MODULAR BRAKE LINE KITS

J042842021-03-30

GENERAL

Kit Number

Table 1. Upper Brake Line Kits (Banjo Angle 0° - Straight)

Diamond-Black Kit	Diamondback Kit	Length
N/A	41800024A	20 inch
N/A	41800025A	21 inch
N/A	41800026A	22 inch
N/A	41800027A	23 inch
N/A	41800028A	24 inch
41800341	41800029A	25 inch
N/A	41800030A	26 inch
41800104A	41800031A	28 inch
41800580	41800042A	30 inch
N/A	41800043A	32 inch
N/A	41800044A	34 inch

Table 2. Upper Brake Line Kits - Banjo Angle 35°

Diamond-Black Kit	Diamondback Kit	Length
41800106A	41800051A	19 inch
N/A	41800052A	20 inch
41800108A	41800053A	21 inch
41800110A	41800054A	22 inch
N/A	41800055A	23 inch
N/A	41800056A	24 inch
N/A	41800057A	25 inch
N/A	41800058A	26 inch
41800112A	41800059A	28 inch
41800114A	41800060A	30 inch
41800116A	41800061A	32 inch
41800118A	41800062A	34 inch

Table 3. Upper Brake Line Kits - Banjo Angle 90°

Diamond-Black Kit	Diamondback Kit	Length
41800120A	41800080A	20 inch
N/A	41800082A	21 inch
N/A	41800084A	22 inch
N/A	41800088A	23 inch
41800122A	41800090A	24 inch
N/A	41800092A	25 inch
N/A	41800094A	26 inch
N/A	41800096A	28 inch
N/A	41800098A	30 inch
N/A	41800100A	32 inch
N/A	41800102A	34 inch

Table 4. Lower Brake Line Kits

Diamond-Black Kit	Diamondback Kit	Length	Caliper Banjo Angle
48920-10	42371-07	20.25 in.	78°
38116-10	42110-07	21.5 in.	78°
48924-10	42366-07	22.75 in.	78°
N/A	45770-08	23.25 in.	78°
48926-10	42108-07	24.0 in.	78°
38135-11A	38132-11A	N/A	65°
N/A	38186-11A	N/A	65°
41800022B	41800308A	N/A	65°
41800076A	41800032A	N/A	78°
N/A	41800050	N/A	78°
41800369	41800370	N/A	60°
41800375	41800374	20.25 in.	60°

NOTE

Diamondback™ and Diamond-Black Upper Brake Line Kits are available in a variety of master cylinder banjo angles and brake line lengths. Shorter or longer lines may be necessary when modifications (i.e., optional handlebars) have been made to the motorcycle. See the P&A retail catalog or a Harley-Davidson dealer for more information.

Models

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

Tools and Supplies Required

Fresh, uncontaminated brake fluid will be needed. Refer to the owner's manual or service manual for this year/model motorcycle to determine the correct brake fluid for this vehicle.

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

The rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)

Electrical Contact Lube (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.

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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.

Kit Contents

See Table 5 , Table 6 and Table 7.

PREPARATION

NOTE

For vehicles equipped with security siren:

Verify that the Hands-Free Fob is present.
Turn the ignition key switch to IGNITION.

For ALL vehicles with main fuse:

WARNING

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

Refer to the service manual and follow the instructions to remove the main fuse.

For ALL vehicles with main circuit breaker:

WARNING

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

WARNING

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

1.	Refer to the service manual and follow the instructions to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping the 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 an H-D Service Cover or polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid.
	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)
2.	Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual.

INSTALLATION, NON-ABS MODELS

Original Front Brake Line Removal

NOTE

Cover the front fender and the front of the fuel tank with H-D Service Covers or clean shop towels to prevent scratching. Damage to the finish could result.

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

Disconnect the front brake line from the front brake master cylinder and front brake caliper. Save the master cylinder and caliper banjo bolts. Discard all sealing washers.

NOTE

Some 2009-Earlier FXCW and FXCWC models do not use P-clamps, screws or washers to retain the original brake line.

For all models except FXCW and FXCWC: Remove the existing P-clamps and mounting hardware retaining the original brake line at the following locations: Save the mounting hardware for later installation. Discard the P-clamps.
1. Under the lower fork clamp.
2. Along the right side of the steering head at the upper triple clamp and/or between the upper and lower fork clamps.
For all models EXCEPT FXCW and FXCWC: Carefully make note of the front brake line routing and orientation of the banjo fittings, then remove the existing front brake line. For FXCW and FXCWC models: Carefully make note of the orientation of the banjo fittings, then remove the existing front brake line.

Braided Front Brake Line Installation

NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)

Verify that the correct upper and lower Brake Line Kits have been obtained.

In some cases, the Upper Brake Line Kit has already been specified.
In other cases, the proper Upper Brake Line Kit (see Table 1 , Table 2 , or Table 3 ) needs to be determined using the Cable and Brake Line Measurement Tool Kit. See a Harley-Davidson dealer for assistance.
See Table 4 to determine the correct Lower Brake Line Kit for your model motorcycle.

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)

See Figure 1. Install the banjo fitting (1) of the upper brake line (2) at the master cylinder (3), using the larger ID sealing washers (4) from the Upper Brake Line Kit on each side of the banjo fitting.

Install the master cylinder banjo bolt (5, saved earlier) snug, but do not fully tighten at this time.

1	Banjo fitting
2	Upper brake line
3	Master cylinder
4	Sealing washer, larger I.D. (2)
5	Banjo bolt

Figure 1. Upper Brake Line (FLSTF Shown)

1	Banjo fitting
2	Lower brake line
3	Caliper
4	Sealing washer (2)
5	Banjo bolt

Figure 2. Lower Brake Line (FLSTF Shown)

See Figure 2. Install the banjo fitting (1) of the lower brake line (2) at the caliper (3), using the smaller ID sealing washers (4) from the Lower Brake Line Kit on each side of the banjo fitting.

a. Position the banjo fitting away from the vehicle at an angle of approximately 10° from vertical.

b. Install the caliper banjo bolt (5, saved earlier), and tighten to 23–30 N·m (17–22 ft-lbs).

See Figure 3. Route the remainder of the lower brake line under the lower fork clamp. For all models except FXCW and FXCWC: Continue with Step 9. For FXCW and FXCWC models: Proceed to Step 12.

Figure 3. Lower Brake Line Routing (FLSTF Shown)

Upper Front Brake Line Routing (Except FXCW and FXCWC)

Route the upper portion of the upper brake line along the handlebars (similar to the routing shown in Figure 1 ), then:

a. For Dyna and FX Softail models: Install a small P-clamp from the kit onto the brake line at the location shown in Figure 4.

b. For FL Softail models: Install two small P-clamps from the kit onto the brake line at the locations shown in Figure 5.

NOTE

The P-clamp(s) typically must be oriented so the brake line is held away from the vehicle. However, some custom handlebar applications may require the P-clamp to be oriented so the brake line is held toward the vehicle.

1	P-clamp
2	Upper brake line
3	Lower triple clamp

Figure 4. Upper Brake Line Routing (One P-Clamp)

1	P-clamp (2)
2	Upper brake line
3	Lower triple clamp

Figure 5. Upper Brake Line Routing (Two P-Clamps)

For Dyna and FX Softail models: See Figure 6. Obtain the P-clamp screw (1) and star washer (2) removed earlier. Place the washer onto the screw threads, followed by the electrical ground lug (3) and a new small P-clamp (4) from the Upper Brake Line Kit. Loosely install the screw into the upper fork clamp (5) so brake line adjustments can still be made. For FL Softail models: Obtain the P-clamp mounting hardware removed earlier, and loosely install the clamps to the right-rear back panel so brake line adjustments can still be made.

See Figure 4 or Figure 5. Route the remainder of the upper brake line under the lower fork clamp. Proceed to Step 15.

1	Screw
2	Star washer
3	Ground lug
4	P-clamp
5	Upper triple clamp

Figure 6. Electrical Ground Lug Mounting (Dyna Models and FX Softails except FXCW and FXCWC)

1	Upper brake line
2	Right-side handlebar riser
3	Middle opening of upper triple clamp
4	Lower triple clamp
5	Cushioned P-clamp
6	Lower brake line
7	Cable strap (2)

Figure 7. Upper Front Brake Line Routing (FXCW and FXCWC)

Upper Front Brake Line Routing (FXCW and FXCWC)

See Figure 7. Route the upper brake line (1) behind the handlebar riser (2) and through the middle opening (3) of the upper fork clamp. Loop the brake line outward behind the right fork and under the lower fork clamp (4).

Upper/Lower Front Brake Line Connection (ALL Models)

10.

Hold the upper brake line female fitting (with swivel nut) underneath the lower fork clamp, approximately at the P-clamp threaded mounting hole location. Bring the lower brake line male fitting to meet the upper brake line female fitting.

11.

Thread the male and female fittings together by turning the swivel nut on the female fitting.

a. Turn until finger-tight, being careful not to twist the upper or lower brake lines while tightening.

b. Using two 7/16 in. open-end wrenches, holding the rigid lower fitting fixed in place, tighten the swivel nut past finger-tight by 45 degrees (1/8 turn) or 5.1–7.3 N·m (45–65 in-lbs). Make sure only the swivel nut turns.

12.

Obtain the cushioned P-clamp from the Upper Brake Line Kit. Position the P-clamp to the underside of the lower fork clamp so the flat side of the clamp will be up against the bottom of the lower fork clamp, and For Dyna, FXCW/C and FX Softail models: the loop of the cushioned clamp faces towards the front of the vehicle. See Figure 8. For FL Softail models: the loop of the cushioned clamp faces towards the rear of the vehicle. See Figure 9.

1	Female fitting with swivel nut
2	Male fitting
3	Cushioned P-clamp
4	Stock screw

Figure 8. Cushioned P-Clamp Mount (Forward Position)

1	Female fitting with swivel nut
2	Male fitting
3	Cushioned P-clamp
4	Stock screw

Figure 9. Cushioned P-Clamp Mount (Rearward Position)

13.

Open the cushioned P-clamp far enough to place the loop over the fitting connection. Close the P-clamp around the connection, making sure the clamp overlaps both sides equally, and being careful not to twist the brake line.

14.

For all models except FXCW and FXCWC: Mount cushioned P-clamp using original screw (4) previously removed. For FXCW and FXCWC models: Mount cushioned P-clamp using new screw and flat washer from Lower Brake Line Kit. Tighten the screw .

Torque: 10.8–13.6 N·m (8–10 ft-lbs) hex head screw

INSTALLATION, SOFTAIL ABS MODELS

WARNING

Original Front Brake Line Removal

NOTE

Cover the front fender and the front of the fuel tank with H-D Service Covers or clean shop towels to prevent scratching. Damage to the finish could result.

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

Remove both metal clips holding the brake lines to the frame tubes. Save the clips.
Make note of the wheel speed sensor (WSS) routing, clip and cable strap location. Remove the cable straps and clips holding the WSS to the brake line. Save the clips.
Remove the shoulder screw holding the brake line manifold to the lower fork clamp. Save the shoulder screw for later installation with the new brake line. Disconnect the brake line from the caliper and the hydraulic control module. Discard the sealing washers, but save the banjo bolts.
Cut the cable strap holding the brake line to the vent tube. Disconnect the brake line from the hydraulic control module (HCU) and master cylinder. Discard the sealing washers, but save the banjo bolts.

Braided Front Brake Line Installation

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)

NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)

15.	Loosely install both halves of the new brake line manifold to the lower fork clamp using the shoulder screw saved in step 3.
16.	See Figure 2. Install the banjo fitting (1) of the lower brake line (2) at the caliper (3), using the smaller ID sealing washers (4) from the Lower Brake Line Kit on each side of the banjo fitting. a. Position the banjo fitting away from the vehicle at an angle of approximately 10° from vertical. b. Install the caliper banjo bolt (5, saved earlier), and tighten to 23–30 N·m (17–22 ft-lbs).
17.	Connect brake lines to hydraulic control unit with new sealing washers from kit and banjo bolts saved in Steps 3 and 4. Tighten banjo bolts. Torque: 13.6–19 N·m (10–14 ft-lbs) hex head bolt
18.	Tighten manifold shoulder screw. Torque: 4.29–5.42 N·m (38–48 in-lbs) hex head bolt
19.	Thread the male and female fittings together by turning the swivel nut on the female fitting. a. Turn until finger-tight, being careful not to twist the upper or lower brake lines while tightening. b. Using two 7/16 in. open-end wrenches, holding the rigid lower fitting fixed in place, tighten the swivel nut past finger-tight by 45 degrees (1/8 turn) or 5.1–7.3 N·m (45–65 in-lbs). Make sure only the swivel nut turns.
20.	Brake line routing: a. For FL models with fork covers: Remove the top screw on the fork cover. Get the small P-clamp (6) from the upper brake line kit (see Table 5 ). Route the upper brake line though the P-clamp and use the screw to attach it to the same location on the fork cover. DO NOT attach the brake line to the lower hole location on the fork cover. Adjust the position of the brake line to route smoothly from the manifold to the P-clamp. Rotation of the P-clamp may be necessary for some handlebars. Tighten the screw to 2.26–3.39 N·m (20–30 in-lbs). b. For FX models except FXCWC: Remove the screw on the upper fork clamp. Get the small P-clamp (6) from the upper brake line kit (see Table 5 ). Route the brake line through the P-clamp and use the screw to attach it to the same location on the upper fork clamp. Adjust the brake line to route smoothly from the manifold to the P-clamp. Tighten the screw to 4.52–6.78 N·m (40–60 in-lbs). c. For FXCWC models: See Figure 7. Route the upper brake line (1) behind the handlebar riser (2) and through the middle opening (3) of the upper fork clamp. Loop the brake line outward behind the right fork and under the lower fork clamp (4). NOTE For installation with engine guards, route the brake line behind the engine guard. Rotate the clutch cable clip 180 degrees for clearance to the brake line.
21.	Place the original brake line clips over the new brake line hard tubing, and attach to the frame. Route the WSS wiring in the same manner as the original installation. Place the WSS wire retaining clips over the new brake line and wiring.

INSTALLATION, DYNA ABS MODELS

WARNING

Original Front Brake Line Removal

NOTE

Cover the front fender and the front of the fuel tank with H-D Service Covers or clean shop towels to prevent scratching. Damage to the finish could result.

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

Make note of the wheel speed sensor (WSS) routing and cable strap location. Remove the cable straps and clips holding the WSS to the brake line. Save the clips.
See Figure 11. Remove the shoulder screw (2) holding the brake line manifold (1) to the lower fork stem. Save the shoulder screw for later installation with the new brake line. Disconnect the brake line from the caliper. Discard the sealing washers, but save the banjo bolts.
See Figure 10. Disconnect the brake lines (1 and 2) at the lower brake line manifold.
Disconnect brake line from the front brake master cylinder. Discard the sealing washers, but save the banjo bolts.

Braided Front Brake Line Installation

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)

NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)

22.	See Figure 11. Position the brake line manifold (1) on the underside of the fork stem with the lower leg of the brake line coming down the to the rear of the front forks to the brake caliper.
23.	Secure manifold to fork stem with previously removed screw (2). Tighten. Torque: 4.1–5.4 N·m (36–48 in-lbs) Shoulder Bolt
24.	See Figure 10. Connect ABS brake lines (1 and 2) to braided brake line manifold. Tighten tube nuts. Torque: 13.5–16.3 N·m (10–12 ft-lbs) Brake Lines
	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)
25.	See Figure 10. At brake caliper, install a new steel and rubber sealing washer from Lower Brake Line Kit on each side of brake line banjo fitting (4). Insert banjo bolt (3, removed earlier) through washers and fitting. Thread bolt into caliper and tighten. Torque: 29.8–36.6 N·m (22–27 ft-lbs) hex nut
26.	Obtain new upper brake line assembly. Route upper brake line from master cylinder along front of handlebar, behind upper fork clamp and down to male fitting on upper end of lower brake line.
	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)
27.	See Figure 1. Install banjo fitting (1) of new upper brake line at master cylinder using a new sealing washer (4) from Upper Brake Line Kit on each side of fitting.
28.	Install banjo bolt (5, removed earlier) snug, but do not fully tighten at this time.
29.	See Figure 6. Install stock P-clamp (4) over upper brake line and secure it to upper fork clamp with self-tapping screw and lockwasher from kit.
30.	Check routing of upper brake line from master cylinder, along handlebar and through P-clamp, to junction of upper and lower brake lines. Verify that the routing of the brake line is smooth and does not interfere with any vehicle components. If necessary, adjust position of P-clamp.
31.	Connect female fitting on upper brake line to male fitting on manifold. Thread female fitting onto male fitting finger tight. NOTE When using wrenches to final tighten fitting, turn only the swivel nut. Do not allow male fitting or manifold tubing to turn.
32.	Using two wrenches, holding rigid lower fitting fixed in place, tighten swivel nut past finger-tight by 45 degrees (1/8 turn) or 5.1-7.3 Nm (45-65 in-lbs). Make sure only the swivel nut turns.

1	Brake line
2	Brake line
3	Banjo bolt
4	Banjo fitting

Figure 10. Dyna ABS Models

1	Manifold
2	Shoulder bolt

Figure 11. Dyna ABS Lower Front Brake Line and Manifold

Brake Line Routing Check and Adjustment

1.	Using a motorcycle lift, raise the vehicle frame so that the front forks reach maximum extension. Verify that the lower brake line is not pulled tight when the forks are fully extended.
2.	NOTE When routing accessory brake lines, the intention is: Gentle routing without any sharp bends or kinking Free uninhibited movement from steer lock to steer lock Clearance to any pinch-points throughout the steering motion Clearance to any potential snags such as the ignition switch with key installed Avoid any contact with painted surfaces throughout the steering motion (fender, gas tank, miscellaneous body components) Light structure contact with the frame, downtubes, or triple clamp may occur but only at full extents of the steering motion Adjustments to the brake line routing can include: The use of P-clamp in place of stock wire-form retention (on some models) Lower manifold adapter fitting orientation (on some models) Line lengths between mounting locations and banjo fitting angles P-clamp orientation Banjo fitting orientation Make sure all brake lines are routed properly. This includes turning the handlebars from lock to lock, and ensuring that all brake lines do not snag, kink, rub surrounding parts or get pinched between parts. If any of the above occur, check the routing of the brake lines, and adjust as necessary.
3.	Adjust brake lines and/or banjo fitting orientation if brake lines interfere or catch on motorcycle components, or if routing does not look right.
4.	When adjustments are complete, tighten the master cylinder banjo bolt. Tighten. Torque: 23–30 N·m (17–22 ft-lbs) Banjo bolt
5.	For all models except FXCW and FXCWC: See Figure 4 or Figure 5. Tighten the P-clamp screw(s) at the fork clamp while holding the P-clamp(s) and electrical ground lug (if applicable) in the proper orientation. Install cable straps at the same locations as the original cable straps, if applicable. For FXCW and FXCWC models: See Figure 7. Use the two cable straps (7) from the Lower Brake Line Kit to secure the upper brake line to the handlebar switch wire harness in the locations shown. Make sure the brake line does not contact the electrical ground lug under the handlebar riser bolt.

NOTE

For 2006 and later Dyna models with the ignition switch/key location at the front of the frame directly behind the steering head:

If the brake line contacts the key or key fob during full right turn of the handlebars, turn the cushioned clamp (located below the lower fork clamp) towards the left side of the vehicle to move the vertical portion of the brake line between the upper and lower clamps as far to the right as possible, to keep brake line away from the ignition key.

If the brake line contacts the lower fork clamp, then turn the cushioned clamp towards the right side of the vehicle to provide the necessary clearance

FINAL ASSEMBLY

Bleed and Test Front Brake Line

NOTE

Verify that the fuel tank, front fender, chrome, and footboards are properly covered with an H-D Service Cover or polyethylene protective sheet.

1.	Remove front brake master cylinder cover, if not already removed.
2.	Stand motorcycle upright so the master cylinder is in a level position. NOTE This instruction sheet covers motorcycle models that use either DOT 4 or DOT 5 hydraulic brake fluid. The owner's manual and service manual for this motorcycle, and master cylinder cover will all indicate which type of brake fluid should be used for your motorcycle. Do not mix grades of brake fluid as they are not compatible. Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury.
3.	Add DOT 4 hydraulic brake fluid or DOT 5 hydraulic brake fluid (check the owner's manual, service manual or master cylinder cover for the correct type for this model motorcycle) only to master cylinder reservoir until fluid level is 3.2 mm (⅛ in) from the top. Do not reuse brake fluid. Use only brake fluid from a sealed container.
	WARNING Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a)
4.	Verify proper operation of the master cylinder relief port. Slowly apply and release the front brake lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
	WARNING After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
5.	Bleed the brake system following the instructions in the service manual.
6.	Check master cylinder, caliper banjo fittings and male/female connection under lower fork clamp for any signs of leakage.
7.	Tighten bleeder valve. Torque: 9–11.3 N·m (80–100 in-lbs) hex nut
8.	Install the bleeder cap.
9.	Add brake fluid to the master cylinder reservoir until the fluid level is about 3.2 mm (⅛ in) from top. NOTE Before installing master cylinder cover, verify that cover gasket bellows is not expanded. If bellows is expanded, brake fluid will be ejected from reservoir during cover installation, which could damage vehicle finish.
10.	Note that shape of master cylinder cover has one end thinner than the other. Install cover (with gasket compressed) on master cylinder reservoir: a. for 2007 and earlier models, so thinner end is positioned above the brake line fitting. b. for 2008 and later models, so the thicker end is positioned above the brake line fitting. c. ALL models: Install two screws to install the cover to the reservoir. Tighten the screws to 0.7–0.9 N·m (6–8 in-lbs).

RETURN TO SERVICE

NOTE

Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the battery cables.

WARNING

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

1.	Verify that the ignition key switch is turned to the OFF position.
2.	Models with main circuit breaker: Refer to the service manual and follow the instructions to attach the battery cables (positive cable first). Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse.
	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)
3.	Install the seat (if removed) according to the instructions in the service manual.
	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)
4.	ALL models: Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.

SERVICE PARTS

Figure 12. ABS Installation, Modular Front Brake Lines (Typical; FL Softail Shown)

Table 5. Service Parts: Upper Brake Line Kits

Item	Description (Quantity)	Part Number
A	Brake line, upper (1)	Not sold separately
4	Washer, sealing (large ID) (2)	41733-88
5	Cable strap (3)	10065
6	P-clamp, small (2)	10059A
7	P-clamp, cushioned (1) (not used for ABS applications)	42364-07

Table 6. Service Parts: Lower Brake Line Kits (Except 38132-11A, 38135-11A, 38186-11A, 41800022A or 41800308)

Item	Description (Quantity)	Part Number
1	Brake line, lower (1)	Not sold separately
3	Washer, sealing (small ID) (2)	41731-01
5	Cable strap (2)	10065
8	Screw (for Kit 45770-08 only)	3594
9	Washer, flat (for Kit 45770-08 only)	6703

Table 7. Service Parts: Lower Brake Line Kits 38132-11A, 38135-11A, 38186-11A, 41800022A, 41800308, 41800368, 41800371

Item	Description (Quantity)	Part Number
1	Brake line, lower (caliper to HCU)	Not sold separately
2	Brake line, intermediate (HCU to upper brake line)	Not sold separately
3	Washer, sealing (small ID) (2) (41800368 and 41800371 only) Washer, sealing (small ID) (4) (All other kits)	41756-09 . 41731-01 .
4	Washer, sealing (large ID) (2)	41733-88
5	Cable strap (2)	10065

Table 8. Service Parts: Lower Brake Line Kits 41800032A, 41800050, 41800076A

Item	Description (Quantity)	Part Number
1	Brake line, lower	Not sold separately
3	Washer, sealing (small ID) (2)	41731-01
10	Screw	4240
11	Lockwasher	7118

Table 9. Items Mentioned in Text

Item	Description (Quantity)
A	Upper brake line (see Tables 1-3)
B	Hydraulic Control Unit (HCU)
C	Banjo bolts
D	Screw
E	Brake line clip (2)
F	Caliper, front brake