PDF Instructions
Installation Instructions
4 AND 6 PISTON DIRECT BOLT-ON CALIPERS
ATTENTION
Statements in these instructions that are preceded by the follow-
Important Notice
n
ing words are of special significance:
Before installing a caliper or rotor kit, read through these instruc-
tions completely; this will familiarize you with the way in which the
parts fit together and the tools needed to complete the job.
Warning
This means there is the possibility of
injury to yourself or others.
n
In the course of installing these kits you will be replacing the
stock brake caliper with a high-performance brake caliper. Please
pay special attention to the section of the instructions dealing with
Caution
the centering of the caliper over the brake rotor.
This means there is the possibility of
damage to the motorcycle.
n
PM products are design to use both DOT 4 and DOT 5 brake
fluid, please use the manufactures suggested brake fluid. Never
Note
reuse brake fluid, Never mix DOT 4 and DOT 5 brake fluid, don’t
Information of particular importance
has been placed in italics.
use brake fluid that you are not sure is new and clean. This installation should only be attempted by a mechanic with a thorough understanding of and experience with motorcycle hydraulic systems.
WARRANTY
n
If you plan on using the stock brake line/hose that runs
between the master cylinder and the caliper, then you will be just
Performance Machine Inc. warrants to the original purchaser
that the parts of this Brake Kit to be free of manufacturing
defects in materials and workmanship for a period of one (1)
year from the date of purchase. In the event warranty service is
required,you must call Performance Machine immediately with
a description of the problem.
switching the line at the caliper’s banjo fitting. We recommend
that you do not disconnect the line from the stock caliper until
you have the new caliper bolted in place and are ready to bleed
the brake system. This way the brake fluid will not run completly out of the master cylinder before you have the new caliper
conected up to it.
If it is deemed necessary for Performance Machine to make an
evaluation to determine whether the part is defective,[a return
authorization number will be given by Performance Machine].
The parts must be packaged properly so as to not cause further
damage and returned prepaid to Performance Machine with a
copy of the original invoice of purchase and a detailed letter
outlining the nature of the problem. If after the evaluation by
Performance Machine the part was found to be defective it will
be repaired or replaced at no cost to you. If we replace it,we
may replace it with a reconditioned one of the same design.
Performance Machine shall not be held liable for any consequential or incidental damages resulting from the failure of a
Performance Machine part.
Disclaimer
Performance Machine shall have no obligation if a part becomes defective as a result of improper installation, modification or abuse.
6892 Marlin Circle, La Palma, CA 90623
Rev. 4-15-08
These Performance Machine parts are designed for high performance motorcycle applications and are intended for the very experienced rider only. The installation of these Performance Machine
parts may adversely affect or void your factory warranty.
n
Phone 714-523-3000
n
FAX 714-523-3007
Harley Davidson is a registered Trademark of the Harley Davidson Motor Company
Fitment
This Performance Machine bolt-on caliper is designed to fit all 1984
and later Harley-Davidson® front fork/wheel assemblies except Springer-Softail®, FX
and 4-speed FL models. (Heritage-Springer® will require bolt kit #0109-0100-CH)
Preparation
Before starting to mount this caliper, please check the packing list
to make sure that the caliper you received is the correct one for your model motorcycle.
Bolt-On Caliper Kit
Have a new bottle of the manufactures suggested brake fluid on hand.
Dual Disc Models
On motorcycles that have dual disc front brakes, it is recommended
that you install the calipers on one at a time and bleed the air out of the brake system
on the side with the new caliper before installing and bleeding the second caliper.
Installing and bleeding the calipers in this manner will keep the master cylinder from
running dry by draining into two empty calipers. This will make the brake system
easier to bleed.
Stock Caliper Assembly
Tools
1.
2.
3.
4.
5.
6.
7.
You will need the following hand tools:
5/16”hex wrench (commonly called an allen wrench)
3/8”12 point socket or box end wrench
9/16”socket wrench
Torque wrench
1/4”end wrench
1/8”inside diameter rubber hose, 2’ long
empty coffee can
Photo #1
Removing The Stock Caliper
Using a 5/16”hex wrench, remove the two mounting bolts from the
stock caliper, see Photo #1. Remove the caliper from the fork leg and reinstall the
lower mounting bolt into the stock caliper, this will keep the outer brake pad carier
from falling out. Using a short piece of wire, hang the stock caliper up out of your
working area, see Photo #2. Tape or zip tie the handle bar master cylinder lever 1”
from the handle bar. This will prevent excessive fluid loss when removing brake line at
caliper. Do not remove line yet.
Photo #2
Installing The Caliper
Note
Before installing your new PM caliper, check the brake rotor for wear and
flatness; use an appropriate straight edge. If the rotor is worn or warped,
replace it with a new one prior to installing this caliper.
Photo #3
Slip the new caliper over the rotor and align its mounting flanges with the
mounting bosses on the fork slider, see Photo #3. Install one of the 3/8X24 1/8” socket
head bolts with one 3/8”lock washer and one 3/8”flat washer through the top mounting
boss on the fork slider into the upper mounting hole on the caliper, see Photo #4. Tighten
this bolt finger tight and install a second socket head bolt with lock and flat washers into
the lower mounting boss. Again,tighten this second bolt only finger tight.
Centering The Caliper
Photo #4
After you have installed the new PM brake caliper onto your motorcycle you must align
its center to the center of the brake rotor; otherwise you will not get maximum brake performance or brake pad wear. The center line of the caliper is where the two halves of the
caliper are joined together, see Photo #5. Look down from the top of the caliper onto the
rotor; if it is off-set to the outside then you will need to install mounting bolt shims. The
caliper shim kit that is included in the caliper kit contains 6 shims: 2ea. .016”,2ea. .032”and
2ea. .062”. These shims are to be inserted between the mounting boss on the fork slider
and the caliper’s mounting boss to position the caliper so that its center line is over the
rotor’s center line, see Photo #6. To install the shims, remove the caliper mounting bolt
slip the shim into place and replace the mounting bolt, see Photo #7. Check the caliper
Photo #5
for centering at both ends, on most installations the same thickness of shim will be needed
behind each mount.
After the caliper is centered over the rotor, torque the caliper
mounting bolts to 22 foot pounds.
Photo #6
Warning
P HOTO #7
Failure to center the brake caliper over the brake rotor will impede the performance of
the brakes. Rotate wheel slowly and with wheel raised, check for possible interference between caliper, wheel and disc assembly. After brake is bled, check for free rotation before
and after master cylinder is activated.
Attaching the Brake Line
Remove the end of the brake line from the stock caliper; you will
need a 3/8”12 point socket wrench or box end wrench to remove the banjo bolt
from the stock caliper. Attach the end of the brake line to the new PM caliper using
the PM supplied banjo bolt and copper washers, one washer goes on each side of
the banjo fitting; see Photo #8. Remove tape or zip tie from handle grip master
cylinder.
Photo #8
Note
Position the banjo fitting so that the brake hose does not rub on
the front fender or other part of the motor cycle.
Using a 9/16”socket,tighten the new banjo bolt to 15 foot pounds
of torque.
Bleeding The Brake System
Photo #9
You will find it is easier to bleed the brake system if you have a helper. First fill the
master cylinder with the manufactures suggested brake fluid and put the cover back
on the master cylinder. Attach a short length of rubber hose to the bleeder screw
on the brake caliper, see Photo #9; put the other end of the hose into a coffee can
or other suitable catch can. Have your helper pull in on the front brake lever several
times, then hold the lever in. See Photo #10. Open the bleeder fitting on the caliper,
you will need a 1/4”end wrench for this. Air and brake fluid should come out of the
end of the hose that is connected to the bleeder fitting. After the air and brake fluid
have stopped coming out of the hose, close the bleeder fitting; your helper can now
release the brake lever. This action will force the air that is trapped in the brake system out the bleeder screw, because the brake system can contain more air than you
can expel in one bleeding, you will need to repeat this procedure more than once.
Check the fluid level in the master cylinder after each bleeding, don’t let the master
Photo #10
cylinder run dry as this will push air back into the brake system which will require
the bleeding procedure to be started over again.
Do not over tighten the bleeder screw.
Warning
Failing to bleed all the air out of the brake system will impede the
performance of the brakes.
Completed Installation
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising