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FRONT BRAKE CALIPER SEAL AND PISTON KIT
J058002013-03-06
GENERAL
Kit Number
44020-83A
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
NOTE
This kit is for the repair of one brake caliper. For vehicle with dual front brakes, two kits are needed.
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)
  1. 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.
  2. See Figure 1. Remove the upper caliper mounting bolt (A) and lower mounting pin (B).
  3. Gently rock the caliper housing (C) to push the piston (2) back into the bore and ease caliper removal.
  4. Lift the caliper off the brake rotor.
    5. NOTE
    After disassembling the caliper, inspect all parts for wear or damage. Replace or repair as necessary.
  5. Follow service manual instructions to:
    1. Remove the screw (E), brake pad retainer (D) and inner brake pad (F).
    2. Remove the outer brake pad (G), mounting plate (H) and spring clip (I) as an assembly.
    3. Remove the retaining ring (5), boot (4) and piston (2) from the caliper bore.
    4. Pull the threaded bushing (upper mounting pin, K) out of the caliper. Remove the pin boot (L) from the caliper groove.
    5. Pry the seal (3) and three O-rings (J) out of the grooves.
INSTALLATION
  1. 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. See Figure 1. Insert the new seal (3) from the kit into the bore of the caliper housing (C).
4. Push the piston boot (4), open side first, over the trailing end of the new piston (2). Seat the inner lip of the boot in the groove of the piston.
5. Get the tube of grease (6) labeled "PISTON LUBE" from the kit.
NOTE
Do not use an excessive amount of grease.
6. Apply a thin coat of grease to the outside diameter and forward chamfer of the piston. Apply a thin coat of grease to the inside diameter of the piston seals.
7. Push the piston and dust boot into the caliper bore.
8. Position the gap of the new retaining ring (5) at the top of the caliper. Compress the ring into the piston bore, and push firmly against the piston boot.
9. Get the tube of grease (7) labeled "PIN LUBE" from the kit. Coat the inside of the O-ring (J) and pin boot (L), and the smooth shafts of the mounting pins (B and K). Insert the mounting pins into the holes in the caliper.
10. Complete the installation of the caliper assembly and brake pads per service manual instructions.
11. Install the pad retainer (D) and fasten with retainer screw (E). Tighten the screw to 4.5–5.6 N·m (40–50 in-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)
12. Get a new banjo bleeder bolt and two new sealing washers (purchased separately). Secure brake line to caliper with banjo bleeder bolt and sealing washers. Tighten the banjo bleeder bolt to 40.7–47.5 N·m (30–35 ft-lbs).
13. Bleed the front brakes 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 front brake lever 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, Front Brake Seal and Piston Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Front brake seal and piston kit (includes items 2-7)
44020-83A
2
  • Piston
Not sold separately
3
  • Piston seal
44047-83
4
  • Boot
Not sold separately
5
  • Retaining ring
Not sold separately
6
  • Piston lube
Not sold separately
7
  • Pin lube
Not sold separately
Items mentioned in text, but not included in kit:
A
Upper caliper mounting bolt
B
Lower caliper mounting pin
C
Caliper housing
D
Brake pad retainer
E
Retainer screw
F
Inner brake pad
G
Outer brake pad
H
Mounting plate
I
Spring clip
J
O-ring (3)
K
Upper mounting pin
L
Pin boot