See also Bleeding the Brake Lines In the REF section of the Sportsterpedia.

For more information:

Refer to these threads:

• 2005 Rear Master Cylinder Re-build
• - http://xlforum.net/forums/showthread.php?t=75157
• 2006 vs 2007 1200L Front Brake Caliper
• - http://xlforum.net/forums/showthread.php?threadid=2057183

Refer to the Reference Section:

• on Brakes (Fluid): brake_system
  

Wrench Sizes & Torque Specs

Caution the use of 6-point sockets and vise-grips will round off the bolt corners. ¹⁾

• Changing pads:
• Caliper to fork mounting bolts (2) (rectangles in pic below):
  • Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38-51.5 Nm). ²⁾
• Brake Pad Slide Pins (2) (five sided box below):
  • The small bolts on the caliper need to be removed in order to change the pads. ³⁾
    They will give an audible click when inserted into the housing. ⁴⁾
  • Wrench (1/4“ 12-point), Torque (180-200 in/lbs / 20.3-22.6 Nm). ⁵⁾
• Bleeder valve:
  • Torque (80-100 in/lbs / 9.0-11.3 Nm) ⁶⁾
• Banjo bolt on caliper (six sided box below):
  • Wrench (3/8” 12-point)
• Banjo bolt at M/C:
  • Wrench (7/16 12-point)

• Disassembling the caliper:
• Bridge bolts (2) (rectangles in pic below):
• The 2 larger bolts to the right on the caliper.
  These hold the caliper halves together and shouldn't need to be removed unless you are rebuilding the caliper. ⁷⁾
  • Wrench (10mm 12-point), Torque (28-38 ft/lbs / 38.0-51.5 Nm). ⁸⁾

02 Caliper 9)

Alternative Calipers:

The 2000 and newer bikes have a completely different mounting boss for the brakes. If you want to upgrade to Brembo calipers you're going to need the lowers from a 2000 and newer model. The stock aluminum style is the same price as the chrome version (at retail) so if you like chrome, it's definitely the way to go. ¹⁰⁾

When removing the rear caliper pin bolt (44184-04) and raising the caliper, the brake pads will rotate and come out of the retention clip. ¹¹⁾
During reassembly you must be certain to visually check that the brake pads are properly reinserted into the retention clip.
If the pads are not positioned properly you will cross thread the pin bolt in the aluminum caliper during reassembly.
A cross-threaded caliper pin bolt may permit the caliper to rock side to side on the bracket when the brake is applied causing drag and noise.

• Kelsey Hayes front master cylinder:
  • The Kelsey Hayes master has no freeplay. The internals are held in place by a seal ring.
  • There were 5 bore sizes on HD motorcycles according to MMI documentation:
    • 1982 (only) had a 3/4” bore.
    • 1983-1995 had 5/8” bore on a single disc and 11/16” on dual discs.
    • 1996 and up had 9/16” on singles and 11/16” on duals (however, S models have a 11/16“ bore).

Front M/C Bore Stamp Locations:

1988 XLH 1200 M/C 26)	1998 XL1200S M/C 27)

2007 XL1200R M/C 28)	2007-2013 single disc M/C 29)

2012 XR1200X M/C 30)