WARNINGInspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a)
NOTE
- Master cylinder cover specifies correct brake fluid.
- When adding or changing brake fluid, be sure to use only the type specified for your motorcycle.
- Use only Harley-Davidson D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77).
Harley-Davidson has provided your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry, wet and high operating temperature conditions. It exceeds all regulatory requirements currently in effect. However, during some braking conditions you may experience noise. This is normal for this friction material.
Refer to Maintenance Scheduling → Regular Service Intervals → Regular Service Intervals: 2005 VRSCSE Models for brake system inspection intervals.
NOTE
The rear brake master cylinder fluid level can also be viewed with a flashlight through back area of radiator cover trim making radiator cover removal unnecessary.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1 | Fastener |
| 2 | Cover trim |
| 3 | Radiator assembly |
Figure 1. Removing Right Side Radiator Cover Trim
Figure 2. Rear Brake Master Cylinder Reservoir: VRSC Models
| 1. | Check the fluid level in the rear brake master cylinder reservoir. a. See Figure 1. Remove the fastener holding the radiator cover side trim. Gently pull the bottom of the side trim outward, lift up on the trim to detach it from its upper attachment point and remove it from the motorcycle. b. See Figure 2. Verify the fluid level in the rear brake master cylinder reservoir is 1/2 in. (12.7 mm) below the top of the reservoir, as viewed through the translucent plastic case of the reservoir. c. If the level is low, clean all dirt and debris from the reservoir cover. Remove the two reservoir cover screws and remove the cover. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) which is available from a Harley-Davidson dealer. Replace the reservoir cover and cover fasteners. Tighten the fasteners to 0.68–0.9 N·m (6–8 in-lbs). d. Carefully reinstall the radiator cover side trim and fastener. Tighten the fastener to 3–4 N·m (26.5–35.3 in-lbs). | |
| 2. | Check the fluid level in the front brake master cylinder reservoir. a. Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface, so the top of the front brake master cylinder is level. b. See Controls and Indicators → Hand Controls: Basic Operation → Handlebar Controls: VRSC Models. Clean all dirt and debris from the front brake master cylinder cover. Remove the two master cylinder cover screws and remove the cover. c. Verify the fluid level in the front brake master cylinder reservoir is 1/8 in. (3.2 mm) below the reservoir top. If the fluid level is low, add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) which is available from a Harley-Davidson dealer. d. Replace reservoir cover and cover fasteners. Tighten fasteners to 0.68–0.9 N·m (6–8 in-lbs). NOTE Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) approved for brake system use and available from a Harley-Davidson dealer. | |
| 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) WARNINGInspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a) | ||
| 3. | Check the brake discs for wear. | |
| 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) WARNINGBrakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a) WARNINGPerform routine scheduled brake maintenance. Lack of maintenance at recommended intervals can adversely affect brake performance, which could result in death or serious injury. (00055a) | ||
| 4. | See Figure 3. Visual inspection of brake pads can be made without removing the caliper by viewing the lower area of each caliper with the aid of a flashlight. Replace the brake pads if the brake friction material is 0.04 in. (1.02 mm) or less above the backing plate. NOTE
|
The rear brake outer pad on all models can be measured from the caliper bracket side using a thin plastic 6 in. (152 mm.) rule.
Place the rule against the brake disc through the space alongside the caliper. If friction material measures less than 0.04 in. (1.02 mm), replace both brake pads immediately.
| 1 | Front brake bottom view |
| 2 | Rear brake top view |
Figure 3. Brake Friction Material