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MODULAR BRAKE LINE KITS
J044312013-06-14
GENERAL
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)
NOTE
ABS and NON-ABS models share upper brake line kits, however ABS model installation instructions are found with the ABS Lower Brake Line Kit instructions (-J04652 or -J05790).
For Non-ABS Models:
These instructions describe the installation of upper and lower brake lines on non-ABS Electra Glide®, Street Glide®, Road King®, Road Glide®, Tri Glide™ Ultra Classic® and Street Glide® Trike models ONLY. For installation of the upper brake line on any other model, including ABS, refer to the instruction sheet included in the Lower Brake Line Kit for that model.
For 2014-later Trike Models:
2014-later Trike models and earlier NON-ABS Trike models share upper brake line kits, however 2014-later linked brake model installation instructions are found with the Linked Lower Brake Line and Linked Adapter Kit instructions (-J05690 or -J05691).
Kit Numbers
Table 1. Upper Brake Line Kits (Banjo Angle 0° - Straight)
Diamond-Black
Kit
Diamondback
Kit
Length
N/A
42393-08
18 inch
N/A
42396-08
19 inch
N/A
42399-08
20 inch
N/A
42428-08
21 inch
41800279A
42439-08A
22 inch
N/A
42461-08
23 inch
N/A
42484-08A
24 inch
N/A
42527-08A
26 inch
41800348
42548-08A
28 inch
N/A
42599-08
30 inch
41800350
44081-09A
32 inch
N/A
46336-09
34 inch
41800281
46566-09
36 inch
Table 2. Upper Brake Line Kits (Banjo Angle 35°)
Diamond-Black
Kit
Diamondback
Kit
Length
N/A
44106-08
18 inch
N/A
44138-08
19 inch
48940-10
44206-08
20 inch
N/A
44213-08
21 inch
N/A
44250-08A
22 inch
38118-10
44259-08
23 inch
N/A
44306-08A
24 inch
38120-10
44340-08
26 inch
38139-10
44355-08A
28 inch
38141-10
44461-08
30 inch
N/A
40958-09
32 inch
41800282
46711-09
34 inch
N/A
46727-09
36 inch
38143-10
38147-10
40 inch
38145-10
38149-10
44 inch
Table 3. Upper Brake Line Kits (Banjo Angle 90°)
Diamond-Black
Kit
Diamondback
Kit
Length
48931-10
44790-08
18 inch
48929-10
45007-08
19 inch
N/A
45082-08
20 inch
48944-10
45094-08
21 inch
N/A
45131-08
22 inch
N/A
45134-08
23 inch
N/A
45150-08
24 inch
N/A
45223-08
26 inch
N/A
45251-08
28 inch
N/A
45260-08
30 inch
48995-10
44162-09
32 inch
N/A
46743-09
34 inch
N/A
46747-09
36 inch
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.
Table 4. Lower Brake Line Kits
Diamond-Black Kit
Diamondback Kit
Models
41800280
44905-08
2008-2013 Electra Glide®
and Street Glide®
48942-10
44907-08
2008-2013 Road King®
and Road Glide®
48938-10
45818-07
1994-2007 Road King®
and Road Glide®
N/A
45820-07
1996-2007 Electra Glide®
and Street Glide®
N/A
83666-10
2008-2013 Street Glide® Trike
and Tri Glide™ Ultra Classic®
41800338
41800336
2014-Later Electra Glide®,
Street Glide® and Road King®
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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 and is available from a Harley-Davidson dealer.
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.
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)
Fresh, uncontaminated DOT 4 (H-D Part No. 99953-99A) or DOT 5 brake fluid (H-D Part No. 99902-77) from a sealed container is required. See the service manual.
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 50.8 mm (2.0 in) longer or more than 25.4 mm (1.0 in) shorter than the above measured distance, see a Harley-Davidson dealer for the correct brake line length.
Kit Contents
See Table 6 , Table 7 , Table 8 and Table 9.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the service manual and follow the instructions given to remove the main fuse.
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)
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).
  1. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual.
    2. NOTE
    Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result.
  2. Disconnect the front brake lines following the instructions in the appropriate service manual. Save the master cylinder banjo bolt, the caliper banjo bolts (for 1994-2007 models), the caliper banjo bleeder bolts (for 2008-later models), the brake line tee attaching screw (for 2008-2013 models) and the hardware mounting the plastic brake line mount bracket at the rear of the lower triple-clamp (for 2014-later models) for later assembly. Discard all sealing washers and the plastic brake line mount bracket (for 2014-later models).
  3. 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.
INSTALLATION (2013-Earlier Models)
  1. 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.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
1. See Figure 1. Obtain the new lower brake line assembly (2).
NOTE
The lower brake line manifold tee is mounted so the two lines to the calipers go to the rear and down.
2. Position the brake line tee (3) to the underside of the fork stem, and center the lower legs of the brake line between the forks.
3. Install the brake line tee attaching screw (4) removed earlier and fasten the tee to the fork stem. Tighten the screw to 13.6–20.3 N·m (10–15 ft-lbs).
NOTE
The brake lines must not contact the forks. If either brake line is touching the fork, loosen the brake tee, reposition and re-tighten.
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)
4. For 2008-Later Models: At each front brake caliper, position a new copper gasket from the Lower Brake Line Kit on each side of the brake line banjo fitting. Insert the banjo bleeder bolt (removed earlier) through the washers and fitting. Thread the bolt into the caliper and tighten to 23–25.8 N·m (17–19 ft-lbs). For 1994-2007 Models: At each front brake caliper, position a new sealing washer (steel/rubber) 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 and tighten to 23–29.8 N·m (17–22 ft-lbs).
1Upper brake line assembly
2Lower brake line assembly
3Brake line tee
4Screw
5Upper brake line female fitting swivel nut
6Lower brake line male fitting
Figure 1. 2013-Earlier Front Brake Lines (Road King Model Shown)
5. Obtain the new upper brake line assembly (1). Route the upper brake line from the master cylinder through the fairing or headlamp nacelle area to the male fitting on the upper end of the lower brake line.
6. Install the banjo fitting of the new upper brake line at the master cylinder, using a new copper gasket from the Upper Brake Line Kit on each side of the fitting.
7. Install the banjo bolt (removed earlier) snug, but do not fully tighten at this time.
8. For Road King and Road Glide models: Using cable straps from the Lower Brake Line Kit, tie the brake line to the handlebar riser. For Electra Glide models: Route the upper brake line the same as the original equipment brake line, along the handlebar between the inner fairing and the inner fairing cap. For ALL models: Review the routing of the upper brake line from the master cylinder, through the fairing or head lamp nacelle area, to the junction of the 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 the position of the cable straps.
NOTE
When tightening the fitting, turn only the swivel nut. Do not allow the male fitting or manifold tubing to turn.
9. See Figure 1. Position the upper brake line female fitting swivel nut (5) to the male fitting (6) on the lower brake line. Thread the nut onto the male fitting finger-tight, do not twist the upper or lower brake lines while tightening.
10. See Figure 3. Using two 7/16 inch open-end wrenches, tighten the swivel nut (2) past finger-tight by 45 degrees (1/8 turn) relative to the male fitting (4) or tighten to 5.1–7.3 N·m (45–65 in-lbs).
INSTALLATION (2014-Later Models)
  1. Verify that the correct upper and lower Brake Line Kits have been purchased.
  • 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.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
11. See Figure 2. Obtain the new upper (1) and lower (2) brake line assemblies.
NOTE
The lower brake line manifold is mounted so the two lines to the calipers go to the rear and down.
12. Position the lower brake line (2) to the backside of the lower triple clamp, and center the lower legs of the brake line between the forks oriented rearward and down.
13. Obtain the large (6) and small (7) brake line P-clamps and attachment screws removed earlier from the plastic brake line mount bracket. Attach the lower brake line assembly and fasten the P-clamps to the triple clamp. The right hand p-clamps will overlap. Tighten the screw to 13.6–20.3 N·m (10–15 ft-lbs).
NOTE
The brake lines must not contact the forks. If either brake line is touching the fork, loosen the p-clamps, reposition and re-tighten.
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)
14. At each front brake caliper (4) position a new copper gasket from the Lower Brake Line Kit on each side of the brake line banjo fitting. Insert the banjo bleeder bolt (removed earlier) through the gaskets and banjo fitting.
15. Orient the banjo fitting against the rotation stop on the caliper and thread the bolt into the caliper. Tighten to 23–25.8 N·m (17–19 ft-lbs).
16. Route the upper portion of the brake line (1) from the master cylinder (3) through the fairing or headlamp nacelle area to the male fitting on the upper end of the lower brake line (5).
17. Install the banjo fitting of the new upper brake line at the master cylinder, using new copper gaskets from the Upper Brake Line Kit on each side of the fitting.
18. Install the banjo bolt (removed earlier) snug, but do not fully tighten at this time.
1Upper brake line assembly (master cylinder to female swivel nut fitting)
2Lower brake line assembly (male fitting to calipers)
3Master cylinder
4Caliper
5Swivel nut connection of upper and lower brake lines
6P-clamp, large
7P-clamp, small (2)
Figure 2. 2014-Later Front Non-ABS Brake Lines
19. For Road King models: Route the upper brake line the same as the original equipment brake line along the handlebar to fit under the riser cover into the headlamp nacelle and secure as needed using cable straps from the Upper Brake Line Kit. For Electra Glide models: Route the upper brake line the same as the original equipment brake line, along the handlebar between the inner fairing and the inner fairing cap and secure as needed using cable straps from the Upper Brake Line Kit. For ALL models: Review the routing of the upper brake line from the master cylinder, through the fairing or head lamp nacelle area, to the junction of the 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 the position of the cable straps.
20. See Figure 3. Position the upper brake line female fitting swivel nut (2) to the male fitting (4) on the lower brake line. Thread the nut onto the male fitting finger-tight. Do not twist the upper or lower brake lines while tightening.
21. Using two 7/16 inch open-end wrenches, tighten the swivel nut (2) past finger tight by 45 degrees (1/8 turn) relative to the male fitting (4) or torque to 5.1–7.3 N·m (45–65 in-lbs).
1Upper brake line
2Female swivel nut
3Lower brake line
4Male fitting
Figure 3. Upper to Lower Brake Line Fittings
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. See Table 5. When all adjustments are complete, tighten the master cylinder banjo bolt to specification.
Table 5. Banjo Bolt Torque Values
Models
Master Cylinder Banjo Bolt Torque
1994-2007 Models
17-22 ft-lbs (23.0-29.8 Nm)
2008-Later Models
12.5-14.5 ft-lbs (17-20 Nm)
FINAL ASSEMBLY
NOTE
This instruction sheet covers motorcycle models that use either DOT 4 Hydraulic Brake Fluid or DOT 5 Silicone Hydraulic Brake Fluid. The specific model'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.
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.
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 to help protect against damage to finish caused by spillage or splash of DOT 4 brake fluid.
1. Add the appropriate brake fluid to the master cylinder reservoir following the instructions in the service manual. Do not reuse old brake fluid. Only use 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. 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.
3. Bleed the brake system following the instructions in the appropriate service manual.
NOTE
Before installing the master cylinder cover, verify that the cover gasket bellows is not expanded. If bellows is expanded, brake fluid will be ejected from the reservoir during cover installation, which could damage the vehicle finish.
4. Note that the shape of the master cylinder cover has one end thinner than the other. For 2008 Models: Install the cover (with gasket compressed) on the master cylinder reservoir so the thinner end is positioned above the brake line fitting. For 1994-2007 Models: Install the cover (with gasket compressed) on the master cylinder reservoir so the thicker end is positioned above the brake line fitting. For All Models: Install two screws to fasten the cover to the reservoir. Tighten the screws to 0.7–0.9 N·m (6–8 in-lbs).
5. Verify that the ignition key switch is turned to the OFF position.
6. Refer to the service manual and follow the instructions to install the main fuse or connect the battery cable.
7. Turn the ignition key switch to IGNITION, but do not start the motorcycle. Actuate the front brake hand lever to verify operation of the brake lamp.
8. Install any other removed components 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)
9. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.
SERVICE PARTS
Table 6. Service Parts, Upper Brake Line Kits - Purchase Separately
Item
Description (Quantity)
Part Number
1
Brake line assembly, upper
Not sold separately
2
Copper gasket, brake line (2)
41751-06A
3
Cable strap (3)
10006
Table 7. Service Parts, Lower Brake Line Kits 44905-08, 44907-08, 48942-10, 83666-10 and 41800280
Item
Description (Quantity)
Part Number
1
Brake line assembly, lower
Not sold separately
2
Copper gasket, brake line (4)
41751-06A
3
Cable strap (3)
10006
Table 8. Service Parts, Lower Brake Line Kits 45818-07, 45820-07 and 48938-10
Item
Description (Quantity)
Part Number
1
Brake line assembly, lower
Not sold separately
2
Sealing washer (4)
41731-01
3
Cable strap (3)
10006
Table 9. Service Parts, Lower Brake Line Kits 41800336 and 41800338
Item
Description (Quantity)
Part Number
1
Brake line assembly, lower
Not sold separately
2
Copper gasket (4)
41751-06A
3
P-clip, large
Not Sold Separately
4
P-clip, small (2)
Not Sold Separately
5
Cable strap (3)
10006