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Sportster Front Master Cylinder 1982 and 1983 Assembly

Sportster Front Master Cylinder 1982 and 1983 Assembly

The Ironhead Sportster 1982 and 1983 front master cylinder are like each other. They can both be put back together the same way. That is why the title reads 1982 and 1983 assembly. Here are the instructions to follow.

 

      

Sportster Front Master Cylinder 1982 And 1983 Assembly 1982 Figure

A Sportster front master cylinder 1982 and 1983 assembly 1982 figure helps the riders of a 1982 Ironhead Sportster see all the parts they are actually having to mess with. Sportster 1982 Front Master Cylinder Figure is the one that shows how the master cylinder was made in 1982.

Sportster Front Master Cylinder 1982 And 1983 Assembly 1983 Figure

A Sportster front master cylinder 1982 and 1983 assembly 1983 figure will also help out. It is meant for the bikers still riding a 1983 Ironhead. Sportster 1983 Front Master Cylinder Figure shows one exactly what a 1983 Sportster front master cylinder is made out of. Sticking with the part figure that represents your Ironhead Sportster helps keep you from messing things up.

Sportster Front Master Cylinder 1982 And 1983 Assembly First

Sportster front master cylinder 1982 and 1983 assembly first dip all internal parts in D.O.T. 5 hydraulic brake fluid.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next

Sportster front master cylinder 1982 and 1983 assembly next install grommet (12), coated with C.O.T. 5 hydraulic break fluid. and sight glass (11) 

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Install

Sportster front master cylinder 1982 and 1983 assembly next install spring (15), stop (16), cup (17), back up disc (18), piston and O-ring (19 and 20), dust boot (21) and push rod and switch (22).

Sportster Front Master Cylinder 1982 And 1983 Assembly Next

Sportster front master cylinder 1982 and 1983 assembly next see Sportster Front Brake Hand Lever 1982 And 1983 Figure. Lightly coat reaction pin (4) with Loctite ANTISIEZE and insert into large hole in brake lever (5). Assemble brake lever (5) to master cylinder assembly (2) using pivot pin (1), and retaining ring (6). Make sure push rod (3) fits into hole in reaction pin (4). Check front brake for proper operation.

Sportster Front Master Cylinder 1982 And 1983 Assembly Caution

The Sportster front master cylinder 1982 and 1983 assembly caution follows. First see the Sportster Hand Lever 1982 And 1983 Figure. Push rod (1) must be inserted into hole in reaction pin (2). There must not be any binding of hand lever when depressed. If hand lever does bind, push rod switch activator is hitting the inside master cylinder casting wall.  

Sportster Front Master Cylinder 1982 And 1983 Assembly Note

Sportster front master cylinder 1982 and 1983 assembly note when assembling hand lever to master cylinder while off the handlebars, use a piece of string or wire to hold push rod stationary. This will simplify aligning reaction pin and push rod.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Install

Sportster front master cylinder 1982 and 1983 assembly next install master cylinder to handlebar by installing clamp (14) and screws (13). Tighten screws to 70-80 in-lbs torque. Note that since there are twelve inches per foot there are twelve inch pounds per foot pound torque.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Install

Sportster front master cylinder 1982 and 1983 assembly next install new washers (6), bolt (5) and hydraulic brake lin (7) into master cylinder. Tighten bolt to 30-35 ft-lbs torque.

Sportster Front Master Cylinder 1982 And 1983 Assembly Caution

The Sportster master cylinder 1982 and 1983 assembly caution is make sure washers (6), bolt (5), hydraulic brake line (7) and master cylinder bore (1) are free of D.O.T. 5 hydraulic fluid, dirt and metal chips before assembly to avoid leakage.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Fill

Sportster front master cylinder 1982 and 1983 assembly next fill the master cylinder with D.O.T. 5 hydraulic brake fluid. Bleed  brake system using procedure outlined in Bleeding The Ironhead Hydraulic Brake System.

Sportster Front Master Cylinder 1982 And 1983 Assembly Note

Another Sportster front master cylinder 1982 and 1983 assembly note is before adding hydraulic fluid check to see that relief port in master cylinder is uncovered, when hand lever is released and that there is no free play in the lever.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Install

Sportster front master cylinder 1982 and 1983 assembly next install gasket (3) and screws (4). Tighten screws 10-15 in-lbs torque.

Sportster Front Master Cylinder 1982 And 1983 Assembly Next Test

Sportster front master cylinder 1982 and 1983 assembly next test ride motorcycle. If brakes feel spongy, repeat bleeding procedure.

Sportster Front Master Cylinder 1982 And 1983 Assembly Final Note

The Sportster master cylinder 1982 and 1983 assembly final note is that the 1982 and later master cylinder asembly is equipped with a sight glass to visually check fluid level without removing cover. When full, the sight glass will be dark. When fluid level drops, glass will lighten.

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