0/0
ABS BRAKE LINE KITS
J046522009-11-18
GENERAL
Kit Numbers
46049-09, 41825-09, 40683-09, 40909-09, 41770-09,
48946-10, 48947-10, 48949-10
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 ABS Models:
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)
Additional Parts Required
An Upper Brake Line Kit (purchased separately) is required for installation of this kit. 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.
DOT 4 brake fluid (part number 99953-99A) is required for the installation of this kit.
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
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)
  • If installing different handlebars, measure the change in distance that will be required from the end of the stock brake line to the brake master cylinder.
  • Compare this revised length to the brake line provided in your kit.
  • If the line is more than 2.0 in. (50.8 mm) longer or more than 1.0 in. (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct brake line length.
Kit Contents
See Figure 1 and Table 2.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Remove the main fuse following the instructions in the service manual.
  2. Refer to the Front Brake Line Removal section in the service manual and remove the components to access the necessary brake components.
    3. NOTE
    Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching.
    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).
  3. Drain the brake fluid from the front brake reservoir and lines following the instructions in the service manual.
  4. 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. Note the brake line routings and cable strap locations before removing brake lines.
  5. Remove the appropriate brake line(s) following the instructions in the service manual. Save the master cylinder banjo bolt, the caliper banjo bleeder bolts and the brake line tee attaching screw for later assembly. Discard all copper sealing gaskets.
INSTALLATION
NOTE
Some stock Touring models are equipped with a locating roll pin on the mounting surface for the lower brake line manifold. Remove the roll pin before installing this brake line kit.
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)
1. Lower Brake Line: Install the brake line following the instructions in the service manual or Instruction Sheet. Install the banjo bolts and brake line tee attaching screw removed earlier. Replace copper gaskets with new copper gaskets provided in this kit.
2. Upper and Middle Brake Lines: See Figure 1. The stock upper brake line is a one-piece brake line. When replacing the upper brake line (A) (purchased separately), connect it to the middle brake line (2) (available in this kit). Install the banjo bolts removed earlier. Replace copper gaskets with new copper gaskets provided in this kit.
3. When connecting the brake line banjo fittings to the ABS module, verify the fittings are connected to the correct ports:
Table 1. ABS Module Port Connections
ABS Module Port Marking
Brake Line Banjo Fitting
F
From Front Brake Calipers
R
From Rear Brake Caliper
MF
From Front Master Brake Cylinder
MR
From Rear Master Brake Cylinder
Brake Line Routing Check
1. Using a motorcycle lift, raise the vehicle frame so that the front forks reach maximum extension. 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. Turn the handlebars to the full-left and full-right fork stops to verify smooth routing and proper slack in the brake lines, and to verify the brake lines do not contact any vehicle components.
4. 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. When all adjustments are complete, tighten the master cylinder banjo bolt to 17–20 N·m (12.5–14.5 ft-lbs). Tighten the caliper banjo bolts to 23.1–25.8 N·m (17–19 ft-lbs).
FINAL ASSEMBLY
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
Do not mix grades of brake fluid as they are not compatible.
1. Add DOT 4 HYDRAULIC BRAKE FLUID to the master cylinder reservoir following 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)
2. Bleed the brake system following the instructions in the service manual.
3. Verify proper operation of the brake system following the instructions in the service manual.
4. Install cable straps (provided in this kit) in the same locations as the stock cable straps.
5. Install heat shrink tubing on the upper-to-middle brake line connection. Follow the instructions in the service manual for installing heat shrink tubing.
6. Verify that the ignition key switch is turned to the OFF position.
7. Install the main fuse following the instructions in the service manual.
8. Turn the ignition key switch to IGNITION, but do not start the motorcycle. Actuate the front brake hand lever to verify operation of the tail lamp.
9. Install components removed earlier following 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)
10. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure following the instructions in the service manual.
SERVICE PARTS
Figure 1. Service Parts: ABS Brake Line Kits
Table 2. Service Parts: ABS Brake Line Kits
Kit Number
Item
Description (Quantity)
Part Number
41825-09
1
ABS Diamondback Brake Line Kit - Lower
40683-09
46049-09
ABS Diamondback Brake Line Kit - Lower
40909-09
48946-10
ABS Diamond-Black Brake Line Kit - Lower
48949-10
  • Brake line, lower
Not Sold Separately
  • Copper gasket, brake line (4)
41751-06A
  • Cable strap (3)
10006
41825-09
2
ABS Diamondback Brake Line Kit - Middle
41770-09
46049-09
ABS Diamondback Brake Line Kit - Middle
41770-09
48946-10
ABS Diamond-Black Brake Line Kit - Middle
48947-10
  • Brake line, middle
Not Sold Separately
  • Copper gasket, brake line (2)
41751-06A
  • Cable strap (3)
10006
  • Heat shrink tubing
70691-09
Items referenced in text, but not included in kit:
A
Diamondback or Diamond-Black Upper Brake Line Kit (purchased separately)