Harley Front Brake Repair

The front brakes on your Harley-Davidson are one of the most important components on a motorcycle. The front brakes assist the rear brakes when needing to stop short or abruptly. Harley-Davidson has had many different brake designs over the years--the Kelsey-Hayes DC-44, Lucas Girling DC-44, Banana AS, Celebrake AS, G322, Large Kelsey-Hayes AS, Dual Piston Kelsey-Hayes, Small Kelsey-Hayes AS, and the Semi-torque free Kelsey-Hayes DC-44. Harley-Davidson has even gone as far as equipping some models with anti-lock braking systems, or ABS.

Things You'll Need

  • Work bench or clean work surface
  • Safety glasses
  • Work gloves
  • Hex head wrench (Allen wrench)
  • Wrench set
  • Small flat-head screwdriver
  • Air compressor
  • Denatured alcohol
  • D.O.T. 5 Hydraulic brake fluid
  • Brake pin grease (Dow Corning MOLY 44 or equivalent)

Removal and Disassembly

  • Remove the upper mounting screw and lower mounting pin to release the caliper assembly from vehicle. Disconnect the brake line at the caliper fitting.

  • Place the caliper assembly on a work bench and remove the pad retainer screw, pad retainer and inboard pad.

  • Remove the outboard pad, pad holder and spring clip as an assembly. Remove the pad from the pad holder by pushing the pad free from the pad hold-down spring clip. Pry out the retaining wire by inserting a small screwdriver into the notched groove at bottom of the piston bore.

  • Remove the piston dust boot. Remove the piston by applying air pressure to the hydraulic brake line inlet. Pull the threaded bushing out of the bushing bore. Remove the pin boot from the groove in the caliper. Remove the seal and three O-rings by prying them out of their respective grooves.

Repair

  • Clean all metal parts with alcohol. Do not use gasoline. Blow-dry the parts with compressed air.

  • Clean all rubber parts in denatured alcohol or brake fluid. Inspect all components carefully for excessive wear or damage. Inspect the brake disc and replace it if warped or badly scored. The minimum acceptable disc thickness is stamped on the disc.

  • Inspect the brake pads for wear or damage. If the pads are worn to 1/16-inch or less of friction material, replace them as a set.

  • Replace any parts that look worn or damaged.