The Tolle Sprocket disc brake kit includes: brake caliper, brake/sprocket disc (for H-D wheels), caliper bracket, 2 spacers for caliper bracket, 2 bolts M10 for the spacers, caliper mounting tab for welding, 3 washers (3, 2, 1 mm) for the disc. Please observe that you must manufacture wheel axle spacers yourself since the caliper bracket has to be fitted on the wheel axle (caliper bracket thickness 4 mm).

Try putting the rear sprocket and caliper in place on the bike, without tightening anything, just to check the clearance between spokes and caliper. If the spokes hit the caliper, simply shim the sprocket assembly outward with the washer supplied in our kit. Tighten the sprocket to the hub.

Test-install the caliper bracket on the rear axle. Now you have to fabricate the wheel axle spacer to fit the caliper bracket. Carefully measure the required distance between hub and bracket to put the caliper in its proper position on the sprocket/brake disc. Sorry, we can not make these spacers ourselves because the variations between different frames and hubs are virtually endless. You can use the existing wheel axle spacer and remove the equivalent of the bracket thickness, remember to make a straight cut.

The caliper mounting tab included has an oblong hole for the bolt since the caliper follows the rear wheel when you adjust the chain. Cheque that the oblong hole is correctly positioned in relation to the axle adjuster on the wheel axle. Weld the mounting tab to the upper side of the bottom rear frame tube. When you weld it is important that the tab is absolutely vertical and straight along the chain since this affects the brakes considerably. Fasten the tab by one spot welding. Put it in correct position and spot weld once again at the other end, correct the position again. Fasten by spot welding in zick-zack on the front and back side, one cm at a time.

Note that you must remove the caliper in order to bleed your brake system. Make sure the bleed screw is pointing straight up and is the highest point, or you will not be able to get all the air out. Put a piece of flat iron about the same thickness as the sprocket/brake disc between the brake pads, or the pistons will get pushed out too far.

The stock H-D master brake cylinder uses a 19 mm plunger. You can keep this cylinder, but your bike will still have the same sluggish brake action as a standard Hog. If you really want the most out of your new brake equipment, you should get our special master cylinder that uses a 14 mm plunger. This will give your Harley super quick and efficient brake action.

The sprocket is zinc plated against rust. This zinc layer is very thin and will quickly be worn away as you start using the brake. Some surface rust may appear on the sprocket, but will instantly vanish when you use the brake. The sprocket is available with 46, 48, 50 and 52 teeth. Most people use 52 teeth at the rear and 22-25 at the front. If you have 52 teeth today and change to a 48 teeth sprocket, you get about the same geering as if you should have gone up two teeth at the front sprocket.

Does your bike use a drum brake rear hub? No problem, you can still use the sprocket disc brake. We have developed a special adapter that will convert your drum hub into a disc brake hub.

Good luck!