Sportster Brake Linkage

Steve Knoble

Duration: 15 mins

Description

Steve Knoble has a 2012 Sportster 883 Iron on the lift. He noticed that the rear brake lever had developed excessive play and decided it was time to investigate the Sportster brake linkage. An issue such as this can be caused by worn ball joints on linkage ends, worn bushings at pivot points, a loose mounting point, a master cylinder that is in need of rebuild, or even from component failure.

Steve begins the Sportster brake linkage disassembly and inspection, starting at the brake lever. On the right side of the motorcycle, T-30 torx bit is used to remove one screw that retains the brake linkage to the rear brake lever.
Moving to the left side of the motorcycle, Steve removes a circular retaining clip and pin that was retaining the linkage to the master cylinder and the bell crank.

A 1/4″ allen is used to release the rear master cylinder from its mounting bracket. A T-40 torx bit is used to remove the three bolts that retain the bracket assembly to the frame of the motorcycle and then the assembly is free to be removed and assessed on the workbench. Steve inspects all Sportster brake linkage pivot points for excessive movement and determines that there is excessive play between the master cylinder mount and the bell crank assembly. There is a single nylon bushing that is worn.

The nylon bushing is easily replaced. Steve removes a c-clip to release the retaining pin that the bell crank pivots on. Now, the bushing can be easily tapped out with a punch. The new nylon bushing presses in easily and Steve test-fits the pin prior to permanent reassembly.

Sportster brake linkage assembly is performed in reverse of disassembly. With the bell crank assembly in place, Steve installs the mounting bracket and master cylinder. The mounting hardware is prepped with blue Loctite and torqued to factory specs. Finally, the Sportster brake linkage is secured to the rear brake lever and the repair is complete.