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CHROME FRONT BRAKE CALIPER KIT
J043592007-05-02
GENERAL
Kit Number
44395-08
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts
These kits may require replacement brake pads and pins not included with this kit. The following kits need to be assembled onto each caliper prior to installation.
  • Pad Kit (44082-08)
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 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
See Figure 4 and Table 1.
1Lower mounting bolt
2Upper mounting bolt
3Bleeder valve and rubber cover
4Banjo bolt
5Steel/rubber gaskets
6Brake pad pin
Figure 1. Remove Existing Calilper
INSTALLATION
Prepare the Motorcycle for Service
1. For all models: Follow Service Manual instructions to remove seat.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2. For all models: Disconnect negative (-) battery cable.
Remove the Existing Caliper
NOTE
When performing the following step, place a container under caliper to catch brake fluid that may flow from brake line when removing banjo bolt.
  1. See Figure 1. Remove the banjo bolt (4) and both steel/rubber gaskets (5) to detach front brake line from caliper. Retain banjo bolt. Discard gaskets.
  2. Loosen but do not remove pad pin (6).
  3. Remove the upper (long) (2) and lower (short) (1) mounting bolts securing caliper to fork leg. Lift caliper upward to remove from brake disc. Discard caliper and bleeder valve cover but save mounting bolts.
  4. Note the orientation of the brake pads and remove the pad pin and the brake pads and springs.
Inspect the Pads and Pins and Springs
  1. Inspect the brake pads. If brake pad is worn to 0.04 in. (1.6 mm) or less above the backing plate, follow the instructions in the Service Manual to replace the pads.
  2. Inspect pad pin for wear and grooving. If wear is more than 0.015 in. (0.38 mm), replace pin.
  3. Inspect brake disc and, if necessary, follow the instructions in the Service Manual to replace brake disc.
Install the Chrome Caliper
1. Obtain left chrome caliper assembly from kit. Remove rubber bleeder valve cover from brake line port (as shipped) and save. Place caliper over brake disc with bleeder valve facing upwards.
2. Loosely install upper (long) mounting bolt to top hole in fork leg.
3. Install lower (short) mounting bolt into bottom hole of fork leg. Tighten bolt to 38–51.5 N·m (28–38 ft-lbs).
4. Final tighten upper (long) mounting bolt to 38–51.5 N·m (28–38 ft-lbs).
5. Install the pre-existing brake pads or, if necessary, follow the instructions in the Service Manual to install new brake pads.
6. Install the pad pin through the inner and outer brake pad. Ensure that pad springs are in place. Tighten to 20.3–22.6 N·m (180–200 in-lbs).
NOTE
Do not mix different grades of brake fluid as they are not compatible and could cause equipment damage. Refer to the appropriate Owner's Manual for the correct grade of brake fluid.
7. Lubricate two new steel/rubber washers (gaskets) (41731-01) with the appropriate brake fluid. Connect the brake line to caliper using new steel/rubber washers (gaskets) and banjo bolt. Tighten banjo bolt to 23–29.8 N·m (17–22 ft-lbs).
Bleed the Brakes
NOTE
Hydraulic brake fluid bladder-type pressure equipment can be used to fill brake master cylinder through the bleeder valve. Remove master cylinder/reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place.
1. See Figure 2. Install end of a length of clear plastic tubing over caliper bleeder valve. Place the other end in a clean container.
Figure 2. Bleeding Brake
2. Stand motorcycle upright and turn the handlebars to level the brake fluid reservoir and remove the cover.
NOTE
Do not mix different grades of brake fluid as they are not compatible and could cause equipment damage. Refer to the appropriate Owner's Manual for the correct grade of brake fluid.
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. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
3. See Figure 3. Refer to the appropriate Owner's Manual and fill the reservoir with the indicated brake fluid to 1/8 in. (3.2 mm) below the gasket surface.
WARNING
Be sure that brake fluid or other lubricants do not contact brake pads or discs. Such contact can adversely affect braking ability, which could cause loss of control, resulting in death or serious injury. (00290a)
4. Depress and hold brake lever to build up hydraulic pressure. Open bleeder valve slowly about 1/2 turn counterclockwise. Brake fluid with air bubbles will flow from bleeder valve. When brake lever has moved its full range of travel, close bleeder valve (clockwise). Allow brake lever to return slowly to its released position.
5. Repeat until all air bubbles are purged and a steady stream of brake fluid flows from the bleeder valve.
6. Tighten bleeder valve to 9–11.3 N·m (80–100 in-lbs). Install rubber bleeder valve cover.
7. Final fill and verify fluid level.
WARNING
Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a)
8. Verify operation of the master cylinder relief port. Actuate the brake lever with the cover removed. A slight spurt of fluid will break the surface if all internal components are working properly.
9. Install gasket and cover on master cylinder. Tighten cover screws to 0.7–0.9 N·m (6–8 in-lbs).
Return the Motorcycle to Service
  1. For all models: Connect negative (-) battery cable to battery.
  2. For all models: Follow the instructions in the Service Manual to install the seat.
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)
Figure 3. Reservoir Fill Level 1/8 in. (3.2 mm) Below Gasket Surface
Test the Brakes
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)
  1. Turn ignition switch ON.
  2. Pump brake hand lever to verify operation of the brake lamp.
  3. Test ride the motorcycle. If the brakes feel spongy, bleed the brake system again.
NOTE
Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs.
SERVICE PARTS
Figure 4. Service Parts: Chrome Front Brake Caliper Kit
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Kit 44395-08
Brake caliper, left
1
Caliper Assembly, left
Not Sold Separately
2
Gasket, brakeline (2)
41731-01
7
Caliper body, inner, front, left
Not Sold Separately
8
Caliper body, outer, front, left
Not Sold Separately
Kit 44313-08
Caliper pistons
10
Piston, front caliper (4)
44313-08
Kit 44315-08
Front caliper seals
11
Seal, square, front caliper (4)
Not Sold Separately
12
Seal, wiper, front caliper (4)
Not Sold Separately
13
Seal, crossover
Not Sold Separately
Kit 44337-08
Pad springs
3
Pad spring, front caliper (4)
44337-08
4
Tapered cap and plug
44147-87A
5
Decal
44338-00
6
Screw, bleeder
44400-00
9
Bridge bolt
4583M