Brembo (front) Brake Conversion
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
Brembo (front) Brake Conversion
OK, so I had done a lot of research and finally decided to do the Brembo thing on my Pops '04 Ultra Classic.
Rather than drop all the coin on a full brake system, we grabbed a set of the silver OEM silver H-D Brembo's...the correct mounting bolts...and a pair of the H-D 'teardrop' floating rotors. Oh, also grabbed the chrome banjo bolt/bleeder kit specific to those calipers.
When I first took everything apart and did my mock-up, I discovered that the banjo bolts for the brembos will not fit thru the banjo fitting on the H-D diamondback (2004) brake lines. Also, the banjo bolt will not fit the '04 master cylinder.
We were ready to go ahead and grab a new set of brake lines, but (fortunately) none of the local H-D shops had them in stock..and we found they were on national back-order. We were also prepared to pick-up a master cylinder/clutch lever mount for an '08.
Since we could not find parts - I grabbed a 3/8" drill bit and shaed a bit off of the banjo fitting for each caliper so the newer style banjo bolt would fit. About an hour later, the system was all put together, bled and operated quite well on a short 1/2 mile test ride.
I still need to swap rotors, which will be done tomorrow - and (weather permitting) give it a 'real' test - but all seems to be well.
- note - I tried to use DOT 4 fluid at first, but I think it was too 'thin' for the 04 master cylinder set-up & opted for DOT 5...Hopefully this will not create issues further down the road (literally).
Rather than drop all the coin on a full brake system, we grabbed a set of the silver OEM silver H-D Brembo's...the correct mounting bolts...and a pair of the H-D 'teardrop' floating rotors. Oh, also grabbed the chrome banjo bolt/bleeder kit specific to those calipers.
When I first took everything apart and did my mock-up, I discovered that the banjo bolts for the brembos will not fit thru the banjo fitting on the H-D diamondback (2004) brake lines. Also, the banjo bolt will not fit the '04 master cylinder.
We were ready to go ahead and grab a new set of brake lines, but (fortunately) none of the local H-D shops had them in stock..and we found they were on national back-order. We were also prepared to pick-up a master cylinder/clutch lever mount for an '08.
Since we could not find parts - I grabbed a 3/8" drill bit and shaed a bit off of the banjo fitting for each caliper so the newer style banjo bolt would fit. About an hour later, the system was all put together, bled and operated quite well on a short 1/2 mile test ride.
I still need to swap rotors, which will be done tomorrow - and (weather permitting) give it a 'real' test - but all seems to be well.
- note - I tried to use DOT 4 fluid at first, but I think it was too 'thin' for the 04 master cylinder set-up & opted for DOT 5...Hopefully this will not create issues further down the road (literally).
Road Warrior
Joined: May 2006
Posts: 1,652
Likes: 5
From: The sticks in SC
Should be fine as long as you flushed the master cly pretty good 
Got my parts off e-bay to do mine to the Brembo's (christy's harley on e-bay I got the M/cly, calibers, rotors, levers, perches, everything for $279) about a week and my small parts should be here from harley to finish the job! 
Got my parts off e-bay to do mine to the Brembo's (christy's harley on e-bay I got the M/cly, calibers, rotors, levers, perches, everything for $279) about a week and my small parts should be here from harley to finish the job!
Thread Starter
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
I'll try to post some pics later when all is buttoned-up.
If these things stop as well as I think they will (based on teh short test ride with the old rotors) I'll be doing the same upgrade on my Road King when I do my 21" front wheel.
If these things stop as well as I think they will (based on teh short test ride with the old rotors) I'll be doing the same upgrade on my Road King when I do my 21" front wheel.
Road Master
Joined: Mar 2008
Posts: 1,038
Likes: 2
From: Florida
Really sharp bike!
However, you might want to research the Dot 4 to 5 swap issue. Not a good idea from my prior readings about the subject. Any residual left anywhere in the lines/ system which causes a mix of the two will create big problems. I think you need to change the lines entirely but I am no expert. Use caution.
However, you might want to research the Dot 4 to 5 swap issue. Not a good idea from my prior readings about the subject. Any residual left anywhere in the lines/ system which causes a mix of the two will create big problems. I think you need to change the lines entirely but I am no expert. Use caution.
Thread Starter
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
Really sharp bike!
However, you might want to research the Dot 4 to 5 swap issue. Not a good idea from my prior readings about the subject. Any residual left anywhere in the lines/ system which causes a mix of the two will create big problems. I think you need to change the lines entirely but I am no expert. Use caution.
However, you might want to research the Dot 4 to 5 swap issue. Not a good idea from my prior readings about the subject. Any residual left anywhere in the lines/ system which causes a mix of the two will create big problems. I think you need to change the lines entirely but I am no expert. Use caution.
I understand that mixing of the two fluids can cause some sort of 'crystalization' (sp?) if left mixed for a long period of time.
When it came time for the fluid, I blew the lines out with my compresor with my compressor prior to dumping in the DOT 5. Then I pushed an 1/4 bottle thru the system before wrapping everything up. Hopefully that was enough.
I took it out for about 2-miles after it was complete and I am sold on the swap...Braking was MUCH improved over the stock '04 hardware. He rode it home today, so I will follow-up with him tomorrow to see how he likes it.
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Road Warrior
Joined: May 2006
Posts: 1,652
Likes: 5
From: The sticks in SC
Isn't the early rotors a good bit smaller than the Brembo rotor's, if so they'll only be better once you get the Brembo rotor's on them!
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Thread Starter
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Road Warrior
Joined: Dec 2006
Posts: 1,573
Likes: 138
From: StL, MO. USA
Yep, when swapping to the Brembos we moved to the newer 'floating' rotor. Diameter increased from 13" to 13.5". Made a big difference.
