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Braided Front Brake Line Kits
J029512010-03-05
GENERAL
Kit Numbers
45510-04, 46695-06, 43374-04B
Models
Fits all 2004-2007 FLHRS/I (Road King® Custom) model motorcycles as stock replacement brake lines.
Also fits 2003-later FLHR/I/CI models with Beach Handlebar kit (Part No. 56855-05) and 2004-later FLHRS/I models with Beach Handlebar kit (Part No. 56856-05).
Additional Parts Required
NOTE
This instruction sheet covers motorcycle models that use either DOT 4 Hydraulic Brake Fluid or DOT 5 Silicone Hydraulic Brake Fluid. The motorcycle's owner's manual, service manual and the master cylinder cover will all indicate which type of brake fluid should be used for this motorcycle.
Fresh, uncontaminated DOT 4 (Part No. 99953-99A) or DOT 5 brake fluid (Part No. 99902-77) from a sealed container is required. See the service manual.
WARNING
Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
Table 1. Kit Contents
Description (Quantity)
Part Number
Braided dual front brake line assembly
Not Sold Separately
Gasket, 0.37 inch (6)
41731-01
Cable strap, 5.5 inch (3)
10065
CAUTION
Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
INSTALLATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware.
NOTE
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
2. See Figure 1. Open the bleeder nipple caps on both front brake calipers. Refer to the service manual and follow the instructions to drain the fluid out of the front brake system. Dispose of brake fluid properly.
NOTE
Compare the new brake line assembly to the old lines before removing the old lines from the motorcycle. Make sure the banjo fittings on the new brake line will be oriented the same as the fittings on the old lines.
Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result.
3. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two brake line gaskets at each banjo fitting.
4. For FLHRS/I Models: Remove and retain the two hex head screws and flat washers attaching the chrome cover to the fork stem and bracket assembly. Remove and retain the button head screw underside the cover that also holds the brake line manifold tee. Remove the cover and set it save for installation. For FLHR/I/CI Models: Remove and retain the buttonhead screw under the brake line manifold tee.
1Caliper Bleeder Valve
Figure 1. Front Caliper
5. Make note of the front brake line routing and the orientation of the banjo fittings, then remove the old brake lines from the motorcycle. Discard the brake lines and all other attaching parts.
6. Inspect the new brake line for damage or defects, and replace the brake line if damaged.
NOTE
The brake line manifold tee is mounted so that the two caliper legs go to the rear and down and the single master cylinder leg goes to the right and up.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
WARNING
Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a)
7. Place the new braided brake line assembly and the chrome fork bracket cover (FLHRS/I models) into position. Check to make sure that there will be no interference between the brake line and the nacelle, fork stem and bracket assembly and the chrome fork bracket cover (FLHRS/I models).
8. For FLHRS/I Models:
a. Attach the chrome fork bracket cover and the brake line manifold tee to the fork stem and bracket assembly with the single TORX head screw removed earlier, but do not tighten.
b. Attach the back of the cover to the fork stem and bracket assembly with the two hex head screws and flat washers removed earlier, but do not tighten.
c. Tighten the screw that holds the middle of the cover and the brake line manifold tee to the fork stem to 3.6–20.3 N·m (10–15 ft-lbs). Tighten the two hex head screws at the back side of the cover to 7.9–12.4 N·m (70–110 in-lbs).
9. For FLHR/I/CI Models: Attach the brake line manifold tee to the fork stem and bracket assembly with the single TORX screw removed earlier. Tighten screw to 3.6–20.3 N·m (10–15 ft-lbs).
10. For All Models:
a. Using the new brake-line gaskets from the kit, lubricate with the proper brake fluid (refer to the owner's manual for your model motorcycle) and position a gasket on each side of the hydraulic fitting (banjo fitting) at the master cylinder.
b. Insert the banjo bolt (removed earlier) through the washers and fitting. Thread the bolt into the master cylinder and tighten to 23–30 N·m (17–22 ft-lbs).
c. Repeat at each front brake caliper with new brake line gaskets and saved banjo bolts.
11. Using the cable straps from the kit, fasten the front brake line to the motorcycle as needed. Fasten the front fender lighting wiring to the brake line.
12. Using a motorcycle lift, raise the vehicle frame so that the front forks reach full extension. Verify that the brake line is of sufficient length to allow full fork extension without pulling the brake line.
a. Fully compress the forks to check that the brake line does not interfere with or catch on motorcycle components. Turn the front wheel to the full right fork stop and then the full left fork stop to be sure the brake line, throttle cables and clutch cable do not interfere with or catch on motorcycle components.
b. Adjust the brake lines and/or banjo fitting orientation if the brake lines interfere or catch on motorcycle components, or if the routing does not appear correct.
13. Remove the master cylinder cover. Stand the motorcycle upright so the master cylinder is in a level position.
NOTE
Do not mix grades of brake fluid as they are not compatible.
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of DOT 4 brake fluid.
14. Add the appropriate hydraulic brake fluid to master cylinder reservoir until the fluid level is 0.12 in (3.2 mm) from the top. Do not reuse brake fluid. Only use brake fluid from a sealed container.
WARNING
A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a)
15. Verify proper operation of the master cylinder relief port. Actuate the brake hand lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
16. Add brake fluid to the master cylinder reservoir until the fluid level is about 0.12 in (3.2 mm) from the top.
17. Activate and hold brake lever to build up hydraulic pressure.
18. Open bleeder valve about one-half turn. Brake fluid will flow from bleeder valve through tubing. Close bleeder valve when brake lever has moved one-half to three-quarters of its full range of travel. Allow brake lever to return slowly to its released position.
19. Repeat Steps 16-18 until all air bubbles are purged.
20. Final tighten bleeder valve to 9–11.3 N·m (80–100 in-lbs). Install bleeder cap. Add brake fluid to master cylinder reservoir until fluid level is about 1/8 in (3.2 mm) from the top. Final tighten master cylinder reservoir cover screws to 0.7–0.9 N·m (6–8 in-lbs).
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
21. Refer to the service manual and follow the instructions given to attach the negative battery cable and install the seat.
22. Turn the ignition/light key switch to IGNITION and apply the front brake hand lever to test operation of the brake lamp.
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
23. Test ride the motorcycle. If the brakes feel spongy, repeat the bleeding procedure.