Harley Davidson Dyna evolution 1991-1998. Service manual - page 29
Inspection
1. Inspect the caliper for damage. Do not hone or bore the piston bore.
2. Inspect the hydraulic fluid passageway in the cylinder bore. Make
sure it is clean and open. Apply compressed air to the opening and make
sure it is clear. Clean out, if necessary, with fresh brake fluid.
3. Inspect the piston and cylinder bore (Figure 31) for scratches,
scoring or other damage. Replace worn, corroded or damaged parts.
4. Inspect the banjo bolt and bleed valve threads in the caliper body.
If damaged, repair the threads with the proper size thread tap. If the
threads are worn or damaged beyond repair, replace the caliper body.
5. Make sure the hole in the bleed valve screw is clean and open. Clean
with compressed air.
6. Check the threaded bushing, upper mounting screw and the lower
mounting pin for thread damage. Repair threads or replace damaged parts
as required. Check the mounting pin shoulder for deep scoring or
excessive wear.
7. Check the pad retainer for cracks or damage.
8. Check the brake pads (Figure 8) for wear or damage. Measure the
thickness of the brake pad friction material (Figure 9). Replace the
brake pads if they are worn to 1/16 in. (1.6 mm) or less. Replace both
pad sets (left and right calipers) at the same time.
9. Check all of the rubber parts (dust boot, O-rings, piston seal and
hoses.) for cracks, wear or deterioration. Because very minor damage or
deterioration can make these parts useless, replace questionable parts.
If you plan to reuse a rubber part, clean the part thoroughly in new
brake fluid and place on a lint-free cloth until reassembly.
10. Clean all serviceable metal parts with rubbing alcohol.
Assembly
1. The parts equipped in a factory rebuild kit are identified in Figure
32. After replacing all worn or damaged parts, coat the following parts
with new DOT 5 brake fluid. To prevent contamination, place the parts on
a clean lint-free cloth.
a. Piston.
b. Piston seal.
2. Make sure the retaining ring, piston and caliper bore are thoroughly
clean.
