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DYNA DIAMONDBACK REAR BRAKE LINE KIT
J044362007-06-01
GENERAL
Kit Number
45754-08
Models
For model fitment information, please 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 D.O.T. 4 brake fluid from a sealed container will be 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 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
See Figure 2 and Table 1.
INSTALLATION
Preparation
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)
IMPORTANT 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).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of D.O.T. 4 brake fluid.
  1. Drain the rear brake master cylinder.
    1. Open the bleeder nipple cap on the rear brake caliper.
    2. Install one end of a length of clear plastic tubing over the caliper bleeder valve, while placing the free end in a suitable container.
    3. Open the bleeder valve about 1/2-turn. Pump the brake pedal to drain the brake fluid from the reservoir and line.
    4. Close the bleeder valve.
Rear Brake Line Removal
1. Disconnect the wiring harness connectors [121] from the brake light switch spade terminals.
2. Remove the existing frame P-clamp. Discard the clamp, but save the clamp mounting screw and lockwasher.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
3. Carefully make note of the rear brake line routing and orientation of the banjo fittings, then remove the existing brake line. Note that the brake light switch is an integral part of the banjo bolt at the master cylinder end of the brake line. See Figure 1.
1Switch terminal (2)
2Terminal isolator wall
Figure 1. Banjo Bolt With Integral Rear Stop Lamp Switch
NOTE
This kit contains all gaskets needed for replacement.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
Braided Rear Brake Line Installation
1. See Figure 2. Run the new braided brake line (1) along the same route as the original brake line.
a. Lubricate the new brake line gaskets (steel/rubber washers) (2) from the kit with D.O.T. 4 Hydraulic Brake Fluid.
b. Note that the banjo bolt with the integral brake light switch installs at the master cylinder (forward) end. Use the O.E. banjo bolts (A) and (B), and new brake line gaskets (one gasket on each side of brake line banjo fitting) to fasten the braided rear brake line at the rear brake master cylinder and the rear brake caliper.
c. Tighten the banjo bolts to 23–30 N·m (17–22 ft-lbs).
NOTE
To prevent interference with the switch terminal isolator wall (between the terminals), align the female wiring harness connectors with the brake light switch terminals so the flat side of the metal receptacle inside the connector housing faces the isolator wall. See Figure 1.
2. Connect the wiring harness connectors [121] detached earlier onto the brake light switch spade terminals.
3. Secure the braided brake line in place with the P-clamp (3) from the kit and the mounting screw (C) and lockwasher (D) saved earlier.
FINAL ASSEMBLY
Bleed the brake fluid from the rear brake reservoir and line per the instructions in the Service Manual.
Refer to Steps 1 through 10 that follow.
  1. Install one end of a length of clear plastic tubing over the caliper bleeder valve, and place the free end in a suitable container. Verify that the caliper bleeder valve is closed tightly.
  2. Remove the rear master cylinder cover. Stand the motorcycle upright so that the master cylinder is level.
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)
NOTE
The brake system on this vehicle uses D.O.T. 4 BRAKE FLUID. 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.
IMPORTANT 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).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of D.O.T. 4 brake fluid.
4. Add D.O.T. 4 HYDRAULIC BRAKE FLUID to the master cylinder reservoir per the instructions in the Service Manual. Do not reuse old brake fluid. Use only D.O.T. 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)
5. Verify proper operation of the master cylinder relief port. Actuate the rear brake foot pedal. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
6. Pump the brake pedal to build up hydraulic pressure.
7. While holding the pedal, open the caliper bleeder valve about 1/2-turn. Brake fluid (and possibly air bubbles) will flow from the bleeder valve through the tubing. Close the bleeder valve as soon as a loss of pressure is detected. Allow the brake pedal 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 completely empty.
8. Repeat Steps 5 and 6 until all air bubbles are purged, and a solid column of fluid is observed in the bleeder tube.
9. Final tighten the bleeder valve to 9–11.3 N·m (80–100 in-lbs), and install the bleeder cap.
10. Add brake fluid as needed to the master cylinder reservoir until the fluid level is about 1/8 inch (3.2 mm) from the top.
NOTE
Before installing the master cylinder cover, verify that the cover gasket bellows is not expanded. If the bellows is expanded, brake fluid will be ejected from the reservoir during cover installation, which could damage the vehicle finish.
11. Install the cover (with gasket compressed) on the master cylinder reservoir. Install two Phillips-head screws to fasten the cover to the reservoir. Tighten the screws to 0.7–0.9 N·m (6–8 in-lbs).
12. Turn the Ignition/Light Key Switch to IGNITION, but do not start the motorcycle. Actuate the rear brake foot pedal 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)
13. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.
SERVICE PARTS
Figure 2. Service Parts, Braided Rear Brake Line Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Rear brake line, Diamondback
Not sold separately
2
Gasket, brake line (2)
41731-01
3
P-clamp
10059A
Items mentioned in text, but not included in kit:
A
Original equipment banjo bolt
(with integral brake light switch)
B
Original equipment banjo bolt
C
Original equipment P-clamp mounting screw
D
Original equipment lockwasher