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Repairing the Brake Systems

  « 1980 Ironhead Sportster Chopper

(Brakes)

Repairing the Brake Systems Neither brake was working very well, but the rear was almost nonexistent. The rear master cylinder cover is broken, the rear brake line has a tear in the outer rubber layer, and the master cylinder was empty except for some sludge. The guy who sold it to me mentioned that the front brakes might need a rebuild as well.


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Cutting away the mounting nut seat
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The original hex-shaped hole where the nut for the mounting bolt fit was completely stripped so I cut the whole chunk out with a dremel

Inside Master Cylinder
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Even after cleaning out the sludge with a rag its still pretty ugly inside.

Inside the rear caliper
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I took the piston out and found that the cylinder was full of the same green sludge that the master cylinder had

Rear Brake Caliper
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The hex-shaped seats for the nuts on the mounting bolts, as well as the nuts themselves, were stripped. One of the bolts had to be cut using a dremel cutter.

Rear caliper dents
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A quick buffing got some shine on this caliper but the dents and deep scratches will require some heavier sanding and grinding

Rear Master Cylinder
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The plastic top was cracked in half and there was no fluid in the reservoir

The other stripped caliper piece
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This hole isnt quite as stripped as the other one but the nut spins freely so it'll have to be cut back as well

Where the rear caliper bolts on
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... apparently to this large ugly chunk of cast aluminum

Where the rear master cylinder bolts on
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