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Sportster Motorcycle Tires, Wheels, and Brakes Discuss issues with Sportster motorcycle tires, wheels and brakes.

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  #1  
Old 24th October 2019
waiteitei's Avatar
waiteitei waiteitei is offline
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Default fitting 2006 rear brake onto a 96

have a 96 sportster and having grief with rear brake caliper

looking at fitting a 2006 rear caliper and hanger bracket on

axle size is correct and both years use an 11.5" disc

however the axle boss on the later calliper hanger bracket is considerably thicker than the earlier and will need to be machined down

has anybody done this before and to save me from reinventing the wheel the dimensions of what had to be machined down / and or spacers that had to be made up
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  #2  
Old 24th October 2019
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ReddTigger ReddTigger is offline
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there are many differences in the way that the 2005 and 1996 calipers in regards to how they bolt on.

i'd just get a used 2003 and earlier caliper and call it a day..
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  #3  
Old 25th October 2019
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Maxeffort Maxeffort is offline
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The stock caliper on my 1996 is strong enough to lock up the rear wheel. I didn’t see any point changing it for something else.

The front caliper desperately needed improvement, but not the rear.

Another rear caliper is short money on eBay and it’s easy to rebuild.

The 2004 up is a single piston sliding caliper, so I don’t see any gain.
Even if you have a free newer style caliper, I don’t see it being worth modifying to fit.

If I were to try and fit one, it would be mock up and measure.
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  #4  
Old 25th October 2019
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have already rebuilt this caliper and its still pissing brake fluid - experience tells me it is time to give up on it and look for an improvment

had one of these calipers on the back of an 86 glide, rebuilt it and replaced it several times but basically these calipers are problematic and know of several other people who have had issues with them

have measured and remeasured everything and dropped caliper bracket off at machine shop to get modifications made

Last edited by waiteitei; 25th October 2019 at 16:14..
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  #5  
Old 28th October 2019
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Quote:
Originally Posted by waiteitei View Post
have already rebuilt this caliper and its still pissing brake fluid - experience tells me it is time to give up on it and look for an improvment

had one of these calipers on the back of an 86 glide, rebuilt it and replaced it several times but basically these calipers are problematic and know of several other people who have had issues with them

have measured and remeasured everything and dropped caliper bracket off at machine shop to get modifications made
Please post back with photos when you get it installed.
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  #6  
Old 28th October 2019
sml1226 sml1226 is offline
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Uhh, you sure about that axle size? 05-07 use a 1" axle.
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  #7  
Old 2nd November 2019
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all done

conversion was very simple - so simple I am surprised more people havn't done this

all that is required is to take 6mm off the swing arm side of the axle boss and to relieve about 2 or 3 mm out of the mounting channel so there is clearance for swing arm

To tidy it up you could move the rubber bung on the underside 6mm further inward and trim 6mm off the ears that locate above and below the swing arm

cant post pictures on this forum - don't have the required permissions to do so

any body wanting any pics pm me and I will email them to you
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  #8  
Old 2nd November 2019
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Quote:
Originally Posted by sml1226 View Post
Uhh, you sure about that axle size? 05-07 use a 1" axle.
100% sure - checked with the guy selling the brake - maybe he had his years mixed up but what I have has the 3/4 axle

if it had a larger axle it would be a simple case of pressing in a bush to take up the difference
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  #9  
Old 2nd November 2019
sml1226 sml1226 is offline
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Definitely not an 06 if it was 3/4” then. You got an 04 part. Same caliper used in 05-06, but 3/4” axle.

And nobody uploads their pics directly here. Host them elsewhere and link to them. imgbb is a good place to look. Upload there and use the bbcode here. (Or get a direct link and put [img][/img] tags around it since that’s all the bbcode is)
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  #10  
Old 2nd November 2019
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waiteitei waiteitei is offline
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Quote:
Originally Posted by sml1226 View Post
Definitely not an 06 if it was 3/4” then. You got an 04 part. Same caliper used in 05-06, but 3/4” axle.
no worries - it works well I will look at getting the pics uploaded
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