MODULAR BRAKE LINE KITS

J044882014-07-15

GENERAL

NOTE

These instructions describe the installation of upper and lower brake lines on FXDF (Fat Bob™) models. Upper and lower brake lines on 2014-later FXDL (Low Rider^® models install in a similar manner.

FXDF or 2014-later FXDL models: When installing upper and lower brake lines, discard any instructions included in the Upper Brake Line Kit. Use these instructions instead.
Models except FXDF/ 2014-later FXDL: When installing upper brake line on any other model, refer to the instructions included in the Lower Brake Line Kit for that model.

Kit Numbers

A Diamondback™ or Diamond-Black Upper Brake Line Kit (purchased separately) is required for installation of this kit. These upper brake line kits are available in various master cylinder banjo angles and brake line lengths. Shorter or longer lines are necessary when certain modifications (like optional handlebars) are made to the vehicle. See the P&A retail catalog or a Harley-Davidson dealer.

Table 1. Brake Line Kits

Fitment	Diamond-Black Kit	Diamondback Kit
Non-ABS, lower only	48928-10	42112-08A
ABS, lower only	41800078	41800048

WARNING

Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a)

Models

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

Installation Requirements

Loctite^® 243 Medium Strength Threadlocker and Sealant - Blue (Part No. 99642-97) is required for proper installation of this kit.

Fresh, uncontaminated DOT 4 brake fluid from a sealed container is also needed.

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

Kit Contents

See Table 2 and Table 3.

PREPARATION

WARNING

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

NOTE

WITH security siren: With security fob present, turn ignition switch ON. See the service manual. After system is disarmed, turn ignition switch OFF. IMMEDIATELY remove the main fuse.
WITHOUT security siren: See the service manual. Remove main fuse.

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)

See the service manual. Drain the brake fluid from the front brake reservoir and lines.

INSTALLATION, NON-ABS MODELS

Original Front Brake Line Removal

NOTE

Cover painted parts to protect finish.

Disconnect the front brake line assembly from the front brake master cylinder and front brake calipers. Save the master cylinder and caliper banjo bolts. Discard all steel and rubber sealing washers.
Note the orientation of the ground wire lug. Remove the self-tapping hex head screw and star washer retaining the brake line P-clamp and ground wire lug to the upper triple clamp. Save the screw and star washer for assembly. Discard the clamp.
Remove and discard the brake line tee attaching screw on the underside of the fork stem. Remove and discard the front brake line assembly from the vehicle.

Braided Front Brake Line Installation

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, determine the proper Upper Brake Line Kit by using the Cable and Brake Line Measurement Tool Kit. See a Harley-Davidson dealer for assistance.

NOTICE

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

See Figure 1. Obtain the new lower brake line assembly (2).

NOTE

The lower brake line manifold is mounted so the two lines to the calipers go to the rear and down.

Position the brake line manifold (3) to the underside of the fork stem. Center the lower legs of the brake line between the forks. Obtain the brake line manifold attaching screw (5) from the Lower Brake Line Kit. Apply a few drops of Loctite 243 (blue) to the screw threads. Fasten the manifold to the fork stem through the center hole as shown. Tighten the screw to 10.8–13.6 N·m (8–10 ft-lbs).

NOTE

The brake lines must not contact the forks. If either brake line is touching the fork, loosen the brake manifold, reposition and tighten.

The gap between the fork tube and the brake line leg must appear equal on each side.

1	Front of vehicle
2	Lower brake line assembly
3	Brake line manifold
4	Lower brake line male JIC fitting
5	Screw
6	Upper brake line assembly
7	Upper brake line female JIC fitting

Figure 1. Front Brake Line Assembly (Non-ABS)

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)

At each front brake caliper, install a new steel and rubber sealing washer from the Lower Brake Line Kit on each side of the brake line banjo fitting. Insert the banjo bolt (removed earlier) through the washers and fitting. Thread the bolt into the caliper. Tighten to 29.8–36.6 N·m (22–27 ft-lbs).

Obtain the new upper brake line assembly (6). Route the upper brake line:

a. from the master cylinder,

b. along the front of the handlebar (as shown in Figure 2 ),

c. behind the upper triple clamp,

d. down to the male fitting on the upper end of the lower brake line (2).

1	P-clamp
2	Lower front brake line
3	Stock self-tapping screw
4	Stock star washer
5	Stock ground wire
6	Upper front brake line
7	Banjo fitting
8	Copper gasket (2)
9	Stock banjo bolt

Figure 2. Upper Front Brake Line Routing

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)

Install the banjo fitting (7) of the new upper brake line at the master cylinder using a new copper gasket (8) from the Upper Brake Line Kit on each side of the fitting.

Install the banjo bolt (9, removed earlier) snug, but do not fully tighten now.

Orient the P-clamp (1) (included in this kit) as shown so the brake line is held away from the vehicle. Insert the upper brake line into the P-clamp. Position the P-clamp on the brake line so the brake line routes smoothly.

Obtain the self-tapping screw (3) and star washer (4) removed earlier. Place the star washer onto the screw threads, followed by the ground wire lug (5).

Insert the screw threads through the hole in the P-clamp. Attach the P-clamp to the mounting hole on the upper triple clamp of the vehicle with the screw. Do not fasten securely now.

10.

Review the upper brake line routing from the master cylinder, along the handlebar, through the P-clamp, to where the upper and lower brake lines meet. Verify that the brake line routing is smooth, and does not interfere with any vehicle components. If necessary, adjust the position of the P-clamp.

11.

See Figure 1. Position the upper brake line female JIC fitting swivel nut (7) to the male fitting (4) on the lower brake line. Install the nut onto the male fitting finger-tight. Do not twist the upper or lower brake lines while tightening.

NOTE

When using wrenches to final tighten the fitting, turn only the swivel nut. Do not allow the male fitting or manifold tubing to turn.

12.

Tighten the swivel nut (7), either:

past finger-tight 45° (1/8 extra turn), relative to the male fitting (4) using two 7/16 in open-end wrenches OR
to 5.1–7.3 N·m (45–65 in-lbs).

Make sure that only the swivel nut turns.

INSTALLATION, ABS MODELS

Original Front Brake Line Removal (ABS)

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)

NOTE

Cover painted parts to protect finish.

Disconnect the front brake line assembly from the front brake master cylinder and front brake calipers. Save the master cylinder and caliper banjo bolts. Discard all the steel and rubber sealing washers.
See Figure 4. Disconnect the OE brake lines (1) and (2) from the brake line manifold. Do not remove the brake lines from the vehicle.
See Figure 3. Remove the screw (2) holding the manifold to the lower fork clamp. Remove and discard the OE front brake line assembly from the vehicle. Save the screw for the installation of the new brake line.

Braided Front Brake Line Installation (ABS)

WARNING

NOTICE

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

1.	See Figure 3. Position the brake line manifold (1) to the underside of the fork stem. Center the lower legs of the brake line between the forks. Secure the manifold to the fork stem with the previously removed screw (2). Tighten the screw to 4.1–5.4 N·m (36–48 in-lbs).
2.	See Figure 4. Connect the OE ABS brake lines (1 and 2) to the braided brake line manifold. Tighten the tube nuts to 13.5–16.3 N·m (10–12 ft-lbs) .
	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)
3.	At each front brake caliper, install a new steel and rubber sealing washer from the Lower Brake Line Kit on each side of the brake line banjo fitting (4). Insert the banjo bolt (3, removed earlier) through the washers and fitting. Thread the bolt into the caliper. Tighten to 29.8–36.6 N·m (22–27 ft-lbs).
4.	Obtain the new upper brake line assembly. Route the upper brake line: a. from the master cylinder, b. along the front of the handlebar (as shown in Figure 2 ), c. behind the upper triple clamp, d. down to the male fitting on the upper end of the 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)
5.	Install the banjo fitting (7) of the new upper brake line at the master cylinder using a new copper gasket (8) from the Upper Brake Line Kit on each side of the fitting.
6.	Install the banjo bolt (9, removed earlier) snug, but do not fully tighten now.
7.	See Figure 2. Use the screw and washer from this kit and the P-clamp from the Lower Brake Line Kit. Attach the brake line to the upper fork clamp. Orient the P-clamp so the line routes smoothly away from the vehicle.
8.	Check the upper brake line routing from the master cylinder, along the handlebar, through the P-clamp, to where the upper and lower brake lines meet. Verify that the brake line routing is smooth, and does not interfere with any vehicle components. If necessary, adjust the position of the P-clamp.
9.	See Figure 3. Position the upper brake line (3) female JIC fitting swivel nut (5) to the male JIC fitting (4) on the lower brake line. Install the nut onto the male fitting finger-tight. Do not twist the upper or lower brake lines while tightening. NOTE When using wrenches to final tighten the fitting, turn only the swivel nut. Do not allow the male fitting or manifold tubing to turn.
10.	Tighten the swivel nut (5), either:

past finger-tight 45° (1/8 extra turn), relative to the male fitting (4) using two 7/16 in open-end wrenches OR
to 5.1–7.3 N·m (45–65 in-lbs).

Make sure that only the swivel nut turns.

1	Manifold
2	Shoulder bolt
3	Upper brake line
4	Brake line male JIC fitting
5	Brake line female JIC swivel nut fitting

Figure 3. Lower Front ABS Brake Line

1	Brake line (2)(Do not remove)
2	Brake line
3	Banjo bolt (2)
4	Banjo fitting (2)

Figure 4. Front Lower ABS Brake Line

BRAKE LINE ROUTING CHECK

1.	Using a motorcycle lift, raise the vehicle frame to extend the front forks fully. Verify that the lower brake lines are not pulled tight when forks are fully extended.
2.	Fully compress the forks to check that the lower brake lines do not interfere with motorcycle components.
3.	Slowly turn handlebars to full left lock and full right lock. Verify that there is no binding.
4.	If the brake lines interfere or catch on motorcycle components or if the routing does not appear correct, adjust the brake lines and/or banjo fitting orientation. When all adjustments are complete, tighten the master cylinder banjo bolt to 29.8–36.6 N·m (22–27 ft-lbs).
5.	Hold the P-clamp and ground wire lug in the proper orientation. Tighten the P-clamp screw securely.

FINAL ASSEMBLY

See the service manual. Bleed the brake fluid from the front brake reservoir and lines.

Install one end of a length of clear plastic tubing over the right side caliper bleeder screw. Place the free end in a suitable container. Verify that both caliper bleeder screws are closed tightly.
Position the handlebar or temporarily adjust the right side handlebar control to make the front brake master cylinder reservoir as level as possible. Remove the master cylinder cover.

WARNING

Clean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury. (00504d)

NOTE

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.

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.

6.	Add DOT 4 HYDRAULIC BRAKE FLUID to the master cylinder reservoir per the instructions in the service manual. Do not reuse old brake fluid. Use only DOT 4 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)
7.	Verify proper operation of the master cylinder relief port by actuating the brake lever. If all internal components are working properly, a slight spurt of fluid breaks the fluid surface in the reservoir compartment.
8.	Pump the front brake hand lever to build up hydraulic pressure.
9.	While holding the lever, open the right side caliper bleeder screw 3/4-turn. Brake fluid flows from the bleeder screw through the tubing. Close the bleeder screw as soon as a loss of pressure is detected. Allow the brake hand lever to return slowly to its released position. NOTE Pay careful attention to the fluid level in the master cylinder reservoir during the bleeding procedure. To avoid drawing air into the brake lines, always add fluid as needed to the reservoir before it becomes empty.
10.	Repeat Steps 5 and 6 until all air bubbles are purged and a solid column of fluid is observed in the bleeder tube.
11.	Final tighten the right side bleeder screw to 9–11.3 N·m (80–100 in-lbs). Install the bleeder cap.
12.	Install one end of a length of clear plastic tubing over the left side caliper bleeder screw. Place the free end in a suitable container. Add brake fluid to the master cylinder reservoir per the service manual. Repeat Steps 5 through 8 for the left side brake line.
13.	Add brake fluid as needed to the master cylinder reservoir per the service manual. NOTE Before installing the master cylinder cover, verify that the cover gasket bellows is not expanded. If bellows is expanded, brake fluid is ejected from the reservoir during cover installation, which could damage the vehicle finish.
14.	The shape of the master cylinder cover has one end thinner than the other. Install the cover (with gasket compressed) on the master cylinder reservoir so the thicker end is positioned above the brake line fitting. Install two screws to fasten the cover to the reservoir. Tighten the screws to 0.7–0.9 N·m (6–8 in-lbs).

COMPLETION

NOTE

Verify that the ignition switch is OFF before installing the main fuse.

1.	See the service manual. Install the main fuse.
2.	Turn the ignition switch to IGN, but do not start the motorcycle. Actuate the front brake hand lever to verify 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)
3.	Test ride motorcycle at low speed. Repeat the bleeding procedure if brakes feel spongy.

SERVICE PARTS

Table 2. Service Parts, Upper Brake Line Kits - Purchase Separately

Item	Description (Quantity)
1	Brake line assembly, upper
2	Copper gasket, brake line (2)
3	Cable strap (3)

Table 3. Service Parts, Lower Brake Line Kit (Kits 42112-08A and 48928-10)

Item	Description (Quantity)	Part Number
1	Brake line assembly, lower	Not sold separately
2	Gasket, brake line (4)	41731-01
3	Screw, button head	923
4	P-clamp	10059A

Table 4. Service Parts, Lower Brake Line Kit (Kits 41800078 and 41800048)

Item	Description (Quantity)	Part Number
1	Brake line assembly, lower	Not sold separately
2	Gasket, brake line (4)	41731-01
3	Screw	4240
4	Lockwasher	7118
5	P-clamp	10059A