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BRAKE LINE ADAPTER KIT
J056902013-06-14
GENERAL
Kit Numbers
41600094
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
An upper brake line kit is required to complete this adapter installation. See the P&A Retail Catalog, the Parts and Accessories section of www.harley-davidson.com or your Harley-Davidson Dealer for the correct upper brake line kit for your handlebar application.
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.
Tools and Supplies Required
Fresh, uncontaminated D.O.T. 4 brake fluid from a sealed container is required and is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 3 and Table 1.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1. Remove main fuse.
2. Remove the outer front fairing following instructions in the service manual.
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)
3. Drain the brake fluid following the instructions in the service manual.
a. If installing only an UPPER brake line kit, only drain the FRONT circuit.
b. If installing both UPPER and LOWER brake line kits, drain both the FRONT and REAR circuits.
4. See Figure 1. Remove the stock banjo fitting from the front circuit manifold. Save the banjo bolt for installation. Discard the sealing washers.
5. Remove the stock banjo bolt at the master cylinder. Save the banjo bolt for installation. Discard the sealing washers.
6. Make note of the complete brake line routing and any cable ties or other brake line mounting locations. Remove all cable ties that mount the upper brake line from manifold to master cylinder.
7. Remove the upper brake line from the vehicle.
8. If installing a LOWER brake line kit, refer to that kit and perform any other removal procedures.
INSTALLATION
1. If installing an accessory handlebar or LOWER brake line kit, refer to that kit for installation instructions for that accessory.
2. See Figure 3. Install the brake line adapter (1) and sealing washers (2) into the front circuit manifold.
3. See Figure 2. Install the M12 banjo bolt (removed earlier) into the brake line adapter and sealing washers. Note the orientation of the adapter.
4. Position the adapter so it is resting against the forward portion of the manifold anti-rotation pin and tighten the banjo bolt to 36.6–39.3 N·m (27–29 ft-lbs).
5. Route the upper brake line similar to the original routing from master cylinder to adapter.
6. Install the UPPER brake line to the master cylinder using the M10 banjo bolt removed earlier and new sealing washers from the upper brake line kit. Tighten the banjo bolt to 17-22 ft-lb (23.0-29.8 Nm).
NOTE
Only turn the swivel nut when tightening the swivel nut fitting. Do not allow the male fitting or adapter tubing to rotate.
7. Install and tighten the female swivel nut onto the male fitting finger-tight. Do not twist the upper brake line or adapter while tightening.
8. Tighten the swivel nut past finger-tight by 45 degrees (1/8 turn) relative to the male fitting or tighten to 5.1–7.3 N·m (45–65 in-lbs). Use two 7/16 inch open-end wrenches.
9. Install cable straps from either the adapter or upper brake line kits to secure the upper brake line as previously noted.
1Banjo bolt and adapter
2Front brake circuit manifold
3Rear of lower triple clamp
Figure 1. Front Circuit Manifold
1Banjo bolt and adapter
2Swivel nut upper brake line connection
3Upper brakeline
Figure 2. Upper Brake Line Routing
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.
  • 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 D.O.T. 4 brake fluid.
1. Add the appropriate brake fluid to the master cylinder reservoir and bleed the brake system following the instructions in the service manual. Do not reuse old brake fluid. Only use fluid from a sealed container.
2. Install the main fuse.
3. With the ignition/light key switch turned to IGNITION, actuate the front brake hand lever to verify operation of the brake lamp.
WARNING
Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)
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)
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
4. Test ride the motorcycle.
a. If the brake feels spongy, repeat the front brake bleeding procedure.
SERVICE PARTS
Figure 3. Service Parts: Brake Line Adapter
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Banjo adapter
Not Sold Separately
2
Washer, copper sealing (2)
10600007
3
Cable strap (2)
10065