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techtalk:ih:wheels02 [2021/01/22 02:22] – [Sub-Documents] hippysmacktechtalk: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-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))| 
-|45019-84|L1984-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
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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 ===== 
- 
-==== Sub-Documents ==== 
- 
-* . . . [[techtalk:ih:wheels02m|1973 Front Banana Caliper Pics]] \\ 
-* . . . [[techtalk:ih:wheels02n|1974-1977 Front Pie Slice Caliper Pics]] \\ 
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-===== Rear ===== 
- 
-==== Sub-Documents ==== 
- 
-**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**:
  

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