Complete brake and brake system overview including brake pad replacement procedures, bleeding the brake system, removing the caliper with diagrams part names for the 2008 Harley Davidson XL 883 Sportster (2008), XL 883C Sportster (2008), XL 883L Sportster (2008), XL 1200L Sportster (2008), XL 1200R Sportster (2008), XL 1200N Sportster (2008), Harley Davidson XL 1200C Sportster( 2008), XL 1200C Sportster Custom 105th Anniversary Edition (2008). 08 Harley Custom, 08 Harley Nightster, 08 Roadster, Sportster Low. XL883, XL1200, XL883C, XL883L, XL1200L, XL1200C Motorcycle. This factory service manual covers it all.
BRAKES 1.6
GENERAL
The front and rear brakes are fully hydraulic disc brake systems
that require little maintenance. The front brake master cylinder
is an integral part of the brake hand lever assembly on the right
handlebar. The rear brake master cylinder is located at the
rear of the motorcycle's frame, beneath the rear fork pivot point
and is actuated by the rear brake pedal via mechanical linkage.
BLEEDING HYDRAULIC BRAKE SYSTEM
GENERAL
Bleed the hydraulic brake system any time a hydraulic brake
line, brake master cylinder or brake caliper has been opened,
or whenever brake lever/pedal operation feels "spongy."
Bleeding evacuates air from the system leaving only incompressible
hydraulic fluid.
BRAKE PADS AND DISCS
INSPECTION
Check brake pads and discs:
At scheduled service intervals as specified in
Whenever the components are removed from the vehicle
Brake Pads
during service procedures.
See
material on either the front or rear caliper is worn to 0.04
in. (1.02 mm) or less above the backing plate (4). Always
replace both pads in a caliper as a set. See
When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.
Figure 1-39. Replace brake pads (3) if brake pad friction
Brake Disc Thickness, Lateral Runout and
Warpage
The minimum brake disc (2) thickness is stamped on the side
of the disc. Replace disc if worn past minimum thickness or
badly scored.
Maximum brake disc lateral runout and warpage is 0.008
in. (0.2 mm) when measured near the outside diameter.
•
To replace front brake disc(s)
BRAKE PAD REPLACEMENT: FRONT
Note:
1. See
cylinder reservoir (1) is level.
2. See
(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).
Figure 1-40. Position motorcycle so that front masterFigure 1-41. Remove two screws (5), reservoir cover
7. See
Figure 1-51. Install new
inside brake pad (2) using
same orientation as pad previously removed. Make sure
front mounting tab (3) is seated in slot (6) in caliper
mounting bracket (5) and pad friction material faces brake
disc.
8. While holding
new
inside pad in place, pull pad pin out
and remove outside brake pad (1). Note the pad's original
orientation for replacement purposes.
9. Install
new
outside brake pad using the same orientation
as pad previously removed. Make sure front mounting tab
is seated in slot in caliper mounting bracket and pad friction
material faces brake disc.
10. Temporarily insert a 1/8-in. (3.175 mm) drill bit in caliper
pad pin hole to hold pads in place.
