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1980 Ironhead Sportster Chopper

Repairing the Brake Systems

Posted by Justin on 5/6/2005

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.

Images

Inside the rear I took the piston out and found that the cylinder was full of the same green sludge that the master cylinder had 1024 x 768 px (225 KB) 0 Comments		DSCN7205 1024 x 768 px (216 KB) 0 Comments
Cutting away th 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 1024 x 768 px (126 KB) 0 Comments	Inside Master C Even after cleaning out the sludge with a rag its still pretty ugly inside. 1024 x 768 px (198 KB) 0 Comments	Rear Brake Cali 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. 1024 x 768 px (207 KB) 0 Comments
Rear caliper de A quick buffing got some shine on this caliper but the dents and deep scratches will require some heavier sanding and grinding 1024 x 768 px (161 KB) 0 Comments	Rear Master Cyl The plastic top was cracked in half and there was no fluid in the reservoir 1024 x 768 px (214 KB) 0 Comments	The other strip 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 1024 x 768 px (124 KB) 0 Comments
Where the rear ... apparently to this large ugly chunk of cast aluminum 1024 x 768 px (183 KB) 0 Comments	Where the rear 1024 x 768 px (194 KB) 0 Comments

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1980 Ironhead Sportster Chopper

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