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2002 Fatboy brake upgrade.

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2.1K views 12 replies 6 participants last post by  tahig  
#1 ·
I have a 2002 Fatboy I'm upgrading the brakes on. I figured I'd post this here if anyone has already done it and can lend some advice. I have a set of calipers from a 2019 CVO Road Glide. I am replacing the current 11.5" rotors with 11.8" rotors, the 9/16" master cylinders with 11/16" master cylinders, and throwing some stainless braided brake lines on it. The front brake caliper and rotor look like they're going to bolt right on and work with no problems. The rear caliper and bracket is where I have a concern. The stock bracket is wider than the CVO bracket where the axle passes through it. By what looks like about 1/4". Easy answer is get a 1/4" spacer, throw it in there, and be done with it. That's where I have questions. Is it as easy as throwing 1/4" spacer in there? Or, do I need 2 1/8" spacers so there's one on each side of the bracket? Or, do I need something else? I'll be making a youtube video of the install when I do it to hopefully help someone else in the future.
 
#4 ·
.... The front brake caliper and rotor .... The rear caliper and bracket ....
That sounds singular to me. If so, you don't need an 11/16" MC. Those are for dual discs. If you just got to have a new MC, find one for a single front brake.

I see lots of issues out back.

Your 3/4" axle vs the 25mm axle of the newer brake.

You can easily figure out the spacing when you mock it up.

I would be more concerned with how you are going to mate up the newer bagger caliper bracket with your older Softail swingarm. Especially the anchor point. They aren't similar.

Other stuff too.
 
#6 ·
That sounds singular to me. If so, you don't need an 11/16" MC. Those are for dual discs. If you just got to have a new MC, find one for a single front brake.

I see lots of issues out back.

Your 3/4" axle vs the 25mm axle of the newer brake.

You can easily figure out the spacing when you mock it up.

I would be more concerned with how you are going to mate up the newer bagger caliper bracket with your older Softail swingarm. Especially the anchor point. They aren't similar.

Other stuff too.
There is a single disc in the front. You are correct. The 11/16" MC worked fine. It actually stops better now. Pretty happy with how the front turned out.
The rear anchor point is where I ran into the problem. The axle was easy. I made a 1" to 3/4" bushing that fits into the axle hole of the bracket. When I slide the bracket onto the anchor point, it doesn't line up with the axle hole. I'm going to have to explore some geometry to make this work. Or find a different rear brake caliper setup to use....
When I figure it out, I'll post what I come up with.
 
#9 ·
I cut part of the bracket off.

From this:
Image


To this:
Image


Next, I need to find a shoulder bolt and drill/tap that hole to fit the bolt.
I'll cut the head off the bolt and the "pin" that's left will serve as the lower anti-rotation pin/stop.
That should allow me to pivot the bracket enough to line up the axle.

Then we worry about axle spacers, the caliper hitting the swingarm, and rotor diameter......
 
#10 ·
This morning I found a good bolt to use. M8-1.25X56mm.
Image


Drilled the original hole in the bracket out to 17/64" and ran a M8X1.25 tap through it.
Installed the bolt and marked where to cut the extra threads off. Removed the bolt. Cut off the excess threads and filed it down really nice.
Installed the bolt using red loctite and a bit of elbow torque.
Image

Image

Image


Then I cut the head off the bolt and smoothed out the tip...

Image

Image


To finish it off, I threw a rubber vacuum port cover on the stud. Try and keep any extra rattles away.

Image


We'll have to wait until later in the week to mock it up.
 
#13 ·
I have a 2002 Fatboy I'm upgrading the brakes on. I figured I'd post this here if anyone has already done it and can lend some advice. I have a set of calipers from a 2019 CVO Road Glide. I am replacing the current 11.5" rotors with 11.8" rotors, the 9/16" master cylinders with 11/16" master cylinders, and throwing some stainless braided brake lines on it. The front brake caliper and rotor look like they're going to bolt right on and work with no problems. The rear caliper and bracket is where I have a concern. The stock bracket is wider than the CVO bracket where the axle passes through it. By what looks like about 1/4". Easy answer is get a 1/4" spacer, throw it in there, and be done with it. That's where I have questions. Is it as easy as throwing 1/4" spacer in there? Or, do I need 2 1/8" spacers so there's one on each side of the bracket? Or, do I need something else? I'll be making a youtube video of the install when I do it to hopefully help someone else in the future with motorcycle brake lines.
Hello. I replaced the front brakes on my 2002 fatboy without a problem but the rear brakes are causing some confusion. The rear calliper is one unit that is attached to the rear axle. The manual says to loosen the pad pins and push the caliber against the rotor to compress the piston. I don't understand how the caliber can be pushed against the rotor when it fixed to the axle. Am I missing something here?? Any advice would be appreciated.