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

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Tags
adapter, caliper, cylinder, master, upgrade

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  #1  
Old 2 Weeks Ago
tedcool tedcool is offline
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Location: Central Maine
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Sportster/Buell Model: XLH 1100
Sportster/Buell Year: 87
Other Motorcycle Model: KTM 450 XC-W
Other Motorcycle Year: 2014
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Default Front brake upgrade adventure

While getting my neglected 87 ready for the road, I have discovered that the front caliper is seized.

I can't find a good rebuild kit in stock anywhere!
The HD kit will cost me about $70 at the local stealership.

This bike has the unloved single piston caliper.
I checked prices on eBay, and found a good 4 piston caliper for $35.

Of course, you need an adapter to mount it ( or change the fork leg ), so that is another $50.

"Biker's Choice Front Brake Caliper Adapter Chrome #148200". Gonna have to black that out....

Not bad! Better brakes for only a little more!

But then, I remembered reading about master cylinder size.

Sure enough, My bike has a 5/8 MC, and the Sporties that have the single disc 4 pot caliper use a 9/16.

Dang! The brakes are probably going to feel way too stiff!

Now my budget is blown!

I see some new ones for about $100, but full chrome. I'm going for all black on this bike.

So - off to eBay to find a 45019-96

Tons of big HD's from about 96 - 2006 used this.

There are a few available. About $80 for one in decent shape.

I hope to get lucky on an auction - my budget is about half that.

Until then, I'll hook it up with the current 5/8 MC and see just how bad it is...

Anyone have a 9/16 DOT5 MC that they are willing to part with, or trade for a 5/8 that works fine but looks a little rough( needs paint )?

Anyways - wish me luck! I hope to have it together some time next week.
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  #2  
Old 2 Weeks Ago
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Default

If you'll read this page in the Sportsterpedia, it explains everything about master to caliper ratio.
This might save you some cash of just willy nilly buying a master and trying your luck.
Master Cylinder and Caliper Relationship
http://www.sportsterpedia.com/doku.p...k:ref:wheels12

I really would appreciate it if you could measure the OD of your caliper piston.
We need that info in the pedia.
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  #3  
Old 2 Weeks Ago
tedcool tedcool is offline
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Default

Thanks - I have made good use of the Sportsterpedia info - That's how I discovered that the correct MC is 9/16.

I double checked the part numbers at Ronnie's.

I did the math for the ratio and got about 17:1 - not good!

I will be glad to measure the pistons and post the info here.
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  #4  
Old 2 Weeks Ago
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Default

Good.
Yeah that sounds pretty tight even if you could get a lever.
I've gone about as far as I can without the caliper piston sizes.
But I'd like to eventually collect a list of good combinations to make it easier for folks in the future.
Thank you.

This page has the factory combinations with a few numbers on calipers I've been able to collect.
http://www.sportsterpedia.com/doku.p...k:evo:wheels02

The factory ratio was pretty low presumably to keep newbs from going over the bars.
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  #5  
Old 2 Weeks Ago
tedcool tedcool is offline
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Default

That page is gold - I've had it open for a few days now.

I'll be glad to help add to it.

My thanks to you and those who created it!
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  #6  
Old 1 Week Ago
tedcool tedcool is offline
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Default

Got it all together today.

The adapter required two thick washers to use as spacers between it and the fork. The kit came with a good selection.

The brakes bled with no problem. The lever felt a bit stiff.

My son rode it and reported that it worked well with no concerns.

So - the 5/8 mc is at least acceptable.

I will measure the original piston diameter and report back later this week.
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  #7  
Old 1 Week Ago
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That's good to hear.
Thank you for the update... and for measuring the piston.
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