Start with a suitable container placed under the rear caliper brake line banjo fitting to catch any brake fluid that may leak out. NEVER reuse brake fluid. Use only Dot 5 Brake Fluid in a 2006 XLH motorcycle. NEXT remove the banjo bolt and both washers to detach the rear brake line from the brake caliper and throw away the washers, remove the pad pin plug, unscrew and remove the brake pad pin, remove the brake pads, unscrew and remove the caliper bolt pin, slide the brake caliper on the rear bolt pin away from the brake disc as far as possible. THEN with an open end wrench unscrew the mounting bracket bolt pin from the caliper mounting bracket and lift the brake brake caliper straight up and away from the brake disc and the caliper bracket.
LUBRICATING THE REAR CALIPER BOLT PINS AND BOOTS
FIRST apply about 0.4 g of G40M BRAKE GREASE inside the caliper bushing boot and the caliper pin boot and inside the boot lip to prevent sticking between the boots and the bolt pins and insert the mounting bracket bolt pin into the caliper bushing boot.
INSTALLATION
Before installing the caliper ensure that the retainer bracket is properly installed on the mounting bracket, then apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the mounting bracket bolt pin, place the rear caliper assembly onto the mounting bracket and using an open end wrench thread the mounting bracket bolt pin into the caliper mounting bracket and tighten it to 87-130 in-lbs (9.8-14.7 Nm). THEN apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the caliper bolt pin, slide the caliper bolt pin through the front mounting hole in the caliper, carefully insert the bolt pin shaft into the caliper pin boot in the mounting bracket and screw the bolt pin into caliper and tighten it to 15-18 ft-lbs (20.4-24.6 Nm).
NOTE that the brake caliper housing has a positive stop for banjo fitting and so when tightening the banjo bolt into the brake caliper you will need to rotate the banjo fitting clockwise until it contacts the positive stop.
THEN position a new washer onto each side of the hydraulic brake line banjo fitting, insert the banjo bolt through the washers and fitting into the caliper housing and tighten it to 20-25 ft-lbs (27.1-33.9 Nm). THEN insert the brake pads into the caliper with the friction material on the pad towards the brake disc and with the curved portion of the pad fitting into the recessed area of the caliper and the brake pad front mounting tab fitting into its slot in the caliper mounting bracket. THEN press the brake pads tightly up and against the brake pad spring and install the brake pad pin but if the pin does not easily fit in ensure that you are suing the correct brake pads and not two identical pads, that the brake pad spring is oriented correctly, that the brake pad front mounting tabs are properly seated in the slots in the mounting bracket and that the brake pads are correctly pushed tight up against the brake pad spring BEFORE the brake pad pin is installed. AND THEN tighten the brake pad pin to 131-173 in-lbs (14.8-19.6 Nm). THEN install the brake pad pin plug and tighten it to 18-25 in-lbs (2.0-2.9 Nm). THEN with the rear brake master cylinder reservoir in a level position verify the brake fluid level in the reservoir. If necessary and with the bike upright and not resting on its jiffy stand remove the rear brake master cylinder reservoir cap and add sufficient new D.O.T. 5 BRAKE FLUID to the reservoir to cause the fluid to reach the upper fluid level mark, but do not exceed this mark. THEN verify the proper operation of the master cylinder relief port because a plugged or otherwise blocked relief port could cause the brakes to drag or stick on. Do this by pressing against the rear brake caliper to push the caliper piston back into its bore and push brake fluid back through the master cylinder and into the reservoir. THEN pump the brake pedal until the caliper piston pushes the brake pads out against the brake disc and firm pressure is returned to the brake system.THEN turn ignition switch ON and pump the brake pedal to verify correct operation of the brake lamp and test ride the motorcycle at low speed to safely test the brake system. If the brakes feel at all soft or spongy, bleed the system until you get a firm, hard pedal and avoid making hard stops for the first 100 miles (160 km) to allow the new pads to become conditioned to the brake disc.
Replace brake pads at any time the brake pad friction material on either the front or rear caliper is worn to 0.04 in. (1.02 mm) or less above the backing plate and always replace both pads in a caliper as a set.
The minimum brake disc thickness is stamped on the side of the disc and it must be replaced if and when it is badly scored or worn past the minimum thickness. Maximum brake disc lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter.
SOURCE: 2003 rear brake caliper lock up on a harley sportster
Check your pads to make sure they are in the right position and haven't started to wear too thin and move.
Check the operation of the pads is real smooth when you apply pressure on the lever (might need someone else to operate it while you look ).
Witth the rear wheel raised off the ground and the bike not running turn the wheel slowly and check to see if it warped. (I used to do this on my sportster by using a couple of car axle stands under the footpeg brackets and raising the bike up on an old hydraulic car jack - might not be the best way but it worked enough for me to get the rear wheel off to change tyres without spending a fortune-an extra pair of hands is really handy(!) here).
Look down the rear caliper and check that no **** from the road has got stuck in there anywhere.
check your wheel alignment - have you adjusted the belt lately or latered the set-up?
Hope something here helps!
SOURCE: 1979 Lowrider shovel rear brake calipers rattle
Here is a link to the aftermarket service manual.>>
http://sunnymeadcycles.com/files/1966-84_Shovels_Aftermarket_Service.pdf
SOURCE: spark plug for 2006 HD sportster the plug is a NGK
emegtei hvnig dur taviulah arga 2007 satrip
SOURCE: how do I replace rear brakes on a 1200 2007 harley
Remove the two bolts that hold the rear brake caliper into the rear brake caliper support bracket. Lift off caliper. Notice how the pads and anti-vibration clips are positioned in the rear brake caliper support bracket. Install new pads and anti-rattle clips or springs.
Now, using a large C-clamp or a large pair of slip joint pliers, depress piston all the way back into the caliper. Carefully reposition the caliper back on the rear brake caliper support bracket without disturbing the pads or clips. Install the two bolts and torque to 25 foot pounds of torque. Slowly depress and release the rear brake pedal until a good firm pedal is obtained. Check the brakes for proper operation prior to riding the bike. Failure to properly service the brakes can cause sever injury or death.
SOURCE: replace rear brake pads on 2003 harley davidson
If you'll look at the caliper, you'll see two bolts that hold the caliper into the caliper bracket. Usually they take Torx wrenches to remove them. Take these two bolts out and lift the caliper.
Notice the way the pads and any anti-rattle hardware is positioned in the caliper bracket. Replace the pads and the hardware.
Now you must press the piston back into the caliper. I use either a large C-clamp or a large pair of slip joint pliers to squeeze the piston back down into the bore completely. Use a rag or some thing pieces of wood to prevent damage to the caliper.
Now, replace the caliper over the pads without disturbing them and replace the screws. Torque them to 30-45 foot pounds.
Good luck
Steve
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