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  #1  
Old 25th November 2022
jp2code jp2code is offline
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Default How do I remove the Rear Caliper?

On my 2003 Sportster, I was replacing the rear brake pads. The bolts I took out actually caused the rear caliper to open. I thought I was taking the caliper off so that I could replace the pads.

Anyway, I got the new pads on and the calipers back together, but now the rear caliper is locked up (back tire slides on the ground), and the brake lines will not bleed out. It's like nothing happens when I push the brake lever down.

I'd like to take the caliper off and see what went wrong, but nothing that I've found online shows how to remove it. I even went to the Sporsterpedia, but the EVO section only covered the 2004 and newer - and they are different.

Anyway, I need to know how to remove the rear brake caliper. My guess is a piston is a little tweaked and won't move.
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  #2  
Old 25th November 2022
Andy56 Andy56 is offline
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I cannot help with your predicament and by your post it is too late now but do you have a service manual? I do recall in one of them it shows specifically to not remove certain bolts or to disassemble some part of the caliper.


This is from 2008 manual. The caliper and mounting bracket are held in place by the wheel. Once the wheel has been removed the whole caliper assembly can be removed.

• Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and
bushings which could damage caliper during vehicle
operation.
• It is further not required or recommended to remove or
loosen the caliper mounting pins.
• it is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to perform
caliper service.
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  #3  
Old 25th November 2022
OCRyder OCRyder is offline
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Default

Remove the rear wheel and the caliper slides off the rear swingarm. The caliper has no bracket. It's all one piece. There is a tab on the swingarm that the caliper slides onto and there are no bolts other than the rear axle holding it on.
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  #4  
Old 25th November 2022
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Fivecats Fivecats is offline
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Default

Scroll thru this for the '86-'03 Sportster manual. The '00-'03 calipers are what you want.

https://www.ratbikeservice.com/HD/in...ervice-manuals
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  #5  
Old 27th November 2022
jp2code jp2code is offline
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Quote:
Originally Posted by OCRyder View Post
Remove the rear wheel and the caliper slides off the rear swingarm. The caliper has no bracket. It's all one piece. There is a tab on the swingarm that the caliper slides onto and there are no bolts other than the rear axle holding it on.
I got it off, and I did have to remove the rear wheel.




Since I've already opened the caliper and the service manual says to replace the neoprene seals every time, I've ordered a caliper rebuild kit.

https://www.amazon.com/gp/product/B000WJKLOY/

But they do not include instructions, and I do not know how to get the old pistons out.
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  #6  
Old 27th November 2022
Andy56 Andy56 is offline
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Default

You might be able to use a foot pump or similar to generate some pressure. The piston isn't actually fixed in but held by the seal. Without the pad and with enough pressure it will come out.

You could connect back up, bleed some fluid and use hydraulics to push it out.
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  #7  
Old 28th November 2022
jp2code jp2code is offline
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Default

Quote:
Originally Posted by Andy56 View Post
You might be able to use a foot pump or similar to generate some pressure. The piston isn't actually fixed in but held by the seal. Without the pad and with enough pressure it will come out.

You could connect back up, bleed some fluid and use hydraulics to push it out.
Got it.

Is there an issue with emails not being sent? I have to physically come here to check to see if there were replies.
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  #8  
Old 28th November 2022
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rejeanprimeau rejeanprimeau is offline
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