For more information, refer to the Reference Section on Brakes (Fluid):
brake_system

• A total of 635 XLH and XLS models were produced and shipped between March 30 and April 19, 1979 with a possible defect in the assembly of the brake pedal stop bolt jam­ nut not being securely tightened at the time of assembly. This could allow the bolt to unscrew from the pedal shaft arm & the bolt head to contact the lower inside edge of the sprocket cover, possibly locking or hindering the rear brakes. Each dealer was reimbursed 0.2 hours for each motorcycle serviced to cover costs for labor and pro­cessing. ¹⁾
  • Suspect engine VINs were:

XLH ²⁾

XLS ³⁾

• The brake pedal stop bolt is located underneath the right side of the engine just below the rear. ⁴⁾
• Always check the jam nut for tightness and check the brake linkage for proper adjustment as follows: ⁵⁾
  • Work the rear brake pedal by hand to determine free play (movement before the plunger contacts the piston in the master cylinder).
  • Free play of the plunger should be app. 1/16“ (to be sure the rear brake pressure is relieved when the brake pedal is released.
  • To adjust the free play, loosen the jam nut and turn the stop bolt inward (clock­ wise) to decrease or outward (counterclockwise) to increase the free play. When 1/16” free play is obtained, tighten the jam nut against the shaft lever while holding the stop bolt in position.
  • Recheck free play.

* . . . Rear Drum Fitting Issues with a Rigid Frame

• On 1963-1978 XLH/XLCH Models, a bearing spacer washer HD part #41195-63 (or V-Twin part number 44-0395 ⁶⁾) is placed between the two bearings on the right hub (brake side). This spacer washer is reportedly not installed at the factory but is a service part for alignment where the aluminum back plate butts to the bearing inner race due to wear. The race will plow right into the soft back plate when the axle flexes ⁷⁾.
  • Approximate dimensions of this spacer are: ID -.737“, OD - 1.008”, Thickness .018“. ⁸⁾
• This is not a grease shield for the bearing. The grease shield used on the brake side →'62 was no longer use by '63 and up models.
• This small washer has a lip, its very thin, and is not a regular flat washer. It goes in between the right side bearings in the hub, and pushes/holds the outer bearing flush with the hub where it goes up against the inside of the brake backing plate. Others have also said it is OK to use a second one in between the backing pate and the outer bearing if you need a little clearance so the backing plate wont rub, but if you need more than those 2, you should look inside your hub for issues… ⁹⁾