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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 5

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1.

Phillips Screw

f1866x2x

2.

Sight Glass

3.

Cover

1

4.

Gasket

5.

Master Cylinder Reservoir

1

2

6.

Spring

7.

Primary Cup

8.

Piston

9.

O-Ring

10. Piston Cap

11. Wiper

3

12. T27 TORX Screw

13. Flat Washer

14. Handlebar Clamp

4

15. Pivot Pin

16. Bushing

12

17. Retaining Ring

13

18. Brake Hand Lever

19. Lubricant

5

15

14

A

6

16

7

8

B

9

10

C

D

E

F

G

17

18

11

A Brake Line Seating Surface

B Metal Retainer

C Shoulder

D O-Ring Groove

Provided in Service Parts Kit

19

E Pin

11/16 Inch Bore - HD Part No. 45072-96C

F Shoulder

G Flat Side

Figure 2-44. Front Brake Master Cylinder Assembly

2-36

2006 Touring: Chassis

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13. Position the brake lever/master cylinder assembly

f1225x2x

inboard of the switch housing assembly engaging the

tab on the lower switch housing in the groove at the top

of the brake lever bracket. See Figure 2-46.

14. Align the holes in the handlebar clamp with those in the

Groove

master cylinder housing and start the two T27 TORX

screws (with flat washers). Position for rider comfort.

Beginning with the top screw, tighten the screws to 60-

80 in-lbs (6.8-9.0 Nm).

CAUTION

To avoid leakage, verify that the steel/rubber washers,

banjo bolt, brake line fitting and master cylinder bore are

5/32 Inch

(4.0 mm)

completely clean.

Cardboard

Insert

15. Position new steel/rubber washers on each side of

hydraulic brake line fitting. Insert banjo bolt through

washers and fitting. Thread bolt into master cylinder

housing and tighten to 17-22 ft-lbs (23-30 Nm).

16. Remove the master cylinder reservoir cover. If the

Figure 2-45. Install Cardboard Insert

motorcycle is resting on jiffy stand, turn front wheel as

Before Installing Master Cylinder Assembly

necessary until the master cylinder reservoir is level.

1WARNING

9.

Install the master cylinder reservoir cover. Install two

Phillips screws to fasten cover to the reservoir, but do

Use only fresh, uncontaminated DOT 4 brake fluid. Fluid

not tighten at this time.

containers that have been opened may have been con-

taminated by dirt or moisture. Use of contaminated

10.

Align hole in brake hand lever with hole in master cylin-

brake fluid may adversely affect braking ability and lead

der bracket. From the top of the assembly, slide pivot pin

to brake failure which could result in death or serious

through bracket and hand lever.

injury.

1WARNING

f1785x8x

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from

4

the pliers and could be propelled with enough force to

1

cause serious eye injury. (00312a)

2

11. Install new retaining ring in pivot pin groove. Verify that

retaining ring is completely seated in groove.

CAUTION

Do not remove or install the master cylinder assembly

without first positioning a 5/32-inch (4 mm) thick insert

between the brake lever and lever bracket. Removing or

3

installing the master cylinder assembly without the

insert in place may result in damage to the rubber boot

and plunger on the front stoplight switch. (00324a)

1.

Tab

3.

Switch Housing Assembly

12. Place the cardboard insert between the brake lever and

2.

Groove

4.

Brake Lever Bracket

lever bracket. Use the eyelet of an ordinary cable strap if

the cardboard insert is not available. See Figure 2-45.

Figure 2-46. Fit Brake Lever/Master Cylinder to

Right Handlebar Switch Housings

2006 Touring: Chassis

2-37

HOME

REAR BRAKE MASTER CYLINDER

2.11

IMPORTANT NOTE

REMOVAL

Immediately wipe up any brake fluid spillage with a

clean, dry, soft cloth. Follow up by thoroughly wiping

affected area with a clean, damp, soft cloth (small spills)

PRELIMINARY INSTRUCTIONS

or washing with a large quantity of soapy water (large

spills).

1.

Remove right fairing lower, if present. See Section 2.29

LOWER FAIRING/ENGINE GUARD, LOWER FAIRING

5.

Remove bleeder valve cap on rear brake caliper. Install

(FLHTCU), REMOVAL.

end of a length of clear plastic tubing over caliper

bleeder valve, while placing free end in a suitable con-

2.

Remove two allen head socket screws (with lock wash-

tainer. Open bleeder valve about 1/2-turn. Pump brake

ers and flat washers) to release right side front footboard

pedal to drain brake fluid. Close bleeder valve.

brackets from frame weldment. For best results,

approach from left side of vehicle using a 3/8 inch ball

allen with extension.

BRAKE PEDAL/MASTER CYLINDER

3.

Remove right side saddlebag. See Section 2.26 SAD-

ASSEMBLY, REMOVAL

DLEBAG, REMOVAL.

1.

See PRELIMINARY INSTRUCTIONS on this page.

4.

Gently pull side cover from frame downtube (no tools

2.

Remove banjo bolt and two steel/rubber washers to dis-

required).

connect brake line front fitting from master cylinder

assembly. Discard washers.

CAUTION

3.

Release rear brake line as needed to move front fitting

forward far enough to access hex nut. For further

DOT 4 brake fluid will damage painted and molded-in

instructions See REAR BRAKE LINE, REMOVAL, steps

color surfaces it comes in contact with. Always use cau-

3-6, in this section.

tion and protect surfaces from spills whenever brake

work is performed. Failure to comply can result in cos-

4.

Using 1-1/8 inch wrench, remove hex nut to free brake

metic damage. (00239a)

pedal/master cylinder assembly from mounting bracket.

f2053x2x

2

3

1

4

1.

Rear Brake Pedal

2.

O-Ring (2)

5

3.

Clevis Pin

7

4.

Flat Washer

5.

Cotter Pin

6

6.

Retaining Ring

7.

Master Cylinder Reservoir

Figure 2-47. Rear Brake Pedal/Master Cylinder Assembly

2006 Touring: Chassis

2-39

HOME

f1460x2x

8

7

5

2

9

Locating Tab

3

1.

Banjo Bolt

2.

Steel/Rubber Washers

6

1

3.

Brake Line Tube

4.

Cable Clips (Lower Frame Tube)

5.

Rear Brake Light Switch

6.

Screw and Weld Nut (Frame Weldment)

4

7.

P-Clamp and Screw (Swingarm Bracket)

8.

Brake Line Hose

9.

Cable Clips (Top of Rear Swingarm)

Figure 2-48. Rear Brake Line Assembly

5.

Remove locknut with flat washer to free brake pedal/

fitting collar on cartridge body into square-shaped hole

master cylinder assembly from pedal shaft. Remove

in mounting bracket. Install flat washer and new locknut

assembly from vehicle. Remove and discard O-ring on

on pedal shaft and tighten to 15-20 ft-lbs (20-27 Nm).

each side of brake pedal shaft bore. See Figure 2-47.

5.

Apply Loctite Medium Strength Threadlocker 243 (blue)

6.

Remove cotter pin and flat washer from clevis pin. Sup-

to threads of hex nut. Install hex nut on threaded end of

porting rear brake pedal/master cylinder assembly in

cartridge body and tighten to 30-40 ft-lbs (41-54 Nm).

vise, tap out clevis pin using a brass drift. Remove mas-

6.

Position new steel/rubber washers on each side of brake

ter cylinder assembly from brake pedal flange.

line fitting. Insert banjo bolt through washers and fitting.

7.

For further instructions, see MASTER CYLINDER, DIS-

Thread bolt into master cylinder assembly and tighten to

ASSEMBLY, in this section.

17-22 ft-lbs (23-30 Nm).

7.

Secure rear brake line if released during master cylinder

BRAKE PEDAL/MASTER CYLINDER

removal. For further instructions, see REAR BRAKE

LINE, INSTALLATION, steps 4-7, in this section.

ASSEMBLY, INSTALLATION

8.

See FINAL INSTRUCTIONS on the next page.

1.

If master cylinder was disassembled, see MASTER

CYLINDER, ASSEMBLY, in this section, for instructions.

2.

Install master cylinder assembly on brake pedal flange.

REAR BRAKE LINE, REMOVAL

Supporting assembly in vise, tap in clevis pin using a

1.

See PRELIMINARY INSTRUCTIONS on the previous

brass drift. Install flat washer and cotter pin on clevis pin.

page.

See Figure 2-47.

3.

Install new O-ring on each side of brake pedal shaft

2.

Remove banjo bolt and two steel/rubber washers to dis-

bore.

connect brake line front fitting from master cylinder

assembly. Discard washers. See Figure 2-48.

4.

Apply a light coat of Wheel Bearing Grease (Part No.

99855-89) to the brake pedal shaft and bore. Install

3.

Open two cable clips on lower frame tube T-studs. Free

brake pedal/master cylinder assembly on the pedal shaft

rear brake line from cable clips.

2-40

2006 Touring: Chassis

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f2316x2x

3rd

Cable Clip

4th

Cable Clip

2nd

Cable Clip

1st

Cable Clip

Rear

Swingarm

Frame

Weldment

Cable Strap

Captures Rear Brake Light Switch Wires,

Main Harness Conduit and Lower Frame Tube

Figure 2-49. Rear Brake Line Routing (Right Side View)

IMPORTANT NOTE

10. Install the master cylinder reservoir cover, but first verify

that the cover gasket bellows is not extended or brake

Immediately wipe up any brake fluid spillage with a

fluid will be ejected from the reservoir. Install two Phillips

clean, dry, soft cloth. Follow up by thoroughly wiping

screws and alternately tighten to

6-8 in-lbs

(0.7-0.9

affected area with a clean, damp, soft cloth (small spills)

or washing with a large quantity of soapy water (large

Nm).

spills).

11. With the Ignition/Light Key Switch turned to IGNITION,

4.

Add DOT 4 BRAKE FLUID to the master cylinder reser-

actuate the rear brake pedal to verify operation of the

voir until the fluid level is 1/4 inch (6.4 mm) from the top.

brake lamp.

NOTE

12. Install right fairing lower, if present. See Section 2.29

LOWER FAIRING/ENGINE GUARD, LOWER FAIRING

Use only Harley-Davidson DOT 4 BRAKE FLUID, Part No.

99953-99A (12 ounce bottle), from a sealed container.

(FLHTCU), INSTALLATION.

5.

Depress and hold the rear brake pedal to build up

13. Align barbed studs in side cover with grommets in frame

hydraulic pressure.

downtubes and push firmly into place

(no tools

required).

6.

Open bleeder valve about 1/2-turn. Brake fluid will flow

from bleeder valve through tubing. Close bleeder valve

14. Install right side saddlebag. See Section 2.26 SADDLE-

when rear brake pedal has moved 1/2 to 3/4 of its full

BAG, INSTALLATION.

range of travel. Allow rear brake pedal to return slowly to

its released position.

1WARNING

7.

Repeat steps 4-6 until all air bubbles are purged.

8.

Final tighten the bleeder valve to

80-100 in-lbs

After repairing the brake system, test brakes at low

(9.0-11.3 Nm). Install the bleeder cap.

speed. If brakes are not operating properly, testing at

high speeds can cause loss of control, which could

9.

Add brake fluid to the master cylinder reservoir until the

result in death or serious injury. (00289a)

fluid level is about 1/4 inch (6.4 mm) from the top.

2-42

2006 Touring: Chassis

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1WARNING

Clevis

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from

the pliers and could be propelled with enough force to

cause serious eye injury. (00312a)

4.

Push down on large flat washer to compress spring.

While holding the spring in a compressed state, remove

retaining ring from groove in clevis and then carefully

release spring. See Figure 2-50. Discard retaining ring.

NOTE

The push rod, clevis and spacer washer are a one-piece

assembly.

5.

Remove the large flat washer, dust boot and spring from

the cartridge body. Remove spring and spring retainer

from dust boot.

Shop

f2050x2x

Cloth

6.

Push on threaded end of cartridge body to remove from

reservoir adapter. Use hand pressure only. Exercise

Figure 2-50. Compress Spring and Remove

caution to keep cartridge body free of dirt and grease.

Retaining Ring

See Figure 2-51.

7.

Carefully remove two O-rings from cartridge body. Exer-

15. Test ride the motorcycle. If the brake feels spongy,

cise caution to avoid scratching O-ring grooves.

repeat the bleeding procedure.

8.

Remove small retaining ring from groove in cartridge

body bore. Piston assembly is spring loaded so be sure

NOTE

to hold parts together as retaining ring is removed.

A sight glass enables the rider to visually check the brake

fluid level without removing the master cylinder cover. The

sight glass is dark when the reservoir is full, but as the fluid

level drops, the glass lightens to alert the rider of this condi-

Reservoir

tion.

f2054x2x

Adapter

MASTER CYLINDER

DISASSEMBLY

NOTE

If installing the Master Cylinder Reservoir Kit

(Part No.

42454-99A), see steps 1-7 below. If installing the Push Rod

Kit (Part No. 41957-97A) or the assembled cartridge body

from the Master Cylinder Repair Kit (Part No. 42382-87C),

see steps 1-9.

1.

See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,

REMOVAL, in this section.

2.

Thoroughly clean exterior of master cylinder assembly

with denatured alcohol.

Cartridge

3.

Stand master cylinder assembly upright on banjo sealing

Body

surface. For best results, suspend reservoir over edge of

table. Be sure to lay down a clean shop cloth to protect

the sealing surface from damage.

Figure 2-51. Remove Cartridge From Reservoir Adapter

2006 Touring: Chassis

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18

19

f2100x2x

1.

Hex Nut

2.

Reservoir

17

3.

O-Ring

14

4.

Cartridge Body

5.

Spring

13

6.

Primary Cup

7.

Piston

16

12

8.

O-Ring

15

9.

Push Rod/Clevis/Spacer Washer*

11

10. Retaining Ring

11. Retaining Ring

10

12. Spring

13. Spring Retainer

9

8

7

Banjo

6

Sealing Surface

14. Dust Boot

5

15. Washer

16. Retaining Ring

3

17. Clevis Pin

18. Flat Washer

4

19. Cotter Pin

3

1

2

*Push rod, clevis and spacer washer are a one-piece assembly

Figure 2-52. Rear Brake Master Cylinder Assembly (Exploded View)

9.

Remove push rod with captured spacer washer from

CLEANING AND INSPECTION

cartridge body. Remove small retaining ring from push

rod, if attached. Discard retaining ring.

1WARNING

NOTE

Use denatured alcohol to clean brake system compo-

Do not disassemble the cartridge body. The cartridge body

nents. Do not use mineral-based solvents (such as gaso-

components are not sold separately. If piston seal leakage is

line or paint thinner), which will deteriorate rubber parts

evident, replace the entire cartridge body assembly.

even after assembly. Deterioration of these components

can cause brake failure, which could result in death or

serious injury. (00291a)

1.

Clean all metal parts, except the cartridge body assem-

bly, and blow dry with compressed air. Clean all rubber

parts using denatured alcohol.

2-44

2006 Touring: Chassis

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2.

Inspect the reservoir adapter bore for scratches.

Replace the reservoir if scratches are present.

f2049x2x

3.

Check the dust boot for cuts or tears. Replace as neces-

sary.

4.

Inspect the threads on the cartridge body. Replace if

threads are damaged.

5.

Inspect the spring for distortion, cracks or broken coils.

4

3

Replace as necessary.

6.

Inspect O-ring grooves on the cartridge body for dirt.

2

Carefully clean grooves using a soft cotton cloth moist-

ened with alcohol and allow to dry. Inspect O-ring

grooves for scratches. Replace cartridge body if grooves

are scratched.

7.

Inspect the reservoir cover gasket for cuts, tears or gen-

eral deterioration. If gasket and/or sight glass replace-

ment is necessary, proceed as follows:

a. From inboard side, push sight glass toward top of

1

cover until free.

b. Pull rubber gasket from cover.

1.

Shop Cloth

3.

Push Rod

c. Fit nipple of new gasket into hole of cover aligning

2.

Cartridge Body

4.

Retaining Ring

gasket and cover thru holes.

d. From bottom of gasket, push flat end of sight glass

Figure 2-53. Compress Spring and Install Retaining Ring

through nipple until top of glass is flush with top of

gasket. Verify that glass is square in bore. If some

lubrication is necessary, use a small quantity of

4

clean brake fluid.

3

ASSEMBLY

NOTE

If installing assembled cartridge body from Master Cylinder

Repair Kit (Part No. 42382-87C), begin at step 2 below. If

installing the Push Rod Kit (Part No. 41957-97A), begin at

2

step 3. If installing the Master Cylinder Reservoir Kit (Part

No. 42454-99A), start at step 7.

1.

To install piston in cartridge body, proceed as follows:

a. Install small spring into cartridge body making sure

that spring is seated in counterbore.

b. Lightly lubricate primary cup and O-ring on piston

with DOT 4 BRAKE FLUID.

c. Install piston over spring.

f2055x2x

1

2.

Install new large retaining ring in groove on push rod

side of cartridge body.

1.

Reservoir

3.

Spring Retainer

3.

Position new retaining ring on push rod between spacer

2.

Spring

4.

Dust Boot

washer and clevis, or on clevis inboard of the retaining

ring groove.

Figure 2-54. Install Spring, Spring Retainer and Dust Boot

NOTE

The push rod, clevis and spacer washer are a one-piece

assembly.

2006 Touring: Chassis

2-45

HOME

f2051x2x

*Push rod, clevis and spacer washer are a one-piece assembly

15

17

14

19

18

16

Must Not Be

Scratched or Dented

During Handling

13

12

20

11

1

4

6

9

3

5

10

8

2

7

1.

Mounting 1-1/8 Inch Hex Nut

11. Retaining Ring

2.

Spring

12. Clevis*

3.

Cartridge Body

13. Flat Washer

4.

Primary Cup

14. Dust Boot

5.

Piston

15. Retaining Ring

6.

O-Ring

16. Spacer Washer*

7.

Drain/Air Hole

17. Retaining Ring

8.

Push Rod*

18. O-Ring

9.

Spring

19. Reservoir Adapter

10. Spring Retainer

20. Brake Line Seating Surface

Figure 2-55. Rear Brake Master Cylinder Assembly (Cross Sectional View)

4.

Stand cartridge body upright on banjo sealing surface.

6.

Verify that retaining ring is completely seated in groove

Lay down a clean shop cloth to protect the sealing sur-

and that push rod rotates freely.

face from damage. See Figure 2-53.

7.

Lubricate new O-rings with DOT 4 BRAKE FLUID and

carefully install in grooves on outside of cartridge body.

1WARNING

8.

Wipe bore of reservoir adapter with DOT 4 BRAKE

FLUID.

Wear safety glasses or goggles when removing or

installing retaining rings. Retaining rings can slip from

9.

Insert cartridge body into reservoir adapter indexing tab

the pliers and could be propelled with enough force to

on adapter in slot on threaded end of cartridge. Use

cause serious eye injury. (00312a)

hand pressure only. Cartridge body is fully installed

when reservoir adapter contacts large retaining ring.

5.

Insert ball end of push rod into piston cup. Pushing down

on push rod to compress spring, fit captured spacer

10. Stand master cylinder assembly upright on banjo sealing

washer into cartridge body. Further compressing spring

surface. For best results, suspend reservoir over edge of

as necessary, install retaining ring positioned in step 3 in

table. Be sure to lay down a clean shop cloth to protect

groove of cartridge body bore.

the sealing surface from damage.

2-46

2006 Touring: Chassis

HOME

FRONT BRAKE CALIPER

2.12

INSPECTION

1

Check brake pads and discs:

● At every scheduled service interval.

● Whenever the components are removed during normal

service procedures.

BRAKE DISC THICKNESS/WARPAGE

The minimum brake disc thickness is stamped on the side of

the disc. Replace disc if excessively worn or badly scored.

Maximum brake disc lateral runout or warpage is 0.008 inch

3

(0.20 mm) when measured near the outside diameter.

4

Replace disc if warped beyond specification. For replace-

ment instructions, see Section 2.3 FRONT WHEEL, DISAS-

SEMBLY.

2

f1756x2x

BRAKE PADS

NOTE

Brake pad inspection can be performed without removing the

1.

Right Front Brake Caliper (Bottom View)

caliper.

2.

Brake Disc

3.

Backing Plate

1.

Look up at the back of the right side caliper. See Figure

4.

Outer Pad Friction Material

2-56.

2.

Place a thin plastic 6 inch rule against the brake disc and

Figure 2-56. Measure Brake Pad Wear

measure the friction material of the brake outer pad.

Using a small hand mirror, visually check the friction

material of the inner pad.

FRONT BRAKE PAD

3.

Repeat above checks at the front of the right side cali-

REPLACEMENT

per. Replace both pads If the friction material above the

backing plate on either pad is 0.04 inch (1.02 mm) thick

or less.

PAD REMOVAL

4.

Repeat steps 1-3 on the left side of the vehicle.

1.

Use shop rag or tape to protect fender area adjacent to

caliper, as incidental contact can occur during caliper

removal.

1WARNING

2.

Loosen two pad pins, but do not remove. See Figure 2-

Always replace brake pads in complete sets for correct

57.

and safe brake operation. Improper brake operation

3.

Remove upper and lower caliper mounting bolts from

could result in death or serious injury. (00111a)

front fork mounting lugs. Lift caliper upward to remove

5.

See FRONT BRAKE PAD REPLACEMENT on this

from brake disc.

page.

CAUTION

BRAKE LINE/HOSE INSPECTION

DOT 4 brake fluid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

When checking brake pads and discs, take the time to

tion and protect surfaces from spills whenever brake

inspect the brake lines and hoses for damage or wear.

work is performed. Failure to comply can result in cos-

Replace as necessary.

metic damage. (00239a)

2-48

2006 Touring: Chassis

HOME

CAUTION

1

To prevent dirt and other contaminants from entering the

master cylinder reservoir, thoroughly clean the cover

3

before removal.

5.

Remove two Phillips screws to release cover from front

master cylinder reservoir.

NOTE

As the pistons are pushed back into the caliper, fluid level

may rise more than 1/4 inch (6.4 mm) and overflow the reser-

voir. Watch the fluid level as the pistons are retracted and

remove fluid from the reservoir if necessary.

6.

Pry back inner and outer brake pads pushing the four

pistons back into their bores.

2

7.

With the pistons retracted, remove two pad pins and

both inner and outer brake pads. Inspect pad pins. See

1.

Upper Caliper Mounting Bolt (Long)

f1767x2x

CLEANING AND INSPECTION, step 4.

2.

Lower Caliper Mounting Bolt (Short)

3.

Pad Pins

NOTE

Replacing one pad at a time keeps the anti-rattle spring in

Figure 2-57. Loosen Pad Pins and Remove Caliper

place. Remove both pads to remove or replace the spring.

Mounting Bolts (Right Side View)

PAD INSTALLATION

IMPORTANT NOTE

NOTE

Immediately wipe up any brake fluid spillage with a

clean, dry, soft cloth. Follow up by thoroughly wiping

Both front calipers (as well as the rear brake caliper) use the

affected area with a clean, damp, soft cloth (small spills)

same brake pad set.

or washing with a large quantity of soapy water (large

1.

Install new brake pads into caliper with the friction mate-

spills).

rial facing the brake disc opening. Be sure that the pad is

4.

If the motorcycle is resting on jiffy stand, turn front wheel

oriented so that the curved side faces the rear of the

as necessary until the master cylinder reservoir is level.

vehicle when the caliper is installed. See Figure 2-58.

1

2

2

1

3

3

1.

Outboard Pad

2.

Inboard Pad

Left Side

3.

Faces Rear

f2156x2x

Right Side

Figure 2-58. Front Brake Pad Locations

2006 Touring: Chassis

2-49

HOME

1.

Inside Caliper Housing

2.

Square Seal (4)

3.

Wiper (4)

14

4.

Piston (4)

16

5.

Crossover O-Ring (2)

6.

Inner Brake Pad

7.

Outer Brake Pad

13

8.

Anti-Rattle Spring

9.

Outside Caliper Housing

15

10.

Lower Mounting Bolt (Short)

11.

Upper Mounting Bolt (Long)

12.

Decal

11

12

13.

Pad Pin (2)

2

14.

Bridge Bolt (2)

8

15.

Bleeder Valve

4

16.

Bleeder Valve Cap

10

9

5

3

4

7

6

3

2

f2182x2x

1

Figure 2-59. Front Brake Caliper Assembly (Left Side)

Furthermore, note that the backing plate of each brake

c. Loosely install long caliper mounting bolt into upper

pad has either one or two tabs. On the right side of the

lug of front fork leg.

vehicle, the pad with two tabs is installed on the inboard

d. Install short caliper mounting bolt into lower lug of

side of the caliper, the pad with the single tab is installed

front fork leg. Tighten lower mounting bolt to 28-38

on the outboard side.

ft-lbs (37.9-51.5 Nm).

On the left side of the vehicle, the pad location is

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

reversed. Therefore, the pad with the single tab is

(37.9-51.5 Nm).

installed on the inboard side of the caliper, while the pad

f.

Tighten pad pins to 180-200 in-lbs (20.3-22.6 Nm).

with two tabs is installed on the outboard side.

1WARNING

2.

Install pad pins, but do not fully tighten at this time.

After servicing brakes and before moving motorcycle,

3.

Install calipers as follows:

pump brakes to build brake system pressure. Insuffi-

cient pressure can adversely affect brake performance,

a. Use shop rag or tape to protect fender area adja-

which could result in death or serious injury. (00279a)

cent to caliper, as incidental contact can occur dur-

ing caliper installation.

b. Place caliper over brake disc with bleeder valve top-

side.

2-50

2006 Touring: Chassis

HOME

4.

Pump brake hand lever until pistons contact brake pads

and pads contact brake discs. Verify piston location

against pads. If the front wheel is off the ground, rotate

wheel to check for excessive brake pad drag.

5.

Verify that brake fluid level is 1/4 inch (6.4 mm) below top

of reservoir with master cylinder in a level position. Add

DOT 4 BRAKE FLUID, if necessary.

6.

Install the master cylinder reservoir cover, but first verify

that the cover gasket bellows is not extended or brake

fluid will be ejected from the reservoir. Install two Phillips

screws and alternately tighten to

6-8 in-lbs

(0.7-0.9

Nm).

NOTE

Figure 2-60. Brake Caliper Piston Remover

(Part No. HD-43293A)

Note that one side of the master cylinder reservoir cover is

thicker than the other. Install the cover with the thicker side

closest to the brake line fitting.

7.

Test operation of brake lamp with the front brake applied

and the Ignition/Light Key Switch turned to IGNITION.

1WARNING

After repairing the brake system, test brakes at low

speed. If brakes are not operating properly, testing at

high speeds can cause loss of control, which could

result in death or serious injury. (00289a)

8.

Test ride the motorcycle. If the brakes feel spongy, bleed

the system. See Section 2.14 BLEEDING HYDRAULIC

BRAKES.

NOTE

To allow new brake pads to “wear in” properly with the brake

disc, avoid making hard stops for the first 100 miles (160 km).

Bridge

Brake Caliper

Bolt

Piston Remover

f1776x2x

Figure 2-61. Direct Compressed Air Into Banjo Bolt Hole

CALIPER REMOVAL

NOTE

CALIPER DISASSEMBLY

If only replacing brake pads, see FRONT BRAKE PAD

REPLACEMENT in this section.

1.

See Figure 2-57. Remove two pad pins. Remove brake

pads from caliper housings.

CAUTION

2.

Remove two bridge bolts and separate inside and out-

Damaged banjo bolt surfaces will leak when reassem-

side caliper housings.

bled. Prevent damage to seating surfaces by carefully

3.

Remove anti-rattle spring from channel around boss in

removing brake line components.

outside caliper housing.

1.

Remove banjo bolt and two steel/rubber washers to

detach front brake line from caliper. Discard washers.

4.

Remove bleeder valve, if damaged.

2.

Use shop rag or tape to protect fender area adjacent to

caliper, as incidental contact can occur during caliper

1WARNING

removal.

Compressed air can pierce the skin and flying debris

3.

Remove upper and lower caliper mounting bolts from

from compressed air could cause serious eye injury.

front fork mounting lugs. Lift caliper upward to remove

Wear safety glasses when working with compressed air.

from brake disc.

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

2006 Touring: Chassis

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5.

Remove four pistons as follows:

f1779x2x

a. Obtain BRAKE CALIPER PISTON REMOVER (Part

No. HD-43293A). See Figure 2-60.

b. Seat tool in outside caliper housing aligning outside

holes in tool with bridge bolt holes in housing. Place

inside caliper housing over tool aligning bridge bolt

holes with outside holes in tool.

c. Install bridge bolts and tighten securely.

d. If the bleeder valve was removed, reinstall finger

tight or place a gloved finger over the valve hole.

CAUTION

Wiper

To prevent air from escaping through the banjo bolt hole,

Square

and to avoid scratching or nicking the banjo seating sur-

Seal

face, use only a tapered, rubber tipped nozzle on air

hose. Loss of air pressure will keep the pistons from

moving, while any damage to the banjo seating surface

Figure 2-62. Remove Wipers and Square Seals

requires caliper replacement.

From Piston Bores

e. Using a tapered, rubber-tipped nozzle on the air

hose, apply low pressure compressed air into the

banjo bolt hole to force pistons into contact with

2.

Carefully inspect all components. Replace any parts that

cushion of tool. See Figure 2-61.

appear damaged or worn.

f.

Remove bridge bolts and separate caliper housings.

a. Check pistons for pitting, scratching or corrosion on

face and also on ground surfaces.

g. Remove pistons from caliper piston bores. For best

results, wiggle pistons slightly while pulling.

b. Inspect caliper piston bore. Replace caliper if bore

shows signs of pitting or corrosion. Do not hone

6.

Remove two crossover O-rings from inside caliper hous-

bore for reuse.

ing. Discard O-rings.

c. Always replace wipers, square seals and crossover

O-rings after caliper disassembly.

CAUTION

Do not use metal objects to remove parts from caliper

1WARNING

piston bores or damage will occur. Damaged pistons or

Always replace brake pads in complete sets for correct

bores will leak when reassembled. Use a wooden tooth-

and safe brake operation. Improper brake operation

pick to assist in the removal of parts, if necessary.

could result in death or serious injury. (00111a)

7.

Using a wooden toothpick, remove wiper and square

seal from each piston bore. Discard wipers and seals.

3.

Inspect brake pads and discs. See INSPECTION at the

beginning of this section.

See Figure 2-62.

4.

Inspect pad pins for wear and grooving. Replace both

pins if wear of either pin exceeds 0.015 inch (0.38 mm).

CLEANING AND INSPECTION

CALIPER ASSEMBLY

1WARNING

1.

Install new square seals into caliper piston bores.

Use denatured alcohol to clean brake system compo-

nents. Do not use mineral-based solvents (such as gaso-

2.

Install new wipers into caliper piston bores.

line or paint thinner), which will deteriorate rubber parts

even after assembly. Deterioration of these components

CAUTION

can cause brake failure, which could result in death or

serious injury. (00291a)

Do not use DOT 4 brake fluid for lubrication or in-

creased lever travel will result.

1.

Clean all parts with denatured alcohol or DOT 4 BRAKE

FLUID. Wipe parts dry with a clean, lint free cloth. Blow

3.

Lubricate the following areas using a thin film of G.E.

out drilled passages and bores with a clean air supply.

VERSILUBE^® #G322L SILICONE GREASE (marked

Do not use a wire or similar instrument to clean drilled

“Piston Lube” in the service parts kit):

passages.

2-52

2006 Touring: Chassis

HOME

Furthermore, note that the backing plate of each brake

pad has either one or two tabs. On the right side of the

vehicle, the pad with two tabs is installed on the inboard

side of the caliper, the pad with the single tab is installed

on the outboard side.

On the left side of the vehicle, the pad location is

reversed. Therefore, the pad with the single tab is

installed on the inboard side of the caliper, while the pad

with two tabs is installed on the outboard side.

8.

Install pad pins and tighten to 180-200 in-lbs (20.3-22.6

Nm).

NOTE

If pad pins do not fit, verify the following: (1) Proper pad set is

being used, not two identical pads. (2) Anti-rattle spring is

installed as shown in Figure 2-63. (3) Pads are pushed tight

against anti-rattle spring.

f1780x2x

Figure 2-63. Install Anti-Rattle Spring

CALIPER INSTALLATION

1.

Install calipers as follows:

● Inside diameter of square seals and wipers.

● Caliper piston bores.

a. Use shop rag or tape to protect fender area adja-

cent to caliper, as incidental contact can occur dur-

● Nose radius and outside diameter of piston.

ing caliper installation.

NOTE

b. Place caliper over brake disc with bleeder valve top-

All other surfaces must be kept clean and dry for assembly.

side.

4.

Carefully insert pistons into bores by hand. If resistance

c. Loosely install long caliper mounting bolt into upper

is felt, remove piston and verify that both seal and wiper

lug of front fork leg.

are properly installed.

d. Install short caliper mounting bolt into lower lug of

5.

Install new crossover O-rings into two grooves on inside

front fork leg. Tighten lower mounting bolt to 28-38

caliper housing.

ft-lbs (37.9-51.5 Nm).

6.

Assemble caliper housings as follows:

e. Tighten upper caliper mounting bolt to 28-38 ft-lbs

(37.9-51.5 Nm).

a. Install bleeder valve on outside caliper housing, if

removed. Tighten valve to 80-100 in-lbs (9.0-11.3

f.

Repeat step to install second caliper.

Nm). Install bleeder valve cap.

b. Place outside caliper housing on workbench with

CAUTION

decal side down. Place anti-rattle spring in channel

To avoid leakage, verify that the washers, banjo bolt,

around boss. Spring is not directional. See Figure 2-

brake line and caliper bore are completely clean.

63.

c. Mate inside and outside caliper housings and

2.

Connect brake line to caliper using two new steel/rubber

loosely install two bridge bolts.

washers and banjo bolt. Tighten bolt to

17-22 ft-lbs

(23.0-29.8).

d. Verify that anti-rattle spring is still seated.

3.

Remove two Phillips screws to release cover from front

e. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).

brake master cylinder reservoir. Verify that brake fluid

level is 1/4 inch (6.4 mm) below top of reservoir with

NOTE

master cylinder in a level position. Add DOT 4 BRAKE

Both front calipers (as well as the rear brake caliper) use the

FLUID, if necessary.

same brake pad set.

7.

Install new brake pads into caliper with the friction mate-

1WARNING

rial facing the brake disc opening. Also, be sure that the

pad is oriented so that the curved side faces the rear of

A plugged or covered relief port can cause brake drag or

the vehicle when the caliper is installed. See Figure 2-

lock-up, which could lead to loss of control, resulting in

58.

death or serious injury. (00288a)

2006 Touring: Chassis

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HOME

REAR BRAKE CALIPER

2.13

INSPECTION

1

Check brake pads and discs:

● At every scheduled service interval.

● Whenever the components are removed during service

procedures.

BRAKE DISC THICKNESS/WARPAGE

The minimum brake disc thickness is stamped on the side of

the disc. Replace disc if excessively worn or badly scored.

Maximum brake disc lateral runout or warpage is 0.008 inch

(0.2 mm) when measured near the outside diameter.

Replace disc if warped beyond specification. For replace-

ment instructions, see Section 2.4 REAR WHEEL, DISAS-

3

SEMBLY.

4

BRAKE PADS

NOTE

Brake pad inspection can be performed without removing the

caliper.

2

f1757x2x

1.

Look down at the back of the rear caliper. See Figure 2-

64.

2.

Place a thin plastic 6 inch rule against the brake disc and

1.

Rear Brake Caliper (Top View)

measure the friction material of the brake outer pad.

2.

Brake Disc

Using a small hand mirror, visually check the friction

3.

Backing Plate

material of the inner pad.

4.

Outer Pad Friction Material

3.

Repeat above checks at the front of the rear caliper.

Figure 2-64. Measure Brake Pad Wear

Replace both pads If the friction material above the

backing plate on either pad is 0.04 inch (1.02 mm) thick

or less.

REAR BRAKE PAD REPLACEMENT

1WARNING

PAD REMOVAL/INSTALLATION

Always replace brake pads in complete sets for correct

1.

Remove right side saddlebag. See Section 2.26 SAD-

and safe brake operation. Improper brake operation

DLEBAG, REMOVAL.

could result in death or serious injury. (00111a)

2.

Loosen both pad pins, but do not remove. See Figure 2-

65.

4.

See REAR BRAKE PAD REPLACEMENT on this page.

CAUTION

BRAKE LINE/HOSE INSPECTION

DOT 4 brake fluid will damage painted and molded-in

color surfaces it comes in contact with. Always use cau-

When checking brake pads and discs, take the time to

tion and protect surfaces from spills whenever brake

inspect the brake lines and hoses for damage or wear.

work is performed. Failure to comply can result in cos-

Replace as necessary.

metic damage. (00239a)

2006 Touring: Chassis

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