REAR PAD KIT
J026702008-06-26
GENERAL
Kit Number
42836-04A, 42029-07
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
Fresh, uncontaminated brake fluid is required for installation of this kit. See the service manual for the correct type of brake fluid.
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
Table 1. Kit Contents
Qty
Description
Part Number
2
Rear pad
Not Sold Separately
1
Retainer clip
Not Sold Separately
There are no Service Parts available with this kit.
BRAKE PADS
WARNING
Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)
NOTE
See Figure 1. Replace brake pads (3) if brake pad friction material on either the front or rear caliper is worn to 0.04 in (1.0 mm) or less above the backing plate (4).
When checking the brake pads and discs, inspect the brake lines for correct routing and any signs of damage.
1Brake disc
2Brake pad (2)
3Brake pad backing plate (2)
4Rear brake caliper (viewed from rear)
Figure 1. Brake Pad Inspection
1Mounting bracket
2Retainer clip
Figure 2. Rear Caliper Retainer Clip
BRAKE DISC THICKNESS, LATERAL RUNOUT AND WARPAGE
NOTE
The minimum brake disc 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 rear brake disc(s), see the service manual.
REAR BRAKE PAD REPLACEMENT
NOTE
Do not remove rear caliper from mounting bracket unless caliper mounting pins require service. Removing caliper from mounting bracket unnecessarily increases the risk of contaminates falling into mounting pin holes and damaging caliper during vehicle operation.
1.
See Figure 3. Remove rear master cylinder reservoir cap (5).
NOTE
As the piston is pushed back into the caliper, fluid level may rise higher than fluid level mark at about 1/4 in (6.4 mm) below top of reservoir. Fluid may have to be removed to allow for this. See the service manual.
1Rear brake master cylinder reservoir
2Reservoir cover
3Upper fluid level
4Lower fluid level
5Reservoir cap
Figure 3. Rear Brake Master Cylinder Reservoir
CAUTION
Direct contact of DOT 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 DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240d)
2.
Press the side of the brake caliper body to move the outside brake pad back to push the caliper piston back into its bore.
NOTE
See Figure 4. When replacing rear brake pads, make sure caliper pad spring does not become dislodged and fall out. If it does, install it before installing new pads.
The rear brake caliper does not use the same brake pad set as the front left and front right (not present on all vehicles) calipers.
3.
See Figure 5. Remove pad pin plug (3).
4.
See Figure 6. Loosen, but do not remove, brake pad pin.
NOTE
Do not completely remove brake pad pin from caliper during the next step. Completely removing pad pin at this time may cause difficulty during assembly.
Figure 4. Rear Caliper Pad Spring
1Rear brake caliper
2Caliper mounting bracket
3Pad pin plug
4Caliper mounting pins
Figure 5. Rear Caliper Assembly
Figure 6. Brake Pad Pin (Plug Removed)
5.
Once the piston has been fully retracted into its bore, pull pad pin part way until outside pad drops free. Note the pad's original orientation for installation.
6.
See Figure 7. Install new inside brake pad (1) using same orientation as pad previously removed. Make sure front mounting tab (3) is seated in retainer clip (5), which is seated in slot (6) in caliper mounting bracket (7), and pad friction material faces brake disc.
7.
While holding new inside pad (1) in place, pull pad pin out, and remove outside brake pad (2). Note the pad's original orientation for installation.
8.
Install new outside brake pad (2) using same orientation as the previously removed pad. Make sure front mounting tab (3) is seated in retainer clip (5), which is seated in slot (6) in caliper mounting bracket (7), and pad friction material faces brake disc.
9.
Temporarily insert a 1/8 in (3.175 mm) drill bit in caliper pad pin hole to hold both pads in place.
10.
Inspect pad pin for grooving and wear. Measure pad pin diameter in an unworn area, and then in the area of any grooving or wear. If wear is more than 0.011 in (0.28 mm), replace pin.
11.
Press brake pads firmly against caliper pad spring, remove drill bit and install pad pin. Tighten to 131-173 in-lbs (14.7-19.6 Nm).
NOTE
If pad pin does not fit, check the following:
  • You are using a set of pads, not two identical pads.
  • Caliper pad spring orientation must match Figure 4.
  • See Figure 7. Pad front mounting tabs (3) must be fully seated in retaining clip (5), which is seated in mounting bracket slot (6).
  • Pads must be pushed tight against caliper pad spring before pad pin is installed.
12.
See Figure 5. Install pad pin plug (3). Tighten to 18-25 in-lbs (2.0-2.9 Nm).
WARNING
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
13.
Pump brake pedal to move piston out until it contacts outside brake pad. Verify piston location against pad.
NOTE
Rear brake master cylinder must be in a level position when filling and checking fluid level.
See Figure 3. Reservoir cover (2) may be removed from rear brake cylinder reservoir (1) to more easily verify fluid level in reservoir.
14.
Position motorcycle upright (not resting on jiffy stand). See Figure 3. Check brake fluid level in master cylinder. Add enough brake fluid to reservoir until fluid reaches upper fluid level (3). Install master cylinder reservoir cap (5). Replace reservoir cover (2), if removed.
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
15.
Test brake system.
a.
Turn ignition switch ON. Pump brake lever to verify operation of the brake lamp.
b.
Test ride the motorcycle. If the brakes feel spongy, bleed the system. See the service manual.
NOTE
Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs.
1Inside brake pad
2Outside brake pad
3Front mounting tab
4Pad pin hole
5Retainer clip
6Slot
7Rear caliper mounting bracket
Figure 7. Rear Brake Pads