Rear brake pads on a Harley-Davidson motorcycle require regular inspection for pad thickness.
Rear brake pads on a Harley-Davidson motorcycle require regular inspection for pad thickness. Ideally, they should be changed whenever they measure below 0.04 inches in thickness. Allowing the pads to run thinner than this can cause failure in the brake system. Harley Davidson recommends that brake pad thickness be inspected every 2,500 miles. Inspect sooner if the brakes are noisy, if you experience difficulty when stopping or if the rear brake pedal requires excessive travel or pressure to bring the motorcycle to a stop.
1. Position a small drain pan on the ground, underneath the rear brake master cylinder. Loosen and remove the master cylinder cover with a Phillips-head screwdriver.
2. Break loose the pad pins on the rear brake caliper, using an SAE socket wrench, but do not remove them.
3. Spread the rear brake pads apart with a putty knife. Partially pull out the pad pins on the caliper to allow the inside brake pad to come free.
4. Install the new inner brake pad into the brake caliper. Tighten the pad pins and pump the rear brake pedal to seat this new pad.
5. Spread the outer pad and brake piston with a putty knife to allow the brake piston to retract. Break loose and completely remove both pad pins. Allow the outer brake pad to come free. Install a new brake pad in its position on the brake caliper. Re-insert the two pad pins and tighten them to six to eight inch-pounds of torque with a torque wrench.
6. Pump the rear brake pedal with your foot several times to pump up the brake caliper and piston. Add D.O.T. 5 silicon brake fluid to the rear master cylinder to the “Full” mark. Install the master cylinder cover back on the rear brake master cylinder with a Philips-head screwdriver.