Brembo (front) Brake Conversion
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
Jumpman, very nice write-up and pics--looks great and glad to hear the system works well with the '04 master cylinder.
Installed the Brembos on my '04 EG today for a test fitting as part of my paint project. One difference in my installation is my banjo fittings didn't require any modification to the Brembo bleeders. My brake lines are HD stainless used on the '04 SE Ultra that I bought new a year or more ago--don't have the part no. handy. Wouldn't think that your Dad's brake lines would have a different Banjo fitting, but that may be the case.
Again, nice job on the install and write-up.
Installed the Brembos on my '04 EG today for a test fitting as part of my paint project. One difference in my installation is my banjo fittings didn't require any modification to the Brembo bleeders. My brake lines are HD stainless used on the '04 SE Ultra that I bought new a year or more ago--don't have the part no. handy. Wouldn't think that your Dad's brake lines would have a different Banjo fitting, but that may be the case.
Again, nice job on the install and write-up.
Let me get this right. All I need , are the floating rotors, bore out my hoses, chrome hardware, a couple banjo bolts, some fluid and a few calipers and I'm into better stopping? What's the total cost???
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
Thats about it.
The boring of the banjo fitting was VERY minimal...I had already installed the DiamondBack lines on his bike previously - and I think the problem was the chrome banjo bolt kit. I used the drill bit to basically remove the layer of chrome from the banjo fitting on the line to get it all to work.
When I do mine, I will have the calipers and the center portion of the floating rotors powdercoated to match my paint - so it will be more costly than a typical swap. I think if you are going to perform the task and don't need chrome parts, or coating - you should be able to do the entire job for well under $300. Mine will cost about $450 (or so).
it will consist of...
'Take-off' Brembos (about $125 (pair) depending on what dealership I pick them up from)
'Take-off' Floating rotors (will prolly cost about $60)
Chrome hardware (banjo & bleeder H-D part number 41843-08 ($44.95))
Brake pads (H-D part number 42897-06A ($41.95))
Chrome screen insert (H-D part number 42054-05 ($25.95 x2))
Caliper mounting bolts (H-D part number unknown ($1.50 x4))
Harley DOT 5 brake fluid (H-D part number 99902-77 ($11.95))
Powder Coating on calipers & center structure on floating rotors (approx. $75)
Last edited by Jumpman; Feb 22, 2009 at 10:19 PM.
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
Thanks lucky.
Here's a couple more pics...and also a few of my Road King.
Mine.
(this one is from my photoshoot for Baggers Magazine)
Here's a couple more pics...and also a few of my Road King.
Mine.
(this one is from my photoshoot for Baggers Magazine)
2nd Gear
Joined: Nov 2014
Posts: 6
Likes: 0
From: Australia
Brembo front brake conversion The Brembos fit perfectly on the lugs on the legs of my '04 Dyna but they are spaced slightly further away from the axle due to the design of the callipers.This spacing creates a slight overlap of the brake pads outside the edge of the brake rotor.
The reason for the calliper spacing is so that the brake pad is perfectly located when the calliper is fitted to a bagger etc.
The old Dyna brake disk is 11.5 inches in diameter.
The newer disks fitted to the later model baggers are 300mm in diameter.
The good news is that the 300mm disk will bolt into the old hub for a perfect fit and the pads are then exactly where they should be on the disk.
8.9mm is not much, but it makes the difference between a near fit and a perfect fit.
I have decided to go to DOT4 brake fluid because DOT5 fluid can attack the seals in the Brembos.
To avoid any cross contamination from the lines and master cylinder I have replaced the brake lines and have a new master cylinder rebuild kit to fit into the master cylinder (Part #45072-96D) for dual disks.
This may seem like going a bit far but DOT5 is a silicon based fluid and silicon is very difficult to remove. (Ask any painter)
I have cleaned the few parts I am re-using with "Prepsol" in an attempt to ensure that the silicon is completely removed.
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JauntyBishop
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Mar 13, 2018 10:13 PM
