I ordered the kit from Zanotti's HD, had it at my door in about a week and a half. Part number is 44531-04, $277.80. It's a really, really nice kit for the money, comes with everything you need including brake pads and a nice set of Goodrich stainless braided brake lines. The only thing you need, is to have a Dyna with 39mm fork tubes, a service manual, and a bottle of DOT 5 brake fluid.

So far, everything has gone pretty smooth. I started by taking off the front wheel and removing the 5 Torx screws and plate that covers the mounting holes for the new rotor. The kit comes with 5 new screws, coated in threadlock to mount the new rotor. Simple.



Next, I drained the stock brake fluid and removed the stock brake line and stock brake master cylinder and lever assembly. Also very simple, and re-installing the new assembly is easy too. Two torx screws and it pops right off.



Next, I ran the new stainless brake lines. There's a coupler piece that screws into the bottom of the fork tree, and the three lines meet in that piece. One from the master cylinder, and one to each caliper. 2 new banjo bolts and all washers are included, one bolt is re-used from the stock caliper.



So that takes care of the easy stuff. Now onto the forks. The right fork lower must be replaced with one with mounts for the new caliper, everything you need is included. I'm also replacing the springs with a Works kit, so I drained and removed springs from both fork legs. Comparison picture:



First, remove the handlebars and set them carefully somewhere. Remove caps from fork tops, again, be careful, they're under pressure from the stock springs. Next, use the handy drain screw on the 05's forks and drain the fluid. Next, remove fender.

The next step was the hardest step for me by far. Removing the chrome cover that houses the fork oil seals. That bastard was totally stuck on there, and I had to destroy it to get it off. So, this write-up will be delayed for about a week while I wait for my dealer to get me a new one. I ended up jamming a screwdriver up inside this slot:



and hammering the shyte out of it until it popped off. Here's the end result:



Next, remove the bolt that holds the damping rod in place, it screws straight up from the bottom of the fork leg. It is a real beeotch too. Just be careful not to strip it, it's a 6mm allen bolt. Since there's nothing holding the fork lower in place now, it turns freely, making things even more tricky. I put a screwdriver through one of the holes that the fender mounts to, put an allen key in the bolt and twisted with both hands. Thanks FastHarley for that tip on his website. It finally popped loose, but be real careful because it'd be VERY hard to get to if it is stripped. Here's the location of the bolt, looking up from underneath:



Now you can remove the fork oil seals from the stock leg, don't worry about damaging them because the kit comes with new ones. Then whack the fork lower downward with some force and it'll pop off.



I'll finish this write-up next week when my new fork seal cover comes in. Stay tuned!!!

 

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Great write up. And good pix.

mud

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What all does this kit include, and what do you need to buy separately (for $277 I can't imagine it includes the rotor and caliper, but I could be wrong)? I've had some interest in doing this project.

Edit: Huh, looks like it does! Too bad they don't sell that kit for Dynas with the bigger fork tubes.

 

good write up thinking about trying to fab up something like this for my '08 with larger tubes. You will have to let us know how the breaking has improved.

 

Nice job- keep us posted. Like I said before, if I ever make money again I'm gonna have to jump on that one.

 

AWESOME!!!! bookmarked this! thanks!

 

only advice I got is dont break that little plastic piece of ****e in the lever assemply when it goes back together.

I hate that thing.

 

It includes everything. Rotor, caliper, pads, stainless lines, new lever and master cylinder, new fork lower, and every bolt, nut, washer, new fork seals, everything. It's a steal in HD money, for sure.

 

Thanks guys. I really wonder why HD doesn't make this kit for anything other than the 39mm tubes. Actually, when I bought my bike, I really wanted to convert it to dual discs, and I actually didn't know that the 05 has the proper size tubes for this kit. It was a nice surprise. Also a nice surprise are the drain screws on the smaller tubes.

Dawg Rider: I hope you find some good fortune in the near future. This kit really is a bargain considering what you get. Stainless lines from HD are what, like $120 for a dual disc setup?

I've got to charge up my camera battery and I'll take a couple more pics of what remains tomorrow morning. Then I'll finish it up when my dust seal cap gets here, and hopefully by then the Works spring kit will arrive.

 

MZBuckeye, glad to see that someone reads my stuff that takes so long to do. I have to thank you and posting the comment as I never ever get that.