The new installed Brakester...
The new installed Brakester on the '91 Softail.
We are still working on our '91 Softail trying to clean up the bike and get a more custom look without spending too much money. The owner wants to continue blacking out parts of the bike before picking a color and painting the tins. Last month on the way back from Dyno Dave's shop where we ran the bike on the dyno we noticed that the brakes felt weak. As we were coming off the highway the rear brake didn't feel as if it was biting on the rotor very well. It was not making any noise but just didn't feel right. Once we got to the shop we borrowed a few tools and checked the brakes. The pads were fine but the stock caliper was not moving freely. We got it working to get us home but we started searching for a replacement caliper. We came across the Brakester from DNA Specialty INC; this is a rear pulley and rotor combo all in one. It uses a four-piston caliper and also cleans up the right side of the rear wheel as well. Since it was only $319.95 we ordered one up.
1. Here is the old setup with...
1. Here is the old setup with the stock H-D pulley.
Once we got started installing the Brakester we realized it was going to take a little more than most home garage guys can handle; you will need to weld a mounting tab to the frame, re-space the wheel and then re-finish the swingarm. For fitment of the wheel spacers, some machining is required to get the wheel properly aligned in the swingarm. With this said we headed back to Freedom Cycles in Orange, California, where shop owner Devin rolled the bike on to the lift as shop tech Kazoo started to remove the old setup and wheel.
2. The DNA Brakester kit comes...
2. The DNA Brakester kit comes with the pulley, four-piston caliper, mounting bracket, welding tab, 3/4-inch and 1-inch wheel spacers, anchor tab, and hardware. DNA offers the pulley in a few different styles. For this install we ordered a blank pulley in raw finish.
3. After a quick mock up,...
3. After a quick mock up, we drilled the holes into the pulley to mount it to the wheel and then sent the wheel and pulley out for powdercoating. In the meantime we started working on the swingarm. The first thing Kazoo did was weld the anchor tab to the swingarm. The directions said to mount it about 6 inches from the axle mount (arrow).
4. Also the stock H-D swingarm...
4. Also the stock H-D swingarm has the mounting brace for the stock caliper on the right side that was removed. You don't have to but it looks better and we needed to repaint the swingarm anyway (arrow).
5. Once we got the wheel and...
5. Once we got the wheel and pulley back from Embee Powdercoating, Kazoo mounted the pulley to the wheel along with the 1/4-inch hub spacer (not shown here), a little threadlocker on each bolt, and then he torqued the bolts to 60 lb-ft.
6. As a safety measure Kazoo...
6. As a safety measure Kazoo drilled all the bolt heads so that safety wire could be installed through all the bolts to keep them from backing out.
7. Next, Kazoo installed the...
7. Next, Kazoo installed the wheel back onto the bike to get some measurements for the axle spacer along with the caliper bracket.
8. Spacers for both sides...
8. Spacers for both sides needed to be cut down to fit. We used the 3/4-inch set.
9. Once both the spacers were...
9. Once both the spacers were cut to size, the one for the left side was placed on the caliper bracket then put in place for the axle. The axle nut was tightened down and a new cotter pin was installed.
10. Next, the four-piston...
10. Next, the four-piston caliper was installed onto the DNA bracket, and then Kazoo checked for clearance. This is where the smaller bolts heads for the pulley come in handy.
11. The two Heim joints were...
11. The two Heim joints were installed onto the adjuster rod for the bracket mount brace. This can be adjusted once installed to ensure that the caliper is in the right position.
12. Next, Kazoo tightened...
12. Next, Kazoo tightened the setscrew on the caliper bracket.
13. The brake line along with...
13. The brake line along with a new banjo bolt and washers were then installed. Then the brake line was bled of all the air.
14. Here you have the DNA...
14. Here you have the DNA Brakester installed. All we needed to do was place the seat back onto the bike and take it out for a test ride.
15. Take a look at the other...
15. Take a look at the other side of the bike where the stock H-D rotor would have been; nice and clean. Once we started to test out the Brakester, we had to be careful on the first ride. The rotor needed time to break in, then after about 10 miles of on and off the pedal to get the pads good and hot we started to notice the biting power. It didn't take long to get the rear wheel to lock up (not that we want it, but it was there).