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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 3 Weeks Ago
BlackHornet BlackHornet is offline
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Default XR1200 caliper on XL883 issue

So, guys.....and/or gals

I purchased a basketcase sporty last year and I am just now getting around to assembling it. Since the front caliper that came with the bike needed the mounting bracket and new pads, I went ahead and purchased a XR1200 caliper to install..

WELLLLL, I go to install the caliper and the mounting points arent correct AND its not seeming like there is any possible way to fit it with the wheel.

The caliper mounting center to center measurement is: 3.8975"
The fork mounting center to center measurement is: 3.4335"

The inside width of my fork STANCHIONS (not sliders/legs) are: 5.530"
These too narrow?


The frame is titled a 1999, the forks are most likely a 1999 as well. Can anyone confirm this based upon those measurements? Did Harley change caliper mounting dimensions on the forks?

The wheel is a mag wheel and I know that the XR caliper is usually VERY close to the wheel but mine will contact and contact good.

any help is greatly appreciated. THANKS!
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  #2  
Old 2 Weeks Ago
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JacksBrother JacksBrother is offline
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Originally Posted by BlackHornet View Post
So, guys.....and/or gals

I purchased a basketcase sporty last year and I am just now getting around to assembling it. Since the front caliper that came with the bike needed the mounting bracket and new pads, I went ahead and purchased a XR1200 caliper to install..

WELLLLL, I go to install the caliper and the mounting points arent correct AND its not seeming like there is any possible way to fit it with the wheel.

The caliper mounting center to center measurement is: 3.8975"
The fork mounting center to center measurement is: 3.4335"

The inside width of my fork STANCHIONS (not sliders/legs) are: 5.530"
These too narrow?


The frame is titled a 1999, the forks are most likely a 1999 as well. Can anyone confirm this based upon those measurements? Did Harley change caliper mounting dimensions on the forks?

THANKS!
Yep, they changed the brake mounts in 2000. Post 2K's no longer used floating calipers. There is an adapter that will make the bolt holes line up, but its the shimming that will get interesting. As you said, there ain't a lot of room to work with. You might also consider one of the Dyna 4-pot calipers, but again, you'll need 2000+ lower legs to make it work.
Good Luck,
Joe
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  #3  
Old 1 Week Ago
BlackHornet BlackHornet is offline
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Originally Posted by JacksBrother View Post
Yep, they changed the brake mounts in 2000. Post 2K's no longer used floating calipers. There is an adapter that will make the bolt holes line up, but its the shimming that will get interesting. As you said, there ain't a lot of room to work with. You might also consider one of the Dyna 4-pot calipers, but again, you'll need 2000+ lower legs to make it work.
Good Luck,
Joe
thanks for the reply! So, most likely about the same time you posted this response, I was heading back to my other bikes and pulled the forks off of a 2000 parts bike that I had and.....

Caliper bolts up! Awesome, right?!?!

well.....theres still no way for the caliper to clear the mag wheel. I have no idea why. It appears as if there just isnt enough room between the rotor and the wheel "spokes"

WHAT AM I MISSING HERE?!??!
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  #4  
Old 1 Week Ago
Randy_rots Randy_rots is offline
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Quote:
Originally Posted by BlackHornet View Post
thanks for the reply! So, most likely about the same time you posted this response, I was heading back to my other bikes and pulled the forks off of a 2000 parts bike that I had and.....

Caliper bolts up! Awesome, right?!?!

well.....theres still no way for the caliper to clear the mag wheel. I have no idea why. It appears as if there just isnt enough room between the rotor and the wheel "spokes"

WHAT AM I MISSING HERE?!??!
You are missing mid glide yokes LOL.
That's the problem with XR calipers, Sometimes they work with stock mag wheels but they are awfully close. Go with mid glide yokes and that will solve the problem properly but you will have to machine some spacers for caliper.
Not too big of a deal. Or search for different caliper like Harrison Billet 6 pot or PM 6 pot that is dedicated to your year model, this way you won't have to change your master cylinder and yokes. XR caliper will need 1/2" master cylinder to work properly anyway.

Good luck!
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Old 1 Week Ago
BlackHornet BlackHornet is offline
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Originally Posted by Randy_rots View Post
You are missing mid glide yokes LOL.
That's the problem with XR calipers, Sometimes they work with stock mag wheels but they are awfully close. Go with mid glide yokes and that will solve the problem properly but you will have to machine some spacers for caliper.
Not too big of a deal. Or search for different caliper like Harrison Billet 6 pot or PM 6 pot that is dedicated to your year model, this way you won't have to change your master cylinder and yokes. XR caliper will need 1/2" master cylinder to work properly anyway.

Good luck!
Oh man, sometimes they work and sometimes they dont? What kind of clearances/tolerances does Harley have to make such large variances?

still banging my head against the wall on this one haha. Ill see what other parts/spacers I have.

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  #6  
Old 1 Week Ago
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Originally Posted by BlackHornet View Post
Oh man, sometimes they work and sometimes they dont? What kind of clearances/tolerances does Harley have to make such large variances?
It’s not about tolerances, it’s about what wheel you have. After all we’re talking about taking the caliper from one bike and putting it on a totally different bike that it isn’t intended for.
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Old 1 Week Ago
Randy_rots Randy_rots is offline
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Originally Posted by BlackHornet View Post
Oh man, sometimes they work and sometimes they dont? What kind of clearances/tolerances does Harley have to make such large variances?

still banging my head against the wall on this one haha. Ill see what other parts/spacers I have.

RIIIIIDIIIICCCCUUUULLLLLOOUUUSSSS
XR1200 has sort of mid glide yokes so they have plenty of clearance.
With narrow yokes it seems that they work with 2000& up mag wheels for some reason. I don't know if the fact they use ball wheel bearings and different spacers has something to do with it or just the 2000& up mag wheel spokes are slightly thinner. Either way as I said, even when they clear, they are still awfully close to the wheel.
Harrison billet 6 pot or PM is the easiest way to go in this case.


Regards
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Old 6 Days Ago
Multihdrdr Multihdrdr is offline
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Originally Posted by Randy_rots View Post
...
With narrow yokes it seems that they work with 2000& up mag wheels for some reason. I don't know if the fact they use ball wheel bearings and different spacers has something to do with it or just the 2000& up mag wheel spokes are slightly thinner...
2000-later Narrowglide Front "Mag" wheels have a slightly wider Hub than 99-earlier
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