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

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39mm, dual discs, front end, spacing, upgrade

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  #1  
Old 6th April 2020
shrimp shrimp is offline
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Default Dual Disc Conversion - Slider Clearance

I've got a 98 883, it's been neglected for a while now. I've been sitting on a pair of 99- dual disc 39mm lowers, and a pair of dual disc calipers, floating rotors and matching master cylinder - all parts I've gotten at swaps. Haven't been riding the sportster much, but decided with the quarantine that now is the time to get the hog back on the road.

Took off my old lowers and loosely assembled the new lowers (without putting in fluid/springs or bolting in the dampeners) I decided to do a test fit with the brakes mounted and put the rotors on the wheel and see how everything fits.

I noticed two things I have questions about.

First, spacing against the right slider and the rotor bolts is very tight compared to the left side. I'm using the factory wheel spacers. Is this normal? The wheel spins fine as it is.
I've tried getting inline pictures but not having luck. Here's a link to the current spacing
https://imgur.com/a/vqnvn5R




Second question: My factory axle doesn't fit into the new left side lower. The new lowers I.D. (where the axle meets) is about 0.15mm smaller than my factory lower (I've ordered proper dial calipers and telescoping gauges so I can get a more accurate measurement)
Thinking about putting the axle on a lathe and using emery paper to get it to fit - unless this is a red flag. Is it normal for tolerances to be this tight? My second thought is to use a master cylinder honing tool and try and gain that space on the fork lower, instead of taking material off the axle.

Thanks

Last edited by shrimp; 6th April 2020 at 23:20.. Reason: Add Images
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  #2  
Old 7th April 2020
shrimp shrimp is offline
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Default

I've continued to try and figure this out. My FSM does NOT have any details on dual disc brakes. I eventually found this post http://xlforum.net/forums/showpost.php?p=3022954&postcount=9

It seems that there are different instructions for dual discs, including mention of a 7/16th drill bit to ensure brake rotor alignment.

Anyone have a copy of a manual that has these instructions and could snap a pic?
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  #3  
Old 8th April 2020
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Default

That drill bit slips into the hole near the end of the axle, it butts up against the flat on the bottom of the slider to give you proper clearancing.
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