Harley-Davidson Sportster Evolution Front Brake Pad Removal Replacement

Written By: Brett Hartt

Comments: 2

Harley-Davidson Sportster Evolution Front Brake Pad Removal Replacement

Difficulty

Moderate

Steps

Time Required

No estimate

Introduction

This guide will show you how to remove the old brake pads, and then install the new ones.

Tools

Step 1

For the best access to the brake pads, we recommend securing the motorcycle in an upright position.
If you do not have a motorcycle lift, you will still be able change the brake pads, but it is still a good idea to secure the front wheel in place.
Be sure to allow time for the brake pads to cool completely before working on them. It may take ten to twenty minutes, especially if the motorcycle has just been ridden.

Step 2

Allowing the brake assembly to dangle from the brake lines can cause damage to the line.
Hang the caliper on a metal hanger attached to the handlebars or headlights.

Step 3

Using a 1/4" hex head or allen wrench, unscrew the two bolts holding the front brake assembly to the fork.
Unscrew and remove the bottom bolt, but do not completely remove the top bolt yet.

Step 4

Supporting the brake assembly with one hand, remove the top bolt.
Carefully slide the brake off of the brake rotor and hang it from the metal hanger.

Step 5

Using a 5/16 wrench, remove the bolt holding the stationary brake pad cover in place.
Remove the stationary brake pad cover from the brake assembly.

Step 6

Being careful to not let any loose parts fall out of the brake assembly, remove the stationary brake pad from the front brake assembly.

whomever was in there last time didn’t install the spring clip correctly.

hogdoctor -

Step 7

Remove the floating caliper and remaining brake pad from the caliper assembly.
The brake pad and floating caliper are not attached to each other. Be careful to not drop either the brake pad or caliper.

Step 8

Using a can of brake cleaner, spray out the piston and inside of the brake caliper.
Make sure to do this over a bucket or tray; there tends to be a lot of grime inside the brake caliper and spraying it out can make quite a mess.

Step 9

Using a Phillips #2 screwdriver, remove the two screws securing the cover on the master brake-fluid reservoir.
Carefully remove the cover of the master reservoir, making sure that you do not spill any of the brake fluid.
Brake fluid can cause ugly stains and scarring on cosmetic components of the motorcycle. Make sure you don't spill any.

Many 90’s Harleys use DOT5, which doesn’t scar the paint like DOT3/4/5.1 will. The reservoir will have a label telling you which type of brake fluid to use.

Wade Bartlett - 08/05/21

Step 10

Position the screw of a large C clamp so that the head of the screw is pressing against the inside of the brake piston.
It is possible to use your hands rather than a C clamp, but it is much more difficult.
Slowly tighten the C clamp, forcing the brake piston back into the brake cylinder until it is completely depressed.
Make sure that you work slowly, or else the piston will force brake fluid out of the master reservoir and all over the motorcycle.