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LINKED LOWER BRAKE LINE KIT
J056912015-04-15
GENERAL
Kit Numbers
41800292, 41800558
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
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. One is available from a Harley-Davidson Dealer.
Tools and Supplies Required
Fresh, uncontaminated DOT 4 brake fluid from a sealed container is required. This brake fluid is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 5 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.
4. See Figure 1. Remove the stock banjo fitting (1) from the front circuit manifold (2). Save the banjo bolt for installation. Discard the sealing washers.
5. See Figure 3. Remove the stock banjo fitting (2) from the rear circuit manifold (4). Save the banjo bolt. Discard the sealing washers.
6. See Figure 4. Remove the stock banjo fittings in both the front (1) and rear (3) circuit locations of the front calipers on both sides of the vehicle. Save the four banjo bolts, discard all the sealing washers.
7. Note locations of cable straps that secure the front fender lighting wire to the left side brake lines. Remove cable straps.
8. See Figure 3. Remove the socket head cap screws that mount the circuit manifolds (3, 4) to the rear of the lower fork bracket. Discard the screws.
9. Remove both front and rear circuit lower brake line assemblies from the vehicle.
10. If installing the Linked Brake Line Adapter Kit, perform the removal steps for that that kit. If installing an accessory handlebar, perform any removals called out in that kit.
INSTALLATION
1. See Figure 5. Obtain the front circuit lower brake line assembly (1) and one socket-head cap screw (6) from the kit.
2. See Figure 1. Install the lower brake line assembly manifold to the right side, rear of the lower triple clamp where shown. Align the manifold so the lower brake lines are facing rearward and down.
3. Align the hole in the manifold with the threaded hole in the triple clamp. Insert the cap screw. Tighten to 10.8–13.6 N·m (8–10 ft-lbs).
4. See Figure 5. Obtain the rear circuit lower brake line assembly (2), the second socket head cap screw (6) and the two plastic support clips (5) from the kit.
5. See Figure 3. Install the lower brake line assembly manifold to the left side, rear of the lower triple clamp where shown. Align the manifold so the lower brake lines are facing rearward and down.
6. Align the hole in the manifold with the threaded hole in the triple clamp. Insert the cap screw. Torque to 10.8–13.6 N·m (8–10 ft-lbs).
7. Install a support clip (5) between the crimp collars at the top of the flexible portion of the brake lines spanning across both front and rear circuit assemblies. Snap the support clip over the crimp collars and center on the collars. Repeat on other side.
8. See Figure 5. Obtain two M12 copper sealing washers (3) from the kit and the banjo bolt removed from the front circuit manifold.
9. See Figure 2. Install either the Linked Brake Line Adapter OR the stock upper brake line banjo fitting (2) with M12 copper sealing washers on either side of the fitting. Insert the banjo bolt through the sealing washers and banjo fitting and thread into the front circuit manifold orienting the fitting as shown.
10. Rotate the banjo fitting so it rests 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).
11. If installing an accessory handlebar or upper brake line kit, refer to that kit for installation instructions for that accessory. Complete instructions to the point of bleeding the brake system.
12. See Figure 5. Obtain two M10 sealing washers (4) from the kit and the banjo bolt removed from the rear circuit manifold.
13. See Figure 3. Install the stock rear brake line banjo fitting (2) with a M10 sealing washer on either side of the fitting. Insert the M10 banjo bolt through the sealing washers and banjo fitting and thread into the rear circuit manifold.
14. Align the fitting as shown and tighten the banjo bolt to 23–29.8 N·m (17–22 ft-lbs).
15. See Figure 5. Obtain eight M10 sealing washers (4) from the kit and the four banjo bolts removed from the brake calipers.
16. See Figure 4. Install an M10 sealing washer on either side of the banjo fitting on each lower brake line banjo fitting (1, 3) at the brake caliper.
17. Align the fitting as shown and tighten the banjo bolt to 23–29.8 N·m (17–22 ft-lbs).
18. Repeat for remaining caliper banjo fitting connections.
19. Install three cable straps evenly spaced to secure the fender lights wire harness to the left side brake lines.
20. Install remaining cable straps to secure the brake lines as needed. Position the brake lines to avoid abrasion with any sharp edges or potential damaging surfaces throughout the rotation limits of the front fairing and compression / extension of the front suspension.
1Banjo bolt and adapter
2Front brake circuit manifold
3Rear of lower triple clamp
Figure 1. Front Circuit Manifold
1Banjo bolt and sealing washers
2Accessory adapter or stock upper brake line banjo fitting
3Accessory or stock upper brake line
4Swivel nut upper brake line connection (if equipped)
5Rear brake line routing
Figure 2. Front Brake Line Manifold Assembly
1Banjo bolt and sealing washers
2Stock rear circuit brake line banjo fitting
3Front brake line manifold
4Rear brake line manifold
5Lower brake line support clip (2)
Figure 3. Rear Brake Line Manifold Assembly
1Front brake line caliper banjo fitting
2Front caliper bleeder valve
3Rear brake line caliper banjo fitting
4Rear caliper bleeder valve
Figure 4. Rear Brake Line Manifold Assembly
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)
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)
NOTE
  • Do not mix grades of brake fluid as they are not compatible.
  • If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
  • 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 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 main fuse.
3. Apply brakes to check proper lamp operation.
4. Install outer fairing following 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)
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)
5. Test ride motorcycle at low speed.
a. Repeat the bleeding procedure if brakes feel spongy.
SERVICE PARTS
Figure 5. Service Parts: Lower Brake Line Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Brake line assembly, linked front circuit
Not Sold Separately
2
Brake line assembly, linked rear circuit
Not Sold Separately
3
Washer, copper sealing (2)
10600007
4
Gasket, sealing (10)
41756-08
5
Support clip (2)
12200077
6
Screw, 1/4-20 x 1.37 in (2)
4813A
7
Cable strap (8)
10065
Items referenced in these instructions but not included in kit:
A
Upper brakeline adapter kit (part no. 41600094) or stock upper brake line assembly
B
Stock rear brake line assembly
C
Banjo bolt, M12 x 1.0 in (part no. 11600009)
D
Banjo bolt, M10 x 1.25 in (part no. 11600001)