44531-04 - Harley
Contents
1. HARLEY DAVIDSON J03183 INSTRUCTIONS REV 01 23 04 Kit Number 44531 04 DUAL DISC FRONT BAART KIT FOR DYNA General This kit is designed for installation on the following 2004 and later DYNA FXD I and FXDL I model motorcycles which have original equipment 39 mm front fork tubes including chromed tubes handlebar and risers and 19 in cast aluminum front wheels e 2004 Later FXD I Super Glide e 2004 Later FXDL I Low Rider This kit can also be installed on the above FXD I and FXDL models which have original equipment 39mm front fork tubes and 19 in laced front wheels only after one of the following pro cedures is performed e The original single flange hub of the 19 in laced front wheel is replaced with a new double flange hub H D part number 43976 04 sold separately which will accept the second brake disc OR The original 19 in laced front wheel assembly which has a single flange hub is replaced with a new 19 in laced front wheel assembly H D part number 43591 04 sold separately which has a double flange hub designed to accept the second brake disc See the Service Parts Illustration for a list of the contents includ ed in this kit WARNING The rider s safety depends on the correct installation of this kit Follow the procedures in this Instruction Sheet and in the appropriate Service Manual s Service Manuals are available at your Harley Davidson dealer If the proce2. Brake line clamp Upper 2 Front fork upper bracket Figure 1 Upper brake cable clamp 5 Remove right mirror and if applicable right turn signal lamp assembly from original front brake master cylinder casting Save all components and fasteners for reinstallation CAUTION See Figure 2 Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4mm thick cardboard insert between the brake lever and lever bracket Removing or installing the master cylinder assembly with out the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch 00324a NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available 6 See Figure 2 Squeeze the brake lever and place the card board insert between the brake lever and lever bracket 1 of 6 5 32 in card ahd board insert emoving Master Cylinder Figure 2 Install Insert Before 7 Using a T27 TORX drive head remove the two screws with flat washers securing the handlebar clamp to the master cylinder housing Remove the brake lever master cylinder assembly and clamp from the handlebar 8 Save screws and clamp for reinstallation 9 Lift assembly of master cylinder brake line and left caliper away from motorcycle Disconnect front brake line from left front brake caliper at banjo fitting Discard original master cylinder brake line and banjo fitting sealing washers
3. 9 Fill master cylinder reservoir with D O T 5 HYDRAULIC BRAKE FLUID to 1 8 in of top CAUTION Direct contact of D O T 5 brake fluid with eyes can cause eye irritation swelling and redness Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 5 brake fluid can cause digestive discomfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00144a WARNING Make sure relief port in master cylinder is operating proper ly After filling master cylinder actuate brake lever with reservoir cover removed A slight spurt of fluid will break through fluid surface if all internal components are working properly A covered relief port could cause brake drag possible brake lockup and or loss of control which could result in death or serious injury 10 Install master cylinder reservoir cover 11 Bleed brake system according to procedures in appro priate Service Manual Bleed both brake calipers but bleed only one caliper at a time Final tighten each bleeder valve 8 to 80 100 in Ibs 9 0 11 3 Nm torque 12 Remove master cylinder reservoir cover Add D O T 5 HYDRAULIC BRAKE FLUID if required to master cylinder reservoir fill to 1 8 in of top 13 Install gasket and cover onto master cylinder reservoir using two screws Tighten screws to6 8 in lbs 0 7 0 9 Nm 14 Test operation o
4. 3 then tighten axle pinch bolt nut to 25 30 ft lbs 33 9 40 7 Nm 10 Remove drill bit from axle hole 11 See Figure 4 Install brake caliper as follows a With the bleeder valve topside position caliper so that brake disc is situated between friction pads Pry inner and outer brake pads back for additional clearance if necessary b Align upper mounting hole in caliper with upper mounting lug on fork leg Loosely install long caliper mounting bolt into upper lug of fork leg c Install short caliper mounting bolt into lower lug of fork leg Tighten lower mounting bolt to 28 38 ft lbs 38 51 5 Nm 2 of 6 Short External Pp Spacer fe Switch housing 3 Groove Tab 4 Brake lever bracket M J J ii E a 1 Axle 3 Contact point oo _ 2 Drill bit 4 Short ext spacer Figure 6 Fitting Master Cylinder To Switch Housing 12 Tighten upper caliper mounting bolt to 28 38 ft lbs 38 51 5 Nm 13 Repeat Steps 11 and 12 for left front brake caliper Assembly and Installation Front Brake Controls WARNING See Figure 5 Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4mm thick cardboard insert between the brake lever and lever bracket Removing or installing the master cylinder assembly with out the insert in place may result in damage to the rubber YW Se 1 boot and plunger on the front stoplight switch 00324a 1 See Figure 6 Position the brak
5. and clamp 1 previously removed in Step 4 of REMOVAL AND DISASSEMBLY FRONT BRAKE SYS TEM 5 32 in cardboard insert Figure 5 Install Cardboard Insert Before Installing Master Cylinder Assembly J03183 3 of 6 OS et PSN Socket head screw 1 4 20 x 1 in Anti rotation guide hidden Dual disc front brake line Frame Front fork lower bracket Lower left hose to left caliper Lower right hose to right caliper Upper end of brake line to master cylinder Figure 7 New Dual Disc Front Brake Line Connect lower left hose 6 of new brake line 3 to Original left front brake caliper using original banjo fit ting bolt and two new banjo fitting sealing washers from kit Refer to appropriate Service Manual for detailed installation procedures Tighten banjo bolt to 17 22 ft lbs 23 29 8 Nm See Figure 4 Connect lower right hose 5 of new brake line to new right front brake caliper 1 using one new banjo fitting bolt 6 and two new banjo fitting sealing washers 7 from kit Follow same installation procedures specified for left side brake in appropriate Service Manual Tighten banjo bolt to 17 22 ft lbs 23 29 8 Nm Connect upper end of new brake line to new front brake master cylinder assembly using one new banjo fitting bolt and two new banjo fitting sealing washers from kit Refer to appropriate Service Manual for detailed installation proce dures Tighten banjo bolt to 17 22 ft lbs 23 29 8 Nm J03183
6. appropriate Service Manual procedures 3 Fill front fork right slider tube assembly with the proper wet fork amount of Harley Davidson Type E Fork Oil Follow procedures listed in appropriate Service Manual Assembly and Installation Right Front Disc Wheel and Calipers 1 Verify that new front brake disc from kit is clean With coun terbored side of brake disc mounting holes facing away from wheel assemble brake disc to right side of front wheel hub using five new 5 16 18 x 7 8 in pan head screws from kit Use a T 40 TORX drive to tighten each screw to 16 24 ft lbs 21 7 32 5 Nm 2 Place wheel into position between forks with the valve stem on the right side of the vehicle 3 Coat the axle with ANTI SEIZE LUBRICANT 4 See Figure 3 Supporting wheel insert threaded end of axle 1 through right fork leg Push axle through fork short external spacer not shown and wheel hub until it begins to emerge from left side 5 Push axle 1 through long external spacer not shown and left fork leg until axle 1 shoulder contacts external spacer on right fork side 6 Install flat washer lock washer and nut over threaded end of axle 7 Insert screwdriver or steel rod through hole in axle on right side of vehicle While holding axle stationary tighten axle nut to 50 55 ft lbs 68 75 Nm 8 See Figure 3 Insert 7 16 inch drill bit 2 into hole in axle 1 9 Pull fork leg so that it just contacts drill bit
7. dures are not within your capabilities or if you do not have the correct tools have your Harley Davidson dealer perform the installation Failure to follow instructions could result in death or serious injury WINNING Brakes are a critical safety component Contact a Harley Davidson dealer for brake repair or replacement Improperly serviced brakes can adversely affect brake per formance which could result in death or serious injury 00054a Removal and Disassembly Front Brake System NOTE A Service Manual for your motorcycle is available at any Harley Davidson Dealer Block motorcycle underneath frame so that front wheel is raised off the ground slightly 2 Refer to Service Manual procedures to remove the original front brake caliper from left side of front fork Let caliper hang loose on brake line Save all components and fasten ers for reinstallation NOTE Do not operate the front brake lever with the front caliper removed because the piston may be forced from the caliper Reseating the piston requires disassembly of the caliper 3 Remove socket head screw which secures a clamp retains front brake line to underside of front fork lower bracket lower triple clamp Discard clamp and screw 4 See Figure 1 Remove screw lockwasher and clamp 1 which secure front brake line to right rear side of front fork upper bracket 2 upper triple clamp Save all compo nents for reinstallation i 06184 tif G a
8. e lever master cylinder 1 Right front j assembly inboard of the switch housing assembly engag 2 Front fork right slider ing the tab on the lower switch housing in the groove at the 3 Bolt Upper caliper mounting top of the brake lever bracket 4 T ee ae front brake line 2 Align the holes in the handlebar clamp with those in the 6 Banio bi bolt master cylinder housing and start the two screws with flat 7 ali gine sealing washer 2 washers Position for rider comfort Beginning with the top 8 Sees aie g screw tighten the screws to 70 80 in Ibs 7 9 9 0 Nm 9 Drain Screw using a T27 TORX drive head Figure 4 New Right Front Brake Disc and Caliper 3 Install original right mirror and if applicable right turn signal lamp assembly onto new brake master cylinder casting Adjust mirror and turn signal lamp as required tighten each f1225x2x securely Groove 4 See Figure 7 and Service Parts Illustration Insert new 1 4 20 x 1 in hex socket head screw 1 from kit through central mounting hole in manifold section of new front brake line specified in NOTE of GENERAL Section and anti rotation guide 16 Install assembly of screw anti rotation guide and brake line onto underside of front fork lower bracket 3 Make certain forked end of anti rotation guide engages cen ter rib of front fork lower bracket 5 See Figure 1 Secure front brake line to right rear side of front fork upper bracket 2 using original screw lockwash er
9. er assy right front black 45013 96B Reflector RH amber 59481 00 Anti rotation guide 45074 95 Brakeline front dual 45194 99 i 2 3 4 5 6 T7 8 9 0 1 NOTE Refer to DYNA Parts Catalog for Service Parts for Caliper assembly Part No 44023 00B Master cylinder assembly Part No 45013 96B J03183 6 of 6
10. f rear brake lamp with both the front brake applied and the ignition light switch turned to LIGHTS or IGNITION position After servicing brakes and before moving motorcycle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake perfor mance which could result in death or serious injury 00279a 15 Test ride the motorcycle If brakes feel spongy repeat bleeding procedure 16 After you determine through testing that the motorcycle brake system is functioning properly allow the new brake pads to wear in by avoiding hard stops for the first 100 miles 4 of 6 wr y O 4 lt AlL an T IQ Cc O LL x 2 2 or QO lt 3 10 O Z pu O QA CM TDR HARLEY DAVIDSO AMANA i01761a NOTE See next page for Item Number Description and Part numbers 5 of 6 J03183 Part No 44531 04 Date 01 04 Service P WY ervice arts Dual Disc Front Brake Kit Item Description Part No Description Part No Screw TORX 5 3655A Oil seal 45378 87 Gasket brake line 6 41731 01 Dust seal 45401 87 Bolt banjo 2 41747 82A Screw SEMS hex socket 45405 75A Caliper assembly right front olack 44023 00B Screw SEMS hex socket 45858 77 Disc right front brake 44136 00 Stopper ring 45905 87 Bolt lower caliper mounting 44160 00 Forkslider right front 46077 04 Bolt upper caliper mounting 44163 00 Screw SEMS hex socket 4741A Master cylind
11. save original caliper and banjo bolt for reinstallation Removal and Disassembly Front Wheel 1 Remove front wheel according to appropriate Service Manual procedures 2 Remove and discard five T 40 TORX screws which secure hub plate to right side of wheel hub Remove and discard hub plate Removal and Disassembly Front Fork Right Slider Tube 1 Remove front fork right slider tube assembly from front fork upper and lower brackets according to appropriate Service Manual procedures 2 Drain oil from front fork right slider tube assembly according to appropriate Service Manual procedures NOTE Note the orientation of parts disassembled in Step 3 of Removal Disassembly Steps on page 1 They will need to be reassembled in the same order in a later procedure 3 Disassemble slider from front fork right slider tube assem bly according to appropriate Service Manual procedures Discard slider fork seal dust seal and retaining ring save all other components and fasteners for reinstallation J03183 Assembly and Installation Front Fork Right Slider Tube 1 Assemble new right slider using new fork seal dust seal and retaining ring and drain screw from kit to original front fork right tube assembly Use new M8 1 25 x 27 mm hex socket compression screw from kit Follow procedures list ed in appropriate Service Manual 2 Install front fork right slider tube assembly onto front fork lower and upper brackets according to
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