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  #1  
Old 4 Weeks Ago
Big Al's Avatar
Big Al Big Al is offline
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Join Date: Aug 2009
Location: Near Dunblane
Posts: 198
Sportster/Buell Model: XLH1200
Sportster/Buell Year: 1989
Other Motorcycle Model: Harley FLH1200
Other Motorcycle Year: 1974
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Default Installing Brembo Goldline brakes on a 1998 XLH1200

I was asked to post a thread on how I fitted Brembo brakes on my wife's 1998 XLH1200 street tracker.
The front caliper bracket was probably the hardest part, as the 34mm Red Wing HX road-race forks only had Ceriani-type fender bosses for support.
I chose to make both front and rear supports from 5mm stainless steel plate, and made a cardboard template to get the shape right before I started cutting the stainless by hand. The fork's 15mm axle acted as the lower support mount...


Once the rough shape was cut out, I bent the stainless in my 10-ton press to the contours I needed for the difference in lateral width between the inside of the fork's fender boss and the bracket's lower axle position - the bracket also acts as an axle spacer...


Once satisfied with the fit, I cut, drilled, and polished the support to take a 2-pot Brembo Goldline P32 caliper. This is usually a rear brake, but a combination of the narrow forks and Honda GL1100 rotor and hub meant the 4-pot Goldline P4 I originally intended for the front interfered with the spokes, so the calipers had to swap positions...


The finished and fitted front caliper, with genuine Brembo pads and genuine Brembo DoT4 fluid.
The custom-made stainless braided brake hose goes up to a 1996-up single brake Harley master cylinder...


Details of the rear brake to follow...
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  #2  
Old 4 Weeks Ago
Big Al's Avatar
Big Al Big Al is offline
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Sportster/Buell Model: XLH1200
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Default

The 5mm stainless rear caliper support was much easier to fabricate - it just required a flat plate to be cut to shape, again using the card template technique avoid cutting mistakes.
Again, the support was drilled to take the 3/4" rear Harley axle, and as before the support also acts as a spacer...


The custom-made stainless brake hose goes to a brass Harley Shovelhead FLH T-piece (which also houses the rear brake switch), and then goes to a Brembo master cylinder...




The brake torque arm is made from stainless rod, with two 5/16" UNF Heim joints, the length of the arm is adjustable for different chain lengths...
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  #3  
Old 4 Weeks Ago
Randy_rots Randy_rots is offline
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Join Date: Mar 2007
Location: Derby
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Sportster/Buell Model: XL 88" softail frame
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Sportster/Buell Year #2: 2009
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Hi

Pretty good job on the brackets but why would you put tiny 2 pot rear caliper on the front and big 4 pot front on the back?
I mean, I don't see anything wrong with 4 pot calipers on the back but that tiny 2 pot on the front is not gonna work good. I'm also afraid that rear Brembo M/C will be too small for that 4 pot caliper...
IMO it would work much better if you swapped the calipers between front and back with the M/Cs in place.
Just sayin...

Regards
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  #4  
Old 4 Weeks Ago
Big Al's Avatar
Big Al Big Al is offline
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As I said in my post, my intention was to fit the 2-pot in the rear, as normal, and the 4-pot on the front, but when I tried it, the front spokes were in the way.
Those 34mm road-race forks are very narrow, so spacing the rotor and caliper out was impossible, so I just swapped the two calipers over.
The bike only weighs 410 lbs unfuelled, and my wife's (and mine!) riding style is relatively sedate, so those Brembos are more than adequate - and much better than stock!
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  #5  
Old 4 Weeks Ago
Randy_rots Randy_rots is offline
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Join Date: Mar 2007
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Ah OK.

In this case you can put second disc and second 2 pot Bermbo on the right hand side.
Now that would look pretty cool
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  #6  
Old 2 Weeks Ago
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JacksBrother JacksBrother is offline
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Quote:
Originally Posted by Big Al View Post
The bike only weighs 410 lbs unfuelled, and my wife's (and mine!) riding style is relatively sedate, so those Brembos are more than adequate - and much better than stock!
+1! That clattering single-pot piece of crap that came on the '98 1200's was bad enough on stock bike's, much less on a high-performance machine like yours.
Great mod! Very impressed with your fab skills. I'd be surprised if that two-pot Brembo wasn't enough brake to handle that bike with ease. Like to hear how that works out long-term.
Terrific job!
Joe
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  #7  
Old 2 Weeks Ago
Big Al's Avatar
Big Al Big Al is offline
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Join Date: Aug 2009
Location: Near Dunblane
Posts: 198
Sportster/Buell Model: XLH1200
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Other Motorcycle Model: Harley FLH1200
Other Motorcycle Year: 1974
Reputation: 112244
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Quote:
Originally Posted by JacksBrother View Post
+1! That clattering single-pot piece of crap that came on the '98 1200's was bad enough on stock bike's, much less on a high-performance machine like yours.
Great mod! Very impressed with your fab skills. I'd be surprised if that two-pot Brembo wasn't enough brake to handle that bike with ease. Like to hear how that works out long-term.
Terrific job!
Joe
Thanks Joe - her Sportster certainly isn't under-braked with those Brembos!
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