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techtalk:ih:wheels02 [2021/01/22 03:41] 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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==== 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 | ||
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+ | | **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| | ||
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+ | ===== Rear ===== | ||
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+ | ==== Sub-Documents ==== | ||
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+ | **Rear Calipers**: \\ | ||
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+ | * . . . [[techtalk:ih:wheels02q|1982-E1987 Rear Lucas Girling Caliper Pics]] \\ | ||
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+ | Caliper ID and Applications \\ | ||
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**Rear Caliper** | **Rear Caliper** | ||
* Banana | * Banana | ||
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* 1984-E1987 FXST | * 1984-E1987 FXST | ||
* 1983-1984 and 1987 FLHS | * 1983-1984 and 1987 FLHS | ||
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- | ===== Front ===== | ||
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- | ==== Sub-Documents ==== | ||
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- | * . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ | ||
- | * . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ | ||
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- | ===== Rear ===== | ||
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- | ==== Sub-Documents ==== | ||
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- | **Rear Calipers**: \\ | ||
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- | * . . . [[techtalk:ih:wheels02q|1982-E1987 Rear Lucas Girling Caliper Pics]] \\ | ||
====== Brake Disc and Pads ====== | ====== Brake Disc and Pads ====== | ||
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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**: | ||