Braided, Dual Disc, Front Brake Line kits

J031092009-03-09

GENERAL

Kit Number

45441-03A, 46697-06, 43349-96B

Models

For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

For OE applications, see the applicable parts catalog.

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 Disc, Front Brake Line	Not sold separately
Gasket (6)	41731-01
Cable strap (3)	10065

INSTALLATION

1	Bleed valve cover

Figure 1. Brake Caliper Bleed Valve Rubber Cover

1	Plastic tube
2	Caliper bleeder valve
3	Container

Figure 2. Draining Brake Fluid

NOTE

This instruction sheet covers motorcycle models that use either DOT 4 or DOT 5 Hydraulic Brake Fluid. The owner's manual will indicate which type of brake fluid should be used on the motorcycle. Read and follow the owner's manual carefully.

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)

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)

1.	See the service manual and disconnect negative (-) battery cable or remove the main fuse. Save the seat hardware for installation.
2.	See Figure 2. Open bleeder nipple cap on front brake caliper. Install end of a length of plastic tubing over caliper bleeder valve (1), while placing free end in a suitable container. Open bleeder valve approximately 1/2 turn. Pump brake lever to drain brake fluid. Repeat step for the other caliper.
3.	Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Save bolt and discard washers. NOTE Carefully 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.
4.	Carefully 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.
	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)
5.	Install new braided brake line into position. Tighten the screw that holds the brake line tee to the fork stem to 13.6–20.3 N·m (10–15 ft-lbs). NOTE The brake line manifold "tee" is mounted so that the two tee-to-caliper legs go rearward and downward and the single tee-to-master cylinder leg goes to the right and upward.
6.	At the master cylinder and calipers, position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Insert bolts saved from steps 2 and 3 through washers and fittings. Thread bolts into master cylinder and calipers and tighten to 23–30 N·m (17–22 ft-lbs).
7.	Remove the master cylinder cover. Stand the motorcycle upright so the master cylinder is in a level position.
8.	Add DOT 4 or DOT 5 Hydraulic Brake Fluid (whichever is applicable for your model motorcycle) to master cylinder reservoir until the fluid level is 1/8 inch (3.2 mm) from the top. Do not reuse brake fluid. Use only DOT 4 or DOT 5 fluid from a sealed container. Read your Owner's Manual for the correct type fluid for your model motorcycle.
9.	See the service manual and bleed the brakes.
10.	See the service manual and connect the negative (-) battery cable or install the main fuse.
	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)
11.	Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure following the instructions in the appropriate Service Manual.