REAR BRAKE CALIPER SEAL AND PISTON KIT

J057992013-03-06

GENERAL

Kit Number

44020-86A, 44045-87A

Models

See a Harley-Davidson dealer or the parts catalog for a specific year/model motorcycle for the correct brake caliper repair parts.

Installation Requirements

If the brake line is disconnected, separate purchase of new brake line sealing washers and banjo bleeder bolts is required. See a Harley-Davidson dealer or the parts catalog for this year/model motorcycle for the correct parts.

Fresh, uncontaminated hydraulic brake fluid is also needed. Refer to the owner's manual for this year/model motorcycle to determine the correct brake fluid.

Use an assistant to aid in the brake bleeding procedure.

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)

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 Harley-Davidson dealer.

Kit Contents

See Figure 1 and Table 1.

PREPARATION

NOTE

For vehicles equipped with security siren: Disarm the siren with the key fob.

1.	Turn the ignition key switch OFF unless already done.
	WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2.	See the service manual to remove the seat and disconnect the negative (black) battery cable from the negative battery terminal. Retain all seat mounting hardware.

REMOVAL

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

If necessary,
1. remove the banjo bleeder bolt and both sealing washers.
2. Detach the brake line from the caliper.
3. Discard the sealing washers and banjo bleeder bolt.
Remove the caliper mounting bolts (A).
Press the caliper housing (B) toward the brake rotor. Push the piston (2) back into the bore a minimum of 3.2 mm (⅛ in) so the piston clears the head of the pad insulator retainer (C).

NOTE

Push the piston further into the bore if the caliper hangs up on the retainer, preventing removal

Lift the caliper off the brake rotor.

INSTALLATION

NOTE

After disassembling the caliper, inspect all parts for wear or damage. Replace or repair as necessary.

Clean all parts EXCEPT BRAKE PADS with denatured alcohol.

Do not contaminate with mineral oil or other solvents.
Wipe parts dry with a clean, lint-free cloth.
Blow out drilled passages and piston bore with a clean air supply. DO NOT use a wire or similar instrument to clean drilled passages.

NOTE

Do not use DOT 5 brake fluid on any parts for assembly.

3.	Insert the new seal (4) into the caliper housing (B). NOTE Do not use an excessive amount of grease.
4.	Get the tube of grease (7) labeled "PISTON LUBE" from the kit. Apply a thin coat of grease to the outside diameter and bottom radius of the new piston (2). Apply a thin coat of grease to the caliper bore and inside diameter of the seal.
5.	Push the piston and dust boot (5) into the caliper bore.
6.	Position the gap of the new retaining ring (6) at the top of the caliper. Compress the ring into the piston bore, and push firmly against the piston boot.
7.	Place both anti-rattle springs (D) onto the caliper mounting bracket (E). The small tabs must be in the holes.
8.	Slide the brake pads (F) over the anti-rattle springs.
9.	Insert the ends of the retainer (C) into the two larger holes in the caliper mounting bracket. Pull the retainer over the brake pads and snap into place. NOTE Spray or coat the rubber mounting bushings (G) with a 50-50 mixture of isopropyl alcohol and distilled water. Collapse the bushings to enter the holes, then use a blunt tool to push the bushings through the bracket.
10.	Insert both rubber mounting bushings (G) into the caliper mounting holes (H) in the bracket.
11.	Get the tube of grease (8) labeled "PIN LUBE" from the kit. Coat the inside of the rubber bushings (G) and the smooth shafts of the mounting bolts (A).
12.	Place the assembled caliper over the brake pads and onto the bracket.
13.	Insert the mounting bolts into the holes in the caliper.
14.	Push the mounting bolts through the caliper and into the bracket. Tighten the mounting bolts to 20.3–27.1 N·m (15–20 ft-lbs).
	WARNING Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
15.	Get a new banjo bleeder bolt and two new sealing washers (purchased separately). Secure brake line to caliper with the banjo bleeder bolt and sealing washers. Tighten the banjo bleeder bolt to 40.7–47.5 N·m (30–35 ft-lbs).
16.	Bleed the rear brake per the service manual. Tighten the bleeder screw to 3.6–4.5 N·m (32–40 in-lbs).

COMPLETION

NOTE

Verify that the ignition key switch is OFF before attaching the negative battery cable.

1.	See the service manual and attach the negative battery cable. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
	WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
2.	See the service manual and install the seat.

Test the Brakes

1.	Pump the rear brake pedal to verify operation of the brake lamp.
	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) 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)
2.	Test ride the motorcycle. Repeat the bleeding procedure if brakes feel spongy.

SERVICE PARTS

Figure 1. Service Parts, Rear Brake Seal and Piston Kit

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	Rear brake seal and piston kit (includes items 2-8)	43946-86A
2	Piston	Not sold separately
3	Seal and boot kit (includes items 4-5)	44045-87A
4	... Piston seal	44152-77
5	... Boot	Not sold separately
6	Retaining ring	Not sold separately
7	Piston lube	Not sold separately
8	Pin lube	Not sold separately
Items mentioned in text, but not included in kit:
A	Caliper mounting bolt (2)
B	Caliper housing
C	Brake pad insulator retainer
D	Anti-rattle spring (2)
E	Caliper mounting bracket
F	Brake pad (2)
G	Rubber bushing (2)
H	Caliper mounting hole (2)