Harley Davidson Sportster Models 2009. Service Repair Manual

passages and piston bore in master cylinder body with
low pressure compressed air from a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages.

Carefully inspect all parts for wear or damage and replace
as necessary.

Inspect piston bore in master cylinder housing for
scratches, grooves, scoring, pitting or corrosion.
Replace housing if any of these conditions are found.

Inspect outlet port that mates with brake line banjo
fitting. This is a critical sealing surface. Replace
housing if any scratches, dents or other damage is
found.

Verify that vent holes in master cylinder are completely
open and free of dirt or debris.

ASSEMBLY

NOTES

•

When assembling rear brake master cylinder, always use
new parts from the service parts kit. Consult the PARTS
CATALOG for the correct kit part number.

•

CCI #20 BRAKE GREASE is recommended for lubrication
of cylinder bore, cups and seals prior to assembly.

•

Stand master cylinder on wooden block or clean, lint-free
towel to protect seating surfaces.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-105

. Coat new o-ring (20) with HARLEY-

DAVIDSON D.O.T. 4 BRAKE FLUID. Install o-ring and
feed port fitting (21) into feed port on top of master cylinder
(19). Secure with new retaining ring (22). Verify that
retaining ring is fully seated in groove.

Slide dust cover (23) onto feed port fitting and press into
place in master cylinder feed port. See

Figure 2-106

. Turn

feed port fitting (4) so it points toward banjo fitting (5) end
of master cylinder body (1).

sm01809

Rear master cylinder assembly

External boot

Tabs (2)

Feed port fitting

Banjo fitting hole

Figure 2-106. Assembled Rear Master Cylinder

NOTE

See

Figure 2-105

. Clamp rear brake master cylinder (19) in a

vise by its mounting bosses (18) only. Use brass jaw covers
or other protective device on vise jaws to prevent damage to
master cylinder.

Clamp master cylinder in a vise with banjo fitting end
pointing down.

See

Figure 2-107

. Lubricate master cylinder bore, new

piston (1) with new secondary cup (3), and new primary
cup (2) with CCI #20 BRAKE GREASE supplied in the
service parts kit.

Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring,
attached components and/or hand tools to fly out which
could result in death or serious injury. (00477c)

Press small end of new piston spring (4) onto mounting
boss (8) on piston (1).

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2-70 2009 Sportster Service: Chassis

sm02308

Piston

Primary cup

Secondary cup

Piston spring

Push rod

Boot collar nut

Push rod retainer

Piston spring mounting boss

Figure 2-107. Rear Master Cylinder Piston, Push Rod and

Spring Assembly

Slide piston/spring assembly, flared end of spring first,
into cylinder bore so that spring seats against counter bore
(recess) at bottom of cylinder.

Apply approximately 0.1 g of G40M BRAKE GREASE to
ball end of push rod (5). Insert ball end of push rod into
cupped end of piston.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-105

. Temporarily thread shoulder nut (4)

onto push rod (13) several turns to protect push rod
threads. Press down on push rod to compress piston
spring (17). Slide push rod retainer (11) down into master
cylinder bore.

Secure push rod assembly with new retaining ring (10).
Verify that retaining ring is fully seated in groove. Remove
shoulder nut from push rod.

10. See

Figure 2-108

. Apply approximately 0.1 g of G40M

BRAKE GREASE around groove (4) in boot collar nut (3).
Carefully slide inner boot (5) down onto push rod (2) and
into end of master cylinder bore. Press lip of inner boot
down around groove in boot collar nut.

11. See

Figure 2-105

. Install external return spring (7) and

spring retainer (6). Thread shoulder nut (4) shoulder-first
onto push rod (13), several turns past flats.

12. Thread yoke (3) onto push rod, at least 2-3 turns past flats.

Install new spring pin (12) into end of push rod.

sm01810

Rear brake master cylinder assembly

Push rod

Boot collar nut

Groove

Inner boot

Figure 2-108. Lubricating and Installing Inner Boot

13. See

Figure 2-109

. Measure distance from centerline of

clevis pin hole (1) in yoke to centerline of master cylinder
mounting boss hole (2) closest to yoke. This distance must
be 3.40-3.48 in. (86.3-88.3 mm). Turn yoke on push rod
in one direction or the other until this distance is obtained.

NOTE

See

Figure 2-104

. Grip yoke by the edges with adjustable

wrench. do not grip yoke by the flats of the yoke may become
deformed.

14. See

Figure 2-104

. Holding yoke with an adjustable wrench,

turn shoulder nut back against yoke. Tighten to 130-173
in-lbs (14.7-19.6 Nm).

15. Remove master cylinder assembly from vise. See

Figure 2-106

. Slide external boot (2) over yoke/push rod

assembly and external return spring.

16. Position external boot so that tabs (3) are at the 3-o'clock

and 9-o'clock position when master cylinder body (1) is
held upright. This assures that drain hole is at bottom of
boot when master cylinder is mounted on motorcycle.
Make sure that lip on large end of external boot fits fully
in groove in end of master cylinder. Make sure that spring
retainer is fully seated in groove in small end of external
boot.

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2009 Sportster Service: Chassis 2-71

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Clevis pin hole

Mounting boss hole

3.40-3.48 in. (86.3-88.3 mm)

Figure 2-109. Adjusting Push Rod Length

INSTALLATION

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-103

. If master cylinder mounting bracket (15)

was removed:

Attach mounting bracket to frame loosely with screws
(23, 24). Then tighten two screws (23) to 17-22 ft-lbs
(23.1-29.9 Nm). Tighten screw (24) to 17-22 ft-lbs
(23.1-29.9 Nm).

Install bell crank (12) with clevis pin (13). Secure with
new retaining ring (14).

Install rear master cylinder assembly (6) on mounting
bracket (15) with screws (7) and washers (8). Tighten to
17-22 ft-lbs (23.1-29.9 Nm).

Fit yoke (10) onto bell crank (12). Install clevis pin (9) and
secure with new retaining ring (11).

NOTE

Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.

Position a new washer (16) on each side of hydraulic
brake line banjo fitting (17). Insert banjo bolt (18) through
washers and fitting. Thread bolt into master cylinder
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

Install rear brake master cylinder feed hose (3) on master
cylinder feed hose port fitting (5). Secure with new hose

clamp (4). See

2.15 REAR BRAKE MASTER CYLINDER

RESERVOIR

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

Reservoir cover may be removed from rear brake master
cylinder reservoir to more easily verify fluid level in reser-
voir.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

Position motorcycle upright (not resting on jiffy stand).

See

Figure 2-117

. Remove reservoir cap (4). If desired,

remove reservoir cover: grasp cover (2) and gently pull
straight out from reservoir (1).

Fill rear master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID until the fluid level reaches
the UPPER mark on the reservoir.

Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

10. Turn ignition/light switch ON. Test operation of brake lamp

with the rear brake applied.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

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)

11. Test ride motorcycle at low speed. If brake feels spongy,

repeat bleeding procedure.

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2-72 2009 Sportster Service: Chassis

2.14

REAR BRAKE MASTER CYLINDER: XR MODELS

GENERAL

The rear brake master cylinder is mounted to the right side
rider footrest/rear brake pedal bracket.

If the rear brake feels spongy or excessive pedal travel exists
or the brake does not work at all, proceed with Inspection which
follows.

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

INSPECTION

Check the level of fluid in the rear brake reservoir. If it is
low, refill and bleed brake system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

Check for fluid leaks in the brake line, around banjo fittings
or rear brake caliper piston or bleeder valve. Repair and
bleed brake system.

For brake line replacement procedure, see

2.18 BRAKE LINES

To repair rear brake caliper, see procedure in

2.17 REAR BRAKE CALIPER: XR MODELS

See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

for hydraulic brake system bleeding procedure.

Check rear brake friction pads and disc for excessive wear
or damage. Replace worn or damaged items.

See

1.10 BRAKE PADS AND DISCS: XR MODELS

for specifications.

See

1.10 BRAKE PADS AND DISCS: XR MODELS,

Brake Pad Replacement: Rear

for brake pad

replacement procedure.

See

2.4 WHEELS

for brake disc replacement pro-

cedure.

Eliminate any air in the hydraulic brake assembly by
bleeding the system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

If none of these conditions exist but the rear brake system does
not operate properly, the rear master cylinder is most likely
defective and must be repaired or replaced.

REMOVAL

See

Figure 2-110

. Drain rear brake master cylinder

reservoir (7) and remove feed hose (8) from master cyl-
inder feed hose port fitting. See

2.15 REAR BRAKE

MASTER CYLINDER RESERVOIR

. Discard hose clamp.

Install end of a length of 5/16 in. (7.9 mm) I.D. clear plastic
tubing over rear caliper bleeder valve and place free end
of tubing in a suitable container.

Open bleeder valve about 1/2-turn. Pump brake pedal to
drain brake fluid. Close bleeder valve but do not tighten.

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)

Remove retaining ring (1) from clevis pin (2). Remove
clevis pin and disengage master cylinder yoke (3) from
brake pedal. Discard retaining ring.

NOTE

Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.

Remove banjo bolt (6) and washers (5). Lift banjo fitting
away from master cylinder. Discard washers.

Remove two screws (4) securing rear master cylinder to
master cylinder mounting bracket and remove rear master
cylinder.

If it is necessary to remove master cylinder/footpeg
mounting bracket, remove fasteners (9). Refer to

2.42 RIDER FOOT CONTROLS: XR MODELS

for disas-

sembly and repair procedures.

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2009 Sportster Service: Chassis 2-73

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Retaining ring

Clevis pin

Yoke

Screw and washer (2)

Washer (2)

Banjo bolt

Reservoir

Feed hose

Fastener (2)

Figure 2-110. Rear Brake Master Cylinder and Reservoir

DISASSEMBLY

NOTE

•

Do not disassemble the rear master cylinder unless prob-
lems are being experienced. Discard all seals during the
disassembly procedure. Install a complete rebuild kit when
the unit is reassembled.

•

Clamp rear brake master cylinder in a vise by its mounting
bosses only. Use brass or aluminum jaw covers or other
protective device on vise jaws to prevent damage to
master cylinder.

See

Figure 2-112

. Clamp rear brake master cylinder in a

vise with yoke (3) pointing up.

NOTE

See

Figure 2-111

. Grip yoke by the edges with an adjustable

wrench. Do not grip yoke by the flats or the yoke may become
deformed.

See

Figure 2-111

. Hold yoke with an adjustable wrench.

Using an open-end wrench, loosen shoulder nut. Remove
yoke.

See

Figure 2-112

.Remove nut (4) from push rod.

Remove and discard boot (5).

NOTE

Do not remove boot collar nut (8) from push rod.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

Thread nut (4) back onto push rod several turns, to protect
push rod threads. Press down on push rod to compress
piston spring (12). Remove retaining ring (6), push rod (7)
with boot collar nut (8), piston (10) with secondary cup (9),
primary cup (11) and piston spring (12). Discard retaining
ring, piston/cup assembly and piston spring.

Remove dust cover (16), retaining ring (15), feed port fitting
(14) and o-ring (13). Discard retaining ring and o-ring.

sm05298

Figure 2-111. Holding Yoke (Top: Incorrect, Bottom:

Correct)

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2-74 2009 Sportster Service: Chassis

sm05290

11.

Primary cup*

Retaining ring

12.

Clevis pin

Piston spring*

13.

O-ring

Yoke

14.

Nut

Feed port fitting

15.

Retaining ring

Boot*

16.

Retaining ring*

Dust cover

17.

Master cylinder body

Push rod

18.

Boot collar nut

Push rod retainer

19.

G40M brake grease*

Secondary cup*

10.

20.

Piston*

CCI #20 brake grease*

Figure 2-112. Rear Brake Master Cylinder (*Provided in Service Parts Kit)

CLEANING, INSPECTION AND REPAIR

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

See

Figure 2-112

. Thoroughly clean master cylinder body

(17) and all brake system components. Blow out drilled
passages and piston bore in master cylinder body with
low pressure compressed air from a clean air supply. Do

HOME

2009 Sportster Service: Chassis 2-75

not use a wire or similar instrument to clean drilled pas-
sages.

Carefully inspect all parts for wear or damage and replace
as necessary.

Inspect piston bore in master cylinder housing for
scratches, grooves, scoring, pitting or corrosion.
Replace housing if any of these conditions are found.

Inspect outlet port that mates with brake line banjo
fitting. This is a critical sealing surface. Replace
housing if any scratches, dents or other damage is
found.

Verify that vent holes in master cylinder are completely
open and free of dirt or debris.

ASSEMBLY

NOTES

•

When assembling rear brake master cylinder, always use
new parts from the service parts kit. Consult the PARTS
CATALOG for the correct kit part number.

•

CCI #20 BRAKE GREASE is recommended for lubrication
of cylinder bore, cups and seals prior to assembly.

•

Stand master cylinder on wooden block or clean, lint-free
towel to protect seating surfaces.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-112

. Coat new o-ring (13) with HARLEY-

DAVIDSON D.O.T. 4 BRAKE FLUID. Install o-ring and
feed port fitting (14) into feed port on master cylinder body
(17). Secure with new retaining ring (15). Verify that
retaining ring is fully seated in groove.

Slide dust cover (16) onto feed port fitting and press into
place in master cylinder feed port.

NOTE

Clamp rear brake master cylinder body (17) in a vise by its
mounting bosses only. Use brass jaw covers or other protective
device on vise jaws to prevent damage to master cylinder.

Clamp master cylinder in a vise with banjo fitting end
pointing down.

See

Figure 2-113

. Lubricate master cylinder bore, new

piston (1) with new secondary cup (3), and new primary
cup (2) with CCI #20 BRAKE GREASE supplied in the
service parts kit.

Press small end of new piston spring (4) onto mounting
boss (8) on piston.

sm05294

Piston

Primary cup

Secondary cup

Piston spring

Push rod

Boot collar nut

Push rod retainer

Piston spring mounting boss

Figure 2-113. Rear Master Cylinder Piston, Push Rod and

Spring Assembly

Slide piston/spring assembly, flared end of spring first,
into cylinder bore so that spring seats against counter bore
(recess) at bottom of cylinder.

Apply approximately 0.1 g of G40M BRAKE GREASE to
ball end of push rod (5).

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-112

. Temporarily thread nut (4) onto push

rod (7) several turns to protect push rod threads.

Insert push rod into master cylinder body. Press down on
push rod to compress piston spring (12). Slide push rod
retainer (18) down into master cylinder bore and hold in
place.

10. Secure push rod assembly with new retaining ring (6).

Verify that retaining ring is fully seated in groove. Remove
nut (4) from push rod.

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2-76 2009 Sportster Service: Chassis

11. See

Figure 2-114

. Apply approximately 0.1 g of G40M

12. See

Figure 2-112

. Thread nut (4) onto push rod (7), sev-

eral turns past flats.

13. Thread yoke (3) onto push rod, at least 2-3 turns past flats.

sm05295

Rear brake master cylinder assembly

Push rod

Boot collar nut

Groove

Inner boot

Figure 2-114. Lubricating and Installing Inner Boot

14. See

Figure 2-115

. Measure distance (3) from centerline

of clevis pin hole (1) in yoke to centerline of master cylinder
mounting boss hole (2) closest to yoke. This distance must
be 2.64-2.76 in. (67.1-70.1 mm). Adjust yoke until this
distance is obtained.

NOTE

See

Figure 2-111

. Grip yoke by the edges with adjustable

wrench. do not grip yoke by the flats or the yoke may become
deformed.

15. See

Figure 2-111

. While holding yoke with an adjustable

wrench, turn shoulder nut back against yoke. Tighten to
130-173 in-lbs (14.7-19.6 Nm).

16. Remove master cylinder assembly from vise.

sm05299

Clevis pin hole

Mounting boss hole

Adjustment distance

Figure 2-115. Adjusting Push Rod Length

INSTALLATION

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)

See

Figure 2-110

. Assemble and install master cyl-

inder/footpeg mounting bracket if it was removed. See

2.42 RIDER FOOT CONTROLS: XR MODELS

Install rear master cylinder assembly to mounting bracket
with screws and washers (4). Tighten to 72-96 in-lbs (8.1-
10.9 Nm).

Fit yoke (3) onto foot pedal. Install clevis pin (2) and secure
with new retaining ring (1).

NOTE

Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.

Position a new washer (5) on each side of hydraulic brake
line banjo fitting. Insert banjo bolt (6) through washers and
fitting. Thread banjo bolt into master cylinder housing.
Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

Install rear brake master cylinder feed hose (8) on master
cylinder feed hose port fitting. Secure with new hose
clamp.

HOME

2009 Sportster Service: Chassis 2-77

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

Reservoir cover may be removed from rear brake master
cylinder reservoir to more easily verify fluid level in reser-
voir.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

Position motorcycle upright (not resting on jiffy stand).

See

Figure 2-116

. Remove reservoir cap (2).

Fill rear master cylinder reservoir (1) with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID until the fluid level reaches
the UPPER mark (3) on the reservoir.

Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

10. Turn ignition/light switch ON. Test operation of brake lamp

with the rear brake applied.

11. Test ride motorcycle at low speed. If brake feels spongy,

repeat bleeding procedure.

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Rear brake master cylinder reservoir

Reservoir cap

Upper fluid level

Lower fluid level

Figure 2-116. Rear Brake Master Cylinder Reservoir (XR

Models)

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2-78 2009 Sportster Service: Chassis

2.15

REAR BRAKE MASTER CYLINDER RESERVOIR

GENERAL

The rear brake master cylinder is equipped with a remote fluid
reservoir. On XL models, this reservoir is located to the rear
of the primary cover, below the left side cover. On XR models,
the reservoir is mounted on the right side rider footrest/rear
brake pedal bracket.

REMOVAL: XL MODELS

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Position motorcycle upright on suitable lift.

See

Figure 2-117

. Grasp reservoir cover (2) and gently

pull straight out from reservoir (1).

Remove screw with captive washer (3).

Remove reservoir cap (4). Hold reservoir upside down
over a suitable container and drain brake fluid.

Loosen hose clamp (5) and pull feed hose (6) from reser-
voir. Slide hose clamp off free end of feed hose.

See

Figure 2-118

. Slide feed hose (2) down through B-

clamp (3). Hold free end of hose down over container and
drain any brake fluid remaining in hose.

Loosen hose clamp (4) and pull feed hose off feed hose
port (5) on master cylinder (1).

Cover feed hose port with a clean, lint-free cloth to keep
dirt and debris out of master cylinder.

sm01331

Rear brake master cylinder reservoir

Reservoir cover

Mounting screw with captive washer

Reservoir cap

Hose clamp

Master cylinder feed hose

Figure 2-117. Reservoir Mount

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2009 Sportster Service: Chassis 2-79

sm01332

Rear brake master cylinder

Master cylinder feed hose

B-clamp

Hose clamp

Feed hose port

Figure 2-118. Master Cylinder Feed Hose

INSTALLATION: XL MODELS

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

See

Figure 2-118

. Slide end of feed hose (2) onto feed

hose port (5) on master cylinder (1). Secure feed hose to
fitting with hose clamp (4).

Slide free end of feed hose up through B-clamp (3).

See

Figure 2-117

. Slide hose clamp (5) onto free end of

feed hose (6).

Push feed hose onto fitting on reservoir (1) and secure
with hose clamp.

Install reservoir using screw with captive washer (3).
Tighten to 20-25 in-lbs (2.3-2.8 Nm).

NOTES

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

Position motorcycle upright (not resting on jiffy stand). Fill
master cylinder reservoir with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID until the fluid level reaches the UPPER
mark on the reservoir.

Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

Install reservoir cover (2).

Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.

10. Test ride motorcycle. If brake feels spongy, repeat bleeding

procedure.

REMOVAL: XR MODELS

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Position motorcycle upright on suitable lift.

See

Figure 2-119

. Loosen reservoir cap (2).

Remove screw (6).

Remove reservoir cap (2). Hold reservoir upside down
over a suitable container and drain brake fluid.

Loosen hose clamp (3) and pull feed hose (4) from reser-
voir. Slide hose clamp off free end of feed hose.

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2-80 2009 Sportster Service: Chassis

Loosen hose clamp (5) and pull feed hose off master cyl-
inder. Cover feed hose port with a clean, lint-free cloth to
keep dirt and debris out of master cylinder.

sm05303

Rear brake master cylinder reservoir

Reservoir cap

Hose clamp

Feed hose

Hose clamp (master cylinder)

Screw

Figure 2-119. Rear Brake Master Cylinder Reservoir: XR

Models

INSTALLATION: XR MODELS

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

See

Figure 2-119

. Slide end of feed hose (4) onto feed

hose port on master cylinder. Secure feed hose to fitting
with hose clamp (5).

Slide hose clamp (3) onto free end of feed hose (4).

Push feed hose onto fitting on reservoir (1) and secure
with hose clamp.

Install reservoir using screw (6). Tighten to 36-60 in-lbs
(4.1-6.8 Nm).

NOTES

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

Position motorcycle upright (not resting on jiffy stand). Fill
master cylinder reservoir with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID until the fluid level reaches the UPPER
mark on the reservoir.

Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

Install reservoir cover (2).

Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.

Test ride motorcycle. If brake feels spongy, repeat bleeding
procedure.

HOME

2009 Sportster Service: Chassis 2-81

2.16

REAR BRAKE CALIPER: XL MODELS

REMOVAL

NOTE

If only replacing brake pads, do not remove rear brake caliper.
For brake pad replacement only, see

1.9 BRAKE PADS AND

DISCS: XL MODELS

NOTE

Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.

NOTES

•

Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and
bushings which could damage caliper during vehicle
operation.

•

It is further not required or recommended to remove or
loosen the caliper mounting pins.

•

it is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to perform
caliper service.

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Position vehicle upright on a suitable lift.

Place a suitable container under the rear caliper brake
line banjo fitting to catch any brake fluid that may leak out.
Do not reuse brake fluid.

See

Figure 2-120

. Remove the banjo bolt (1) and both

washers (2) to detach rear brake line (3) from brake caliper
(4). Discard washers.

Remove pad pin plug (6).

See

Figure 2-121

. Remove brake pad pin.

See

Figure 2-122

. Remove brake pads (15).

Remove rear wheel. See

2.4 WHEELS, Rear Wheel

See

Figure 2-120

. Remove rear brake caliper (4) and

caliper mounting bracket (5) as an assembly.

sm03595

Banjo bolt

Washer (2)

Rear brake line

Brake caliper

Caliper mounting bracket

Pad pin plug

Bleeder valve

Damper

Figure 2-120. Rear Caliper Assembly

sm01451

Figure 2-121. Brake Pad Pin (Plug Removed)

HOME

2-82 2009 Sportster Service: Chassis

sm01813

11.

Bleeder nipple cap

Caliper mounting bracket

12.

Pad spring

Bleeder valve

13.

Brake pad (2)

Caliper pin boot

14.

Damper

Pad retainer (2)

15.

Brake pad set (includes item 20)

Mounting bracket bolt pin (do not remove)

16.

Caliper body

Piston

17.

Piston seal

Caliper bolt pin (do not remove)

18.

Caliper bushing boot

Dust seal

19.

Piston kit

Pad pin plug

10.

20.

Pad pin

Retainer clip (not sold separately)

Figure 2-122. Rear Brake Caliper Assembly

HOME

2009 Sportster Service: Chassis 2-83

DISASSEMBLY

See

Figure 2-122

. Remove pad spring (2). Do not remove

bleeder valve (12) at this time.

See

Figure 2-123

. Install a discarded brake pad in the

caliper with the backing plate (4) facing the piston. Position
the brake pad so the friction material (3) is against the
back of the caliper, as shown.

Loosely install brake pad pin (2) to hold brake pad in place.

When removing piston with compressed air, piston can
develop considerable force and fly out of caliper bore.
Keep hands away from piston to avoid possible injury.
(00530b)

NOTE

Be careful not to damage banjo bolt sealing surface or threads
of banjo bolt hole in brake caliper. It is recommended that you
use an air nozzle with a rubber tip to perform the next step in
this procedure.

See

Figure 2-124

. Gently apply low pressure compressed

air to banjo bolt hole (3) to force piston from caliper bore.

Remove brake pad pin and brake pad from caliper.

See

Figure 2-122

. Remove piston (16) from caliper bore

by hand. If necessary, gently wiggle piston to completely
remove.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to piston, seal and bore by only using
a wooden toothpick when servicing caliper.

See

Figure 2-125

. Using a wooden toothpick (1), remove

dust seal (2) and piston seal (3) from caliper bore. Discard
seals.

See

Figure 2-122

. If necessary, remove bleeder valve

(12).

sm01453

Brake caliper

Brake pad pin

Brake pad friction material

Brake pad backing plate

Brake caliper mounting bracket

Figure 2-123. Preparing Caliper for Piston Removal

sm01454

Low pressure air nozzle

Brake caliper

Banjo bolt hole

Brake pad

Figure 2-124. Removing Piston (Caliper Removed from

Mounting Bracket for Clarity)

HOME

2-84 2009 Sportster Service: Chassis

sm01455

Wooden toothpick

Dust seal

Piston seal

Figure 2-125. Caliper Seals

CLEANING, INSPECTION AND REPAIR

Clean piston bore with denatured alcohol.

Clean all rubber parts with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe parts dry with a clean, lint free cloth.

Blow out drilled passages and piston bore with low pres-
sure compressed air from a clean air supply. Do not use
a wire or similar instrument to clean drilled passages.

Carefully inspect all components. Replace any parts that
appear damaged or worn.

Check piston (16) for pitting, scratching or corrosion
on outside surfaces.

Inspect caliper (6) piston bore. Do not hone bore. If
bore shows pitting or corrosion, replace caliper.

Inspect pad pin (10) for grooving and wear. Measure
the pad pin diameter in an unworn area, and then in
the area of any grooving or wear. If wear is more than
0.011 in. (0.28 mm), replace pad pin.

Always replace all seals after disassembly.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Inspect brake pads (13) and brake disc. Replace if
necessary.

See

1.9 BRAKE PADS AND DISCS: XL MODELS

for

specifications.

See

2.4 WHEELS

for brake disc replacement pro-

cedure.

LUBRICATING REAR CALIPER BOLT PINS
AND BOOTS

See

Figure 2-126