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

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  #21  
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Default

I my case the pistons were stock but not the pad pin, so I had to clean up the old (rusted and worn) one temporarily, for about a week. The pads didn't fully retract (slight rubbing on new disc) so I backed off the pad pin a half a turn and all good till the new one arrived. Two minute job to switch them. The disc and pads were purchased last year. Cleaning the 4 seal grooves in the caliper body probably took as much time as the rest of the work. Well, that and cleaning all the wire spokes while I had the wheel off.
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Default Measurement of single piston caliper

I finally got to measuring the caliper that I took off my 87. This is probably a 44046-84.

I'm still using the original 5/8 " 45019-85 MC - it's a bit too large.... 198 mm2

It's hard to get a caliper in there properly to do a proper measurement.

I was not able to get the piston out - It's stuck hard!

I removed the dust boot to get a reasonably good measurement.

The bore diameter is pretty close to 1.90 " - 1829 mm2

That gives a stock ratio of 9.4. I think. " Single piston calipers are much happier in the 14:1 to 12:1 range." Hmmm.....
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Thank you for measuring that.
I don't think the MoCo was into metrics back then.
That 1.90".
Wreckin that may be 1-7/8" (1.875").
Sometimes it's hard to get accurate without taking it apart.
The numbers are relevant but in checking ratios, there isn't much difference between 1.90 and 1.875.

Thank you very much!

Yeah that would put it around there.
I've been curious what the ratio was on older bikes as a lot of people complain that the brakes suck.
So I've been wondering just how low the ratio was.
If you've got plenty of travel, you might try a 9/16" master and get better locking.
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The brake lever is pretty stiff. I've been spoiled by having good brakes on my Japanese and Austrian dirt bikes.

I've set up an eBay search for a 9/16ths DOT5 MC.

The 45019-96 was used by lots of bigger Harleys for a number of years.

It uses the same 7/16“x24 banjo, so I won't have to re-do my brake line - again!
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Update this thread if you don't mind when you get it installed and checked out.
It's good to know what the travel distance change was and how well the 9/16" MC does.
What's your current caliper ratio on the 4 pot caliper?

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The 4 pot caliper is listed at Sportsterpedia ( thanks! ) as 33mm - so 3421 mm2

That would make the ratio with the current 5/8 MC about 17:1.

The 9/16 MC is 160 mm2, so the ratio would be about 21.

I think a smaller MC would be better, but the 1/2" 45146-04 would require me to re-do the brake line again.

Might be worth it, though!
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Ok.
Dual 4 pot calipers on 2001-2003 S models had a ratio of 28.65:1 with an 11/16" master and they have been said to have great stopping power.
Single 4 pot calipers on 2001-2003 S models had a ratio of 21.60:1 with a 9/16" master which is still not too shabby.

And that sounds like the reason you have a pretty stiff lever with the 5/8" master.
That puts you at a puny 17.28:1 ratio now.
That softer lever may be a bit tricky til you get used to it.

I'm wondering about the big leap from 9.14:1 to 21.60:1
Stopping power should be great but what about throw over rate?
The 04s went down to 9:03:1 on a single disc.

Interesting.
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