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BRAKE CALIPER KIT
J049712009-07-17
GENERAL
Kit Numbers
H1110.1AMZT
Models
For the most up-to-date model fitment information, see product label or www.buell.com (English only).
Additional Parts Required
Separate purchase of a brake line and master cylinder is required for proper installation of this kit. See the Buell New Products Catalog or a Buell Dealer.
Tools and Supplies Required
Fresh, uncontaminated DOT 4 hydraulic brake fluid from a sealed container will be needed.
WARNING
The rider's safety depends 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 Buell dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00334a)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Buell dealer.
Kit Contents
Table 1. Kit Contents
Description (Quantity)
Part Number
Brake caliper
Not Sold Separately
REMOVAL
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. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
  1. Remove the front brake line discarding the line, clamp, banjo bolts and brake line washers following the instructions in the service manual.
  2. Remove the master cylinder following the instructions in the service manual.
  3. Remove the front brake caliper following the instructions in the service manual.
INSTALLATION
Install Caliper and Master Cylinder
  1. Install the front caliper following the instructions in the service manual. Note that the eight-piston caliper in this kit installs the same way as the stock six- or eight-piston caliper.
  2. Install the master cylinder following the instructions in the service manual.
Install Brake Line
  1. For 2008 and later 1125R, 2009 1125CR, 2008 and later XB12R, 2008 XB12STT and 2009 and later XB12Ss Models: Install the new brake line kit (purchased separately) following the Instruction Sheet included with that kit. For 2008 and later XB12X and XB12XT and 2010 and later 1125CR Models: Install the new brake line (purchased separately) following the instructions in the service manual. For All Other Models: Install the new brake line (purchased separately) following the instructions in the service manual with the following exception:
    1. The service manual indicates that the lower portion of the brake line is routed "between the forks" (inboard of the front fork). The lower portion of the new brake line MUST be routed outboard of the right front fork and down to the brake caliper (see Figure 1 ).
Final Assembly
WARNING
Clean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury. (00504d)
1. Add new DOT 4 hydraulic brake fluid to master cylinder/reservoir.
2. Bleed the brakes following the instructions in the service manual.
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)
3. Test the brakes following the instructions in the service manual.
Figure 1. Front Brake Line Guide (Typical)