Installation Instructions
Early FLH (73-83)
4 PISTON Bake Caliper
ATTENTION
Statements in these instructions that are preceded by the following
Important Notice
n
Before installing a caliper or rotor kit, read through these instruc-
words are of special significance:
tions completely; this will familiarize you with the way in which the
parts fit together and the tools needed to complete the job.
Warning
This means there is the possibility of
injury to yourself or others.
n
In the course of installing these kits you will be replacing the stock
bra ke caliper(s) and/or rotor(s) with a high-performance bra ke
caliper(s) and/or rotor(s). Please pay special attention to the section
Caution of the instructions dealing with the centering of the caliper over the
This means there is the possibility of
brake rotor.
damage to the motorcycle.
n
PM products are design to use both DOT 4 and DOT 5 brake
Note
fluid, please use the manufactures suggested brake fluid. Never reuse
Information of particular importance
brake fluid, Never mix DOT 4 and DOT 5 brake fluid, don’t use
has been placed in italics.
brake fluid that you are not sure is new and clean. This installation
should only be attempted by a mechanic with a thorough understand-
WARRANTY ing of and experience with motorcycle hydraulic systems.
Performance Machine Inc. warrants to the original purchaser
n
If you plan on using the stock brake line/hose that runs between
that the parts of this Brake Kit to be free of manufacturing the master cylinder and the caliper, then you will be just switching
defects in materials and workmanship for a period of one (1) the the line at the caliper’s banjo fitting. We recommend that you do
year from the date of purchase. In the event warranty service is not disconnect the line from the stock caliper until you have the new
required,you must call Performance Machine immediately with
caliper bolted in place and are ready to bleed the brake system. This
a description of the problem.
way the brake fluid will not run completely out of the master cylinder
If it is deemed necessary for Performance Machine to make an before you have the new caliper connected up to it.
evaluation to determine whether the part is defective,[a return
authorization number will be given by Performance Machine].
The parts must be packaged properly so as to not cause further
damage and returned prepaid to Performance Machine with a
copy of the original invoice of purchase and a detailed letter
outlining the nature of the problem. If after the evaluation by
Performance Machine the part was found to be defective it will
be repaired or replaced at no cost to you. If we replace it,we
may replace it with a reconditioned one of the same design.
Performance Machine shall not be held liable for any conse-
quential or incidental damages resulting from the failure of a
Performance Machine part.
Disclaimer
Performance Machine shall have no obligation if a part be-
These Performance Machine parts are designed for high perfor-
comes defective as a result of improper installation, modifica-
mance motorcycle applications and are intended for the very expe-
tion or abuse. rienced rider only. The installation of these Performance Machine
parts may adversely affect or void your factory warranty.
6892 Marlin Circle, La Palma, CA 90623 n Phone 714-523-3000 n FAX 714-523-3007
Rev. 4-16-08 Harley Davidson is a registered Trademark of the Harley Davidson Motor Company
Caliper Finish
Caliper kits are available in a standard clear anodized,polished or chrome finish Make
sure that your caliper kit has the correct finish on it before you start to install it; you
cannot return it for incorrect finish once it has been installed.
Preparation
Before starting to assemble a PM caliper kit on your motorcycle, check the packing list
to make sure that the kit you received is the correct one for your model motorcycle.
Have a new bottle of manufactures suggested brake fluid on hand.
PM 4 PISTON CALIPER AND EARLY FLH
(1973 TO 1983) BRACKET. AVAILABLE
FOR USE WITH STOCK 10” DISC OR PM
11.5” DISC.
Modify Early FLH Fork Leg
Caution
Installation of PM brake system on early FLH requires extensive modifica-
tion of the fork leg and may require tools and skills you do not have! For best
results,please consider having a professional complete this installation.
Remove Fork Leg PHOTO 1
Remove front wheel and OEM brake system.Drain fork oil and remove left fork
leg from bike.
Remove OEM Bracket
The factory brake caliper bracket must be cut off of the fork leg to allow clearance
for the PM caliper bracket. We used a band saw to do the job, but other saw types
will also work (do not use a torch!) see Photo 2. Once the bulk of the old bracket
has been cut awaysee Photo 3,use a belt sander or similar tool to smooth out the
remaining inperfections. PHOTO 2
Caution
An improper cut could irreparably damage your fork leg.If you are not com-
fortable removing the OEM bracket,please have a professional do the job.
PHOTO 3
Modifying Fork Leg (Continued)
Using a drill press and a flat surface,clamp fork leg using parallel block and shim ,see
Illustration.Drill completely through fender tabs with 5/16” bit.Rotate leg 180º and
reclamp to drill press.Counter bore as shown for 5/16”allen head cap screw.see Photos
4 and 5.
PHOTO 4
PHOTO 5
Bracket Installation
Re-install fork leg,fender and right side front fender bolts.see Photo 6.
Using supplied hardware and spacers, slide 5/16”allen head cap screws through fender
mount (from outside) and place spacers over bolts, trapping fender between fork leg and
spacer see Photo 7. Slide PM caliper bracket
over spacers (it floats on spacers) see Photo 8
and use supplied lock washers and Nylock nuts
to secure the assembly.Torque specs: 5/16” bolts
16-19 ft.lbs.If you are using chrome plated
hardware, put a drop of Loctite #242
(blue) on the bolt threads to keep them
from galling the threads in the bracket or
PHOTO 6 lock-nuts.
Install disc to front wheel.PM recommends checking flatness of disc prior to installa-
tion, as older discs tend to warp over time and will adversely effect braking performance.
If your disc is warped or grooved, replace with OEM 10”,PM 10”or for best braking
performance PM 11.5”disc.
Original wheel spacers must also be re-installed at this point.
PHOTO 7
PHOTO 8
Installing The Front Wheel
Center front wheel assembly between fork legs. Install supplied axle spacer between PM
bracket and fork leg see Photo 11 and insert axle through fork legs and wheel. Tighten to
factory specifications.
Installing The Caliper
Slide the caliper down over the rotor and attach it to the mount with two 3/8-16 x 1 1/8”
PHOTO 10 socket head cap screws,two 3/8” lock washers and two 3/8” flat washer. Tighten these
screws finger tight at this time, see Photo 3.
Centering The Caliper
After you have installed the new PM brake caliper onto your motorcycle you must align
its center to the center of the brake rotor; otherwise you will not get maximum brake per-
formance or brake pad wear. The center line of the caliper is where the two halves of the
caliper are joined together, see Photo 12. Look down from the top of the caliper
onto the rotor; if it is off-set to the outside then you will need to install mounting bolt
PHOTO 11
shims. The caliper shim kit that is included in the caliper kit contains 6 shims: 2ea. .016”,
2ea .032” and 2ea .062”. These shims are to be inserted between the mounting boss on
the fork slider/rear caliper mount and the caliper’s mounting boss to position the caliper
so that its center line is over the rotor’s center line. To install the shims, remove the caliper
mounting bolt, slip the shim into place and replace the mounting bolt. Check the caliper
for centering at both ends; on most installations the same thickness of shim will be needed
behind each mounting boss.
After the caliper is centered over the rotor, install the lock washers from the kit and torque
the caliper mounting bolts to 22 ft. lbs.
PHOTO 12
Warning
Failure to center the brake caliper over the brake rotor will impede the performance of
the brakes. Rotate wheel slowly and with wheel raised, check for possible interference be-
tween caliper, wheel and disc assembly. After brake is bled, check for free rotation before
and after master cylinder is activated.
PHOTO 13
4
Completing The Brake Installation
Attaching The Brake Line
First tape handle bar master lever 1/2 way closed. This will prevent fluid from free flowing
from hose. Remove the end of the brake line from the stock caliper; you will need a 3/8”
12 point socket wrench or box end wrench to remove the banjo bolt from the stock
caliper. Working rapidly, so that an excessive amount of brake fluid does not run out of the
end of the brake hose, attach the end of the brake line to the new PM caliper using the PM
supplied seal washers, one washer goes on each side of the banjo fitting; see Photo 13.
PHOTO 13
Note
Position the banjo fitting so that the brake hose does not rub on the front
fender or other part of the motorcycle.
Tighten banjo bolt to 10 ft. lbs. of torque.
Bleeding The Brake System PHOTO 14
You will find it is easier to bleed the brake system if you have a helper. First, fill the master
cylinder with the manufactures suggested brake fluid and put the cover back on the master
cylinder. Attach a short length of rubber hose to the bleeder screw on the brake caliper, see
Photo 14; put the other end of the hose into a coffee can or other suitable catch can. Have
your helper pull in on the front brake lever or push down on the rear brake pedal 5 times,
see Photo 15. At the end of the 5th stroke, have your helper hold the brake lever in or pedal
down. While the helper holds the lever/pedal, open the bleeder fitting on the caliper, you will
need a 1/4” end wrench for this. Air and brake fluid should come out of the end of the hose
that is connected to the bleeder fitting. After the air and brake fluid have stopped coming out
of the hose, close the bleeder fitting; your helper can now release the brake lever/pedal.This
action will force the air that is trapped in the brake system out the bleeder screw, because
the brake system can contain more air than you can expel in one bleeding; you will need to PHOTO 15
repeat this procedure more than once. Check the fluid level in the master cylinder after each
bleeding, don’t let the master cylinder run dry as this will push air back into the brake system
which will require the bleeding procedure to be started over again.
Note
Do not over tighten the bleeder screw.
Warning
Failing to bleed all the air out of the brake system will impede
the performance of the brakes. COMPLETED FRONT BRAKE
CALIPER INSTALLATION
