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XR 1200 BRAIDED STAINLESS STEEL FRONT BRAKE LINE KIT
J045572008-06-30
GENERAL
Kit Number
45851-08
Models
This kit fits 2008 and later XR 1200 Sportster® models.
Tools and Supplies Required
Loctite® 243 Threadlocker and Sealant - Blue (H-D part number 99642-97) is required for the proper installation of this kit.
Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed.
NOTE
The brake system on this vehicle uses DOT 4 BRAKE FLUID. Do not mix grades of brake fluid as they are not compatible.
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 this model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 4 and Table 1.
INSTALLATION
Preparation
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.
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).
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.
Original Front Brake Line Removal
NOTE
Cover the front fender and fuel tank with H-D Service Covers or clean shop towels to prevent scratching the finish.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
3. Carefully make note of the brake line routing. See Figure 1. Disconnect the front brake line assembly (1) from the front brake master cylinder and front brake calipers. Save the master cylinder and caliper banjo bolts (2 and 9). Discard all the sealing washers (3 and 8).
NOTE
This kit contains all sealing washers needed for replacement.
1Front brake line assembly
2Banjo bolt, 10 mm (2)
3Brake line gasket, 10 mm ID (4)
4P-clamp
5Hex head screw with washer
6Brake line manifold attaching screw
7Front brake line guide
8Brake line gasket, 12 mm ID (2)
9Banjo bolt, 12 mm
10Front of vehicle
Figure 1. Original Front Brake Line Assembly
4. Note the orientation of the brake line P-clamp (4). Remove the hex head screw with washer (5) retaining the P-clamp to the lower triple clamp. Retain the screw, but discard the clamp.
5. Remove and retain the brake line manifold attaching screw (6) on the underside of the fork stem. Remove and retain the front brake line guide (7). Remove the front brake line assembly from the vehicle and discard it.
6. Refer to REPAIR AND REPLACEMENT PROCEDURES in the service manual for instructions on re-use of fasteners with THREADLOCKING AGENTS.
Braided Front Brake Line Installation
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
7. See Figure 4. Obtain the new braided front brake line assembly (1). Route the upper line, from the rear, over the lower triple clamp but under the throttle and idle cables.
8. Position the front brake line guide (A) to the underside of the fork stem, with the two tabs forward, facing up on either side of the center rib on the underside of the upper triple clamp. Position the brake line manifold (B) to the underside of the fork stem, and center the lower legs of the brake line between the forks.
9. Obtain the manifold attaching screw (C) saved in step 5. Apply a few drops of Loctite 243 - Blue to the clean screw threads, and fasten the manifold to the fork stem through the center hole as shown, but do not fully tighten at this time.
10. Obtain the new brake line P-clamp (2) from the kit. Orient the P-clamp the same as the original, and install the clamp to the rigid metal tube (E) on the upper brake line.
WARNING
Do not bend metal brake line. Bending brake line could cause metal fatigue and brake failure, which could result in death or serious injury. (00543b)
11. Obtain the hex head screw with washer (D) removed in step 4. See Figure 2. Holding the tube (1) and P-clamp (2) in place to prevent twisting, fasten the clamp to the top of the lower triple clamp (3), but do not fully tighten at this time.
NOTE
The brake line assembly should self-align creating a gap (4) between the vertical upper brake line hard tube and the lower triple clamp, and equal gaps (5) to each fork tube by default, but the gaps should be visually confirmed.
The hard line should not touch the triple clamp at any point, and the lower brake lines should not contact the forks. If either situation exists, loosen the brake line manifold if necessary and reposition.
The gap between the fork tubes and the brake line legs should appear equal on each side.
1Upper brake line hard tube
2P-clamp
3Lower triple clamp
4Gap between hard tube and triple clamp
5Gap between brake line and fork tube (right side shown)
Figure 2. Upper Brake Line Hard Tube
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)
12. See Figure 4. Install the banjo fitting of the upper brake line at the master cylinder, using a new, larger diameter sealing washer (3) from the kit on each side of the fitting. Insert the larger banjo bolt saved earlier through the washers and fitting. Thread the bolt into the master cylinder, but do not fully tighten at this time.
13. At each front brake caliper, position a new, smaller diameter sealing washer (4) from the kit on each side of the brake line banjo fitting. Insert a smaller banjo bolt (saved earlier) through the washers and fitting. Thread a bolt into each caliper, but do not fully tighten at this time.
14. Tighten the brake line manifold and P-clamp attaching screws as follows:
a. See Figure 2. Check to make sure gaps (5) between the right and left side brake lines and fork tubes are equal.
b. Make sure there is a gap (4) between the hard tube and the triple clamp. Hold the manifold to prevent twisting of the brake line.
c. Tighten the manifold attaching screw to 13.6–19 N·m (120–168 in-lbs).
d. Hold the hard tube and P-clamp to prevent twisting, and tighten the P-clamp screw to 5.1–7.4 N·m (45–65 in-lbs).
NOTE
The master cylinder housing and brake caliper housings (see Figure 3 ) each have a positive stop for the banjo fitting. When tightening the banjo bolt into the master cylinder and brake caliper housings in the next step, rotate the banjo fitting clockwise until it contacts the positive stop.
Figure 3. Caliper Housing Positive Stops
15. Tighten the caliper and master cylinder banjo bolts to 27.1–33.9 N·m (20–25 ft-lbs).
Brake Line Routing Check
  1. Review the routing of the brake line from the master cylinder, along the handlebar and through the P-clamp to the manifold, and the lower brake lines to the calipers.
    1. Be sure the brake lines are not twisted.
    2. Ensure that the routing of the brake line is smooth and does not interfere with any vehicle components. If necessary, adjust the position of the P-clamp.
    3. Turn the handlebars fully left and right while checking to make sure the brake lines do not contact any vehicle components.
  2. 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 the forks are fully extended.
  3. Loosen the clamp or manifold screws if necessary. Adjust the brake lines and re-tighten.
FINAL ASSEMBLY
Bleed and Test Braided Brake Line
Bleed the brake fluid from the front brake reservoir and lines per the instructions in the service manual, except as noted.
  1. Install one end of a length of 5/16 inch (7.9 mm) ID clear plastic tubing over the right-side caliper bleeder valve, and place the free end in a suitable container. Verify that both caliper bleeder valves are closed tightly.
  2. 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.
NOTE
The brake system on this vehicle uses DOT 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.
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
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.
16. 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)
17. 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.
18. Pump the front brake hand lever to build up hydraulic pressure.
19. While holding the lever, open the right-side caliper bleeder valve about 3/4-turn. Brake fluid 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 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 completely empty.
20. Repeat steps 5 and 6 until all air bubbles are purged, and a solid column of fluid is observed in the bleeder tube.
21. Final tighten the right-side bleeder valve to 4–6.9 N·m (35–61 in-lbs), and install the bleeder cap.
22. Install one end of a length of 5/16 inch (7.9 mm) ID clear plastic tubing over the left-side caliper bleeder valve, and place the free end in a suitable container. Add brake fluid to the master cylinder reservoir per the instructions in the service manual. Repeat steps 5 through 8 for the left-side brake line.
23. Add brake fluid as needed to the master cylinder reservoir per the instructions in 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 will be ejected from the reservoir during cover installation, which could damage the vehicle finish.
24. Note that 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 Phillips flat-head screws to fasten the cover to the reservoir. Tighten the screws to 1–1.9 N·m (9–17 in-lbs).
Return to Service
  1. Verify that the ignition/key switch is turned to the OFF position.
  2. Refer to the service manual and follow the instructions given to install the main fuse.
  3. 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.
  4. Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.
SERVICE PARTS
Figure 4. Service Parts, XR1200 Braided Front Brake Line Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Brake line assembly, braided stainless steel
Not sold separately
2
P-clamp, for 0.187 inch (4.7 mm) tube
41713-86
3
Sealing washer, 12 mm ID (2)
41743-04
4
Sealing washer, 10 mm ID (4)
41732-04
Items mentioned in text, but not included in kit.
A
Original equipment (O.E.) front brake line guide
B
Brake line manifold
C
O.E. manifold attaching screw
D
O.E. hex head screw with washer
E
Rigid metal tube
F
Front of vehicle