FRONT BRAKE PAD KIT

J065712017-08-02

GENERAL

Kit Number

44063-83D

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).

DYNA 1991-1999
FLSTC 2000-later
FLT/FLHT/FLHR 1984-1999
FX 1984-1986
FXR 1984-1999
FXSTS 2000-later
SOFTAIL 1984-1999
XL 1984-1999

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)

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.

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

Replace brake pads if brake pad friction material is worn to 0.063 in. (1.6 mm) or less above the backing plates. Always replace both pads as a set.

When checking the brake pads and discs, inspect the brake hoses for correct routing and any signs of damage or leakage.

Kit Contents

See Figure 4 and Refer to Table 1..

INSPECTION

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)

See Figure 1. Replace brake pads (2, 3) if brake pad friction material on the front caliper (5) is worn to 0.04 inch (1 mm) or less above the backing plate (4). Always replace both pads in a caliper as a set.

When checking the brake pads and brake disc (1), inspect the brake hoses for correct routing and any signs of damage.

NOTE

Inspect pad pins for wear or grooving. Replace both pins if wear of either pin exceeds 0.015 inch (0.38 mm).

Brake Disc Thickness

The minimum brake disc thickness is stamped on the side of the disc. Replace disc if warped or badly scored.

Brake Disc Lateral Runout

The maximum brake disc lateral runout is 0.008 inch (0.2 mm) when measured near the outside diameter.

1	Brake disc
2	Outboard brake pad
3	Inboard brake pad
4	Backing plate
5	Rear brake caliper

Figure 1. Brake Pad Inspection

PREPARE

NOTE

Fluid may have to removed.

Remove front master cylinder reservoir cap. As piston is pushed back into caliper, fluid level may rise.

Depth: 3 mm (⅛ in)

REMOVE

1.	See Figure 2. Remove upper and lower mounting screws (1, 2).
2.	Remove caliper assembly.
3.	Using steady pressure, pry between the pad and the brake disc in order to push the caliper piston back into the bore.
4.	NOTE Note the pad's original orientation for replacement purposes. See Figure 3. Once the piston has been fully retracted into the bore: a. Remove retainer screw (1), pad retainer (2) and inner pad (3). b. Remove the outer pad (4), spring clip (5) and mounting plate (6) as an assembly. c. Remove pad (4) from mounting plate (6) by pushing the pad free of the spring clip (5).

INSTALL

1.	Lay the mounting plate (6) down on flat surface. The upper mounting bolt hole must be positioned at upper right.
2.	See Figure 3. Install spring clip (5) at the top of mounting plate.
3.	Install outer brake pad (4). a. Take outer pad (4) that has the insulator backing, and place it on top of the spring clip (5) with the lower end of the pad slightly entering the opening of the mounting plate. b. With the pad centered (4) within the mounting plate (6) and the insulated back facing downward, push down on the pad until it is against the flat surface and is held firmly by spring tension from the spring clip (5).
4.	NOTE The spring clip loop and friction material must always face away from the piston. If it is wrong, the pad must be removed, the mounting plate reversed and the parts assembled again. Insert mounting plate assembly (6) into place with the backside of the pad against the face of the piston.
5.	Install inner pad (3) (without insulator backing). a. Place inner pad (3) in the machined recessed seat of the caliper. b. Position the pad retainer (2) within the counterbore at the inside end of the caliper. c. Insert self-tapping retainer screw (1) through the hole in the center of pad retainer (2) and thread into the hole in the pad. d. Tighten screw (1). Torque: 4.5–5.6 N·m (40–50 in-lbs)
6.	Install caliper assembly.
7.	See Figure 2. Install upper and lower mounting screws (1, 2). Tighten. Torque: 34–41 N·m (25–30 ft-lbs)

1	Upper mounting screw
2	Lower mounting screw

Figure 2. Brake Caliper (typical)

1	Retainer screw
2	Pad retainer
3	Inner pad
4	Outer pad
5	Spring clip
6	Mounting plate

Figure 3. Brake Pads (typical)

COMPLETE

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)

NOTE

Do not overfill the master cylinder. Overfilling the master cylinder could cause excessive pressure resulting in damage to system components.

Refer to your Owner's Manual for the proper hydraulic brake fluid for your year and model of vehicle.

1.	Check brake fluid level in master cylinder. a. Fill below the top of cylinder if necessary. Depth: 3 mm (⅛ in) b. Use the correct D.O.T. hydraulic brake fluid type as specified in the Owner's Manual. c. Install master cylinder reservoir cap. d. Install reservoir screws. Tighten. Torque: 0.7–0.9 N·m (6–8 in-lbs) Reservoir screw
2.	Actuate master cylinder to move piston out until it makes contact with both brake pads. Verify piston location against pads.
	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.	NOTE Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs. Test brake system. a. Turn ignition switch to ON. Actuate master cylinder to verify operation of brake system. b. Test ride vehicle. If brakes feel spongy, bleed the system according to Service Manual.

SERVICE PARTS

Figure 4.

Table 1.

Item	Description (Quantity)	Part Number
1	Screw	3562
2	Brake pad	Not sold separately
3	Brake pad	Not sold separately
4	Brake grease	44049-83