5 Nm). ((2000 HD XLH FSM pg 2-45))
-|  02 Caliper ((photo by spibbie of the XLFORUM http://xlforum.net/forums/showthread.php?t=1857463))  |
+|  02 Caliper ((photo by spibbie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/173094-what-tool-works-on-brake-caliper-mounting-screw?t=1857463))  |
 |{{:techtalk:evo:wheels:caliper_bolt_sizes_by_spibbie.jpg?direct&300|}}|
@@ Line 147: / Line 149: @@
 **Alternative Calipers:**
-The 2000 and newer bikes have a completely different mounting boss for the brakes. If you want to upgrade to Brembo calipers you're going to need the lowers from a 2000 and newer model. The stock aluminum style is the same price as the chrome version (at retail) so if you like chrome, it's definitely the way to go. ((ReddTigger @ http://xlforum.net/forums/showthread.php?t=908530))
+The 2000 and newer bikes have a completely different mounting boss for the brakes. If you want to upgrade to Brembo calipers you're going to need the lowers from a 2000 and newer model. The stock aluminum style is the same price as the chrome version (at retail) so if you like chrome, it's definitely the way to go. ((ReddTigger @ https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-tires-wheels-and-brakes-aa/103452-97-xlh-dual-brembo-brakes?t=908530))
 ===== 2004 Rear Style Caliper =====
@@ Line 157: / Line 159: @@
 ====== Brake Pads ======
+**87-late thru 1999 Brake Pads**
+**Front**
+\\
+**Rear**
+{{:techtalk:evo:wheels:94-rear-brakepad-1.jpg?400|}}{{:techtalk:evo:wheels:94-rear-brakepad-3.jpg?400|}}((Pics & Annotation by IXL2Relax of the XLForum.net))\\
+{{:techtalk:evo:wheels:94-rear-brakepad-2.jpg?400|}}
 \\
@@ Line 176: / Line 195: @@
 ===== Rear =====
-|  Rear Brake Rotor (41833-08) ((photo by wachuko of the XLFORUM http://xlforum.net/forums/showthread.php?t=1688133&page=3))  |
+|  Rear Brake Rotor (41833-08) ((photo by wachuko of the XLFORUM - Post#27 - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/157717-my-2013-hd-forty-eight-build?t=1688133))  |
 |{{:techtalk:evo:wheels:rear_brake_rotor_41833-08_by_wachuko.png?direct&300|}}|

Trace:

Differences

Navigation

Search

Toolbox