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MODULAR BRAKE LINE KITS
J056532023-11-01
GENERAL
NOTE
ABS and non-ABS Sportster®, Touring, Trike, dual-front disc Dyna® and Softail® models share these upper brake line kits. Only the installation instructions for upper and lower brake lines on all 2014-later ABS and non-ABS Sportster models are found in this document.
Instructions for upper and lower brake line installation on remaining models are found in the Lower Brake Line Kit:
  • Upper and lower brake line installation on non-ABS Touring and 2013-earlier Trike models are found on instruction sheet J04431.
  • Upper and lower brake line installations on any ABS Touring model are found on the instruction sheet for the specific model, J04652 or J05790.
  • Upper and lower linked brake line installations on 2014-later Trike models are found on instruction sheet J05690 (Linked Lower Brake Line) or J05691 (Linked Adapter Kit).
  • Upper and lower brake line installations on dual-front disc Dyna models are found on instruction sheet J04488.
  • Upper and lower brake line installations on 2018-later Softail models are found on instruction sheet J06451.
Kit Numbers
Table 1. Upper Brake Line Kits - Banjo Angle 0° - Straight
Diamond-Black
Kit
Diamondback
Kit
Length
41800534
41800532
13 inch (33.0 cm)
41800248
41800234
15 inch (38.1 cm)
41800250
41800236
16.5 inch (41.9 cm)
---
41800464
18.5 inch (47.0 cm)
41800254
41800240
20.5 inch (52.1 cm)
41800440
41800424
22.5 inch (57.2 cm)
41800258
41800244
24.5 inch (62.2 cm)
41800260
41800246
26.5 inch (67.3 cm)
41800441
41800425
28.5 inch (72.4 cm)
41800456
41800453
30.5 inch (77.5 cm)
41800480
41800465
32.5 inch (82.6 cm)
---
41800466
34.5 inch (87.6 cm)
41800481
41800467
36.5 inch (92.7 cm)
NOTE
DiamondbackTM and Diamond-Black upper brake lines are available in various master cylinder banjo angles and brake line lengths. Shorter or longer lines are necessary when certain modifications (like optional handlebars) are made to the vehicle. See the P&A retail catalog or a Harley-Davidson dealer.
Table 2. Upper Brake Line Kits - Banjo Angle 35°
Diamond-Black
Kit
Diamondback
Kit
Length
---
41800818
15.0 inch (38.0 cm)
41800252
41800238
18.5 inch (47.0 cm)
41800455
41800452
20.5 inch (52.1 cm)
41800256
41800242
22.5 inch (57.2 cm)
41800436
41800420
24.5 inch (62.2 cm)
41800437
41800421
26.5 inch (67.3 cm)
41800438
41800422
28.5 inch (72.4 cm)
41800439
41800423
30.5 inch (77.5 cm)
41800551
41800468
32.5 inch (82.6 cm)
41800482
41800469
34.5 inch (87.6 cm)
---
41800470
36.5 inch (92.7 cm)
41800483
41800471
40.0 inch (101.6 cm)
41800484
41800472
44.0 inch (111.8 cm)
Table 3. Upper Brake Line Kits - Banjo Angle 90°
Diamond-Black
Kit
Diamondback
Kit
Length
41800442
41800426
18.5 inch (47.0 cm)
41800443
41800427
20.5 inch (52.0 cm)
41800457
41800454
22.5 inch (57.2 cm)
41800553
41800473
24.5 inch (62.2 cm)
---
41800474
26.5 inch (67.3 cm)
---
41800475
28.5 inch (72.4 cm)
---
41800476
30.5 inch (77.5 cm)
41800485
41800477
32.5 inch (82.6 cm)
---
41800478
34.5 inch (87.6 cm)
---
41800479
36.5 inch (92.7 cm)
41800907
41800906
12.8 inch (32.5 cm)
Table 4. Lower and Mid Brake Line Kits
Fitment
Diamond-Black Kit
Diamondback Kit
Length, Caliper Banjo Angle
Instruction
Sheet No.
NON-ABS APPLICATIONS
2012-Later Sportster® 1200V models
41800413
41800412
20.5 in (52 cm) long, 10 mm x 65°
-J05653
2004-Later Sportster® models (except 1200V)
41800228
41800226
18.5 in (47 cm) long, 10 mm x 65°
2016-Later Sportster® 1200CX models
41800592A
41800590A
16.5 in (43 cm) long, 10 mm x 65°
Lower & Mid Brake Lines (Reference Only)
1994-2007 Road King®/ Road Glide® models
48938-10
45818-07
16.0 in (40.6 cm) long, 3/8 in x 78°
-J04431
1996-2007 Electra Glide®/ Street Glide® models
---
45820-07
16.0 in (40.6 cm) long, 3/8 in x 78°
2008-2013 Road King®/ Road Glide® models
48942-10
44907-08
15.3 in (38.9 cm) long, 10 mm x 90°
2008-2013 Electra Glide®/ Street Glide® models
41800280
44905-08
15.3 in (38.9 cm) long, 10 mm x 90°
2008-2013 Street Glide® Trike/
Tri GlideTM Ultra Classic® models
--
83666-10
16.8 in (42.7 cm) long, 10 mm x 90°
2008-Later FXDF, 2014-Later FXDL models
48928-10
42112-08A
18.5 in (47.0 cm) long, 3/8 in x 78°
-J04488
2014-Later Electra Glide®/ Street Glide®/
Road King® models
41800338
41800336
22.3 in (54 cm) long, 10 mm x 65°
-J05792
ABS AND LINKED APPLICATIONS
2014-Later Sportster® 1200V models
41800417A
41800416A
21.3 in (54 cm) long, 10 mm x 65°
-J05653
2014-Later Sportster® models (except 1200V)
41800232A
41800230A
19.3 in (49 cm) long, 10 mm x 65°
2016-Later Sportster® 1200CX models
41800587
41800585
16.9 in (43 cm) long, 10 mm x 65°
Lower & Mid Brake Lines (Reference Only)
2009-2013 Electra Glide®/ Street Glide®/
Road King® models
48946-10
41825-09
15.0 in (38.1 cm) long, 10 mm x 90°
-J04652
2009-2013 Road Glide® models
---
46049-09
14.0 in (35.6 cm) long, 10 mm x 90°
2012-Later FXDF, 2014-Later FXDL models
41800078
41800048
19.0 in (48.3 cm) long, 3/8 in x 78°
-J04488
2014-Later Electra Glide®/ Street Glide®/
Road King® models
41800321 Upper Mid
(stock finish)
64.0 in (163 cm) long, 12 mm block
-J05790
41800323 Lower Mid
(stock finish)
68.5 in (174 cm) long, 10 mm block
41800333
41800332
14.9 in (37.8 cm) long, 10 mm x 90°
2014-Later Tri GlideTM Ultra Classic®,
(Linked brake system)
41600094 Adapter (chrome)
1.0 in (2.5 cm), 12 mm x 80°
-J05690
---
41800292
16.8 in (42.7 cm) long, 10 mm x 60°
-J05691
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
Fresh, uncontaminated hydraulic brake fluid is needed. See owner's manual for the correct brake fluid.
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
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)
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. One is available from a Harley-Davidson dealer.
Kit Contents
See Table 5 , Table 6 and Table 7.
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
  • WITH security siren: With security fob present, turn ignition switch ON. See the service manual. Disarm security system. Turn ignition switch OFF. IMMEDIATELY remove the main fuse.
  • WITHOUT security siren: See the service manual. Remove main fuse.
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)
NOTE
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
Cover painted parts to protect finish.
  1. See the service manual. Drain brake fluid from the front brake reservoir and lines.
INSTALLATION, NON-ABS SPORTSTER MODELS
Original Front Brake Line Removal
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
  1. Note front brake line routing and banjo bolt orientation.
  2. See Figure 1 and Figure 2. Disconnect the front brake line from the front brake master cylinder and front brake caliper. Save the master cylinder and caliper banjo bolts. Discard all sealing washers.
  3. See Figure 3 and Figure 4. Remove the existing P-clamps and mounting hardware from the following locations: Save the mounting hardware for later installation. Discard the P-clamps.
    1. Under the lower fork clamp.
    2. Along the right side of the steering head at the upper fork clamp.
  4. Note front brake line routing and orientation of the banjo fittings. Remove the existing front brake line.
Braided Front Brake Line Installation
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
  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, determine the proper Upper Brake Line Kit (see Table 1 , Table 2 or Table 3 ) by using the Cable and Brake Line Measurement Tool Kit. See a Harley-Davidson dealer for assistance.
  • See Table 4 to verify the correct Lower Brake Line Kit for the specific model motorcycle.
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)
1. See Figure 1. Install the banjo fitting (1) of the upper brake line (2) at the master cylinder (3), using the sealing washers (5) from the Upper Brake Line Kit on each side of the banjo fitting.
2. Install the master cylinder banjo bolt (Item 4, saved earlier). Snug, but do not fully tighten now.
1Banjo fitting
2Upper brake line
3Master cylinder
4Banjo bolt
5Sealing washer (2)
Figure 1. Upper Brake Line Master Cylinder
1Banjo fitting
2Lower brake line
3Non-ABS caliper assembly
4Banjo bolt
5Sealing washer (2)
Figure 2. Non-ABS Lower Brake Line
3. See Figure 2. Install the banjo fitting (1) to the lower brake line (2) at the caliper (3), using the sealing washers (5) from the Lower Brake Line Kit on each side of the banjo fitting.
a. Position the banjo fitting away from the vehicle at an angle of approximately 10° from vertical.
b. Install the caliper banjo bolt (4, saved earlier). Tighten to 19–24.4 N·m (14–18 ft-lbs).
4. See Figure 4. Route the remainder of the lower brake line toward the lower fork clamp.
1Upper brake line
2P-clamp, upper fork clamp
3P-clamp screw
4Throttle and idle cables (routed inside brake line)
5Ignition switch
Figure 3. Upper Brake Line Routing
Upper Front Brake Line Routing
NOTE
When routing accessory brake lines, goals are:
  • Gentle routing without any sharp bends or kinking
  • Free uninhibited movement from steer lock to steer lock
  • Clearance to any pinch-points throughout the steering motion
  • Clearance to any potential snags such as the ignition switch with key installed
Adjust brake line routing with P-clamp and banjo fitting orientations and the line lengths between mounting locations.
5. Route the upper portion of the upper brake line along the handlebars (similar to the routing shown in Figure 1 ):
a. XL1200X models stock handlebar, accessory drag handlebar or other low rise handlebar: If routed to upper P-clamp, brake line kinks. Route directly from master cylinder under the lower fork clamp without routing through the former P-clamp position.
b. All other installations: See Figure 3. Use a new P-clamp (2) from the upper brake line kit to install the brake line (1) to the upper fork clamp. Loosely install the screw (3) removed earlier into the upper fork clamp so brake line adjustments can still be made.
1Lower brake line
2P-clamp, lower fork clamp
3P-clamp screw
4Lower fork clamp
Figure 4. Non-ABS Lower Brake Line Routing (single caliper)
1Lower brake line
2P-clamp, lower fork clamp
3P-clamp screw
4Lower fork clamp
Figure 5. Non-ABS Lower Brake Line Routing (dual caliper)
1Upper brake line
2Female swivel nut
3Lower brake line
4Male fitting
Figure 6. Upper to Lower Brake Line Fittings
6. Route the remainder of the upper brake line under the lower fork clamp. See Figure 4. On single-caliper models, loosely install a new cushioned P-clamp (2) from the lower brake line kit over the swivel-nut end of the upper brake line. Position so that it can be mounted with fastener behind the brake line.
7. See Figure 6. Loosely thread the upper brake line (1) female swivel-nut fitting (2) to the male fitting (4) on the lower brake line (3). Turn until finger-tight.
NOTE
When tightening the fitting, turn only the swivel nut. Do not allow the male fitting or manifold tubing to turn.
8. Making sure only the swivel nut turns, tighten the swivel nut past finger-tight by 45 degrees (1/8 turn) or:
Torque: 5.1–7.3 N·m (45–65 in-lbs) swivel nut
9. Install the brake line assembly to the underside of the lower fork clamp stem.
  • See Figure 4. For single-caliper models, position the cushioned P-clamp over the fitting connection, and align with the underside of the lower fork clamp stem. The flat side of the clamp is up against the bottom of the lower fork clamp. The loop of the cushioned clamp faces toward the front of the vehicle.
  • See Figure 5. For dual-caliper models, place the manifold against the bottom of the lower fork clamp, making sure that the fastener hole is rearward of the brake lines.
10. Mount the brake lines using the original screw (3) removed earlier. Tighten the screw to:
Torque: 10.8–13.6 N·m (8–10 ft-lbs) screw
11. To complete the installation, adjust the upper brake line routing by adjusting the master cylinder banjo rotation angle and orientation of the upper P-clamp. Goals are:
  • Gentle routing without any sharp bends or kinking
  • Free uninhibited movement from steer lock to steer lock
  • Clearance to any pinch-points throughout the steering motion
  • Clearance to any potential snags such as the ignition switch with key installed
12. Tighten the master cylinder banjo bolt (installed earlier) to:
Torque: 19–24.4 N·m (14–18 ft-lbs) banjo bolt
13. Tighten the upper P-clamp fastener to:
Torque: 4–5.4 N·m (3–4 ft-lbs) P-clamp Screw
14. Secure the brake line routing with cable straps from the upper brake line kit.
15. Go to BRAKE LINE ROUTING CHECK AND ADJUSTMENT.
INSTALLATION - ABS SPORTSTER 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)
Original Front Brake Line Removal
NOTE
Cover painted parts to protect finish.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
1. Note the Wheel Speed Sensor (WSS) wire routing and cable strap location. Remove the cable straps and clips holding the WSS to the brake line. Save the clips.
2. See Figure 8. Remove the shoulder screw (2) holding the brake line manifold (1) to the lower fork stem. Save the shoulder screw for later installation with the new brake line.
3. Disconnect the brake line tube nut connections (3) at the rear of the lower brake line manifold.
4. See Figure 3. Remove P-clamp fastener (3) and P-clamp (2) from upper fork bracket. Save the fastener. Discard the P-clamp.
5. See Figure 1. Disconnect brake line (2) from the front brake master cylinder (3). Discard the sealing washers (5), but save the banjo bolt (4).
1Banjo fitting
2Lower brake line
3ABS caliper assembly
4Banjo bolt
5Sealing washer (2)
6Wheel speed sensor wire
Figure 7. ABS Lower Brake Line Routing
6. See Figure 7. Note the orientation of the banjo fitting. Remove banjo bolt (4). Discard sealing washers (5). Save banjo bolt.
Braided Front Brake Line Installation
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)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
NOTE
When routing accessory brake lines, goals are:
  • Gentle routing without any sharp bends or kinking
  • Free uninhibited movement from steer lock to steer lock
  • Clearance to any pinch-points throughout the steering motion
  • Clearance to any potential snags such as the ignition switch with key installed
Adjust brake line routing with P-clamp and banjo fitting orientations and the line lengths between mounting locations.
1Brake line manifold
2Shoulder screw
3ABS line tube nut connections (2)
Figure 8. Brake Line Manifold
1. See Figure 8. Position the brake line manifold (1) on the underside of the fork stem with the lower leg of the brake line coming down the rear of the front forks to the brake caliper.
2. Secure the manifold to the fork stem with the previously removed shoulder screw (2). Tighten the screw to:
Torque: 4.1–5.4 N·m (36–48 in-lbs)
3. Connect the ABS brake lines tube nut fittings (3) to the braided brake line manifold. Tighten the tube nuts to:
Torque: 14.5–19.3 N·m (10.7–14.4 ft-lbs) Tube Nuts
4. See Figure 7. At the brake caliper(s), install a new sealing washer (5) from the Lower Brake Line Kit on each side of the brake line banjo fitting (1). Insert the banjo bolt (4, removed earlier) through the washers and fitting. Thread the bolt into the caliper. Tighten to:
Torque: 19–24.4 N·m (14–18 ft-lbs) Banjo Bolt
5. Obtain the new upper brake line assembly. Route the upper brake line from the master cylinder along the front of the handlebar, behind the upper fork clamp and down to the male fitting on the upper end of the lower brake line.
6. See Figure 1. Install the banjo fitting (1) of the new upper brake line at the master cylinder. Use a new sealing washer (5) from the Upper Brake Line Kit on each side of the fitting.
7. Install the banjo bolt (4, removed earlier) snug, but do not fully tighten now.
8. Route the upper portion of the upper brake line along the handlebars (similar to the routing shown in Figure 1 ).
a. XL1200X models stock handlebar, accessory drag handlebar or other low rise handlebar: If routed to upper P-clamp, brake line kinks. Route directly from master cylinder under the lower fork clamp without routing through the former P-clamp position.
b. All other installations: See Figure 3. Use a new P-clamp (2) from the upper brake line kit to install the brake line (1) to the upper fork clamp. Loosely install the screw (3) removed earlier into the upper fork clamp so brake line adjustments can still be made.
9. Check the routing of the upper brake line from the master cylinder, along the handlebar and through the P-clamp, 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 orientation of the P-clamp.
10. Connect the female fitting on the upper brake line to the male fitting on the manifold. Thread the female fitting onto the male fitting finger-tight.
NOTE
When tightening the fitting, turn only the swivel nut. Do not allow the male fitting or manifold tubing to turn.
11. Turning only the swivel nut, tighten the nut past finger-tight by 45 degrees (1/8 turn) or
Torque: 5.1–7.3 N·m (45–65 in-lbs)
12. To complete the installation, adjust the upper brake line routing by adjusting the master cylinder banjo rotation angle and orientation of the upper P-clamp. Goals are:
  • Gentle routing without any sharp bends or kinking
  • Free uninhibited movement from steer lock to steer lock
  • Clearance to any pinch-points throughout the steering motion
  • Clearance to any potential snags such as the ignition switch with key installed
13. Tighten the master cylinder banjo bolt (installed earlier) to:
Torque: 19–24.4 N·m (14–18 ft-lbs) banjo bolt
14. Tighten the upper P-clamp fastener to:
Torque: 4–5.4 N·m (3–4 ft-lbs) P-clamp Screw
15. Secure the brake line routing with the cable straps from the upper brake line kit.
Brake Line Routing Check and Adjustment
1. Raise the vehicle so that the front forks reach maximum extension. Verify that the lower brake line is not pulled tight when the forks are fully extended.
2. Check upper and lower brake line routing and banjo fitting orientation:
a. Verify that the lower brake line is long enough to allow full fork extension without pulling the brake line.
b. Fully compress the forks to check that the lower brake line does not interfere with motorcycle components.
3.
NOTE
When routing accessory brake lines, the intention is:
  • Gentle routing without any sharp bends or kinking
  • Free uninhibited movement from steer lock to steer lock
  • Clearance to any pinch-points throughout the steering motion
  • Clearance to any potential snags such as the ignition switch with key installed
  • Avoid any contact with painted surfaces throughout the steering motion (fender, gas tank, miscellaneous body components)
  • Light structure contact with the frame, downtubes, or triple clamp may occur but only at full extents of the steering motion
Adjustments to the brake line routing can include:
  • The use of P-clamp in place of stock wire-form retention (on some models)
  • Lower manifold adapter fitting orientation (on some models)
  • Line lengths between mounting locations and banjo fitting angles
  • P-clamp orientation
  • Banjo fitting orientation
Make sure all brake lines are routed properly. This includes turning the handlebars from lock to lock, and ensuring that all brake lines do not snag, kink, rub surrounding parts or get pinched between parts. If any of the above occur, check the routing of the brake lines, and adjust as necessary.
4. Adjust the brake lines and/or banjo fitting orientation as needed. If the brake line contacts the inserted key or key fob during full right turn of the handlebars:
a. When adjustments are complete, tighten the master cylinder banjo bolt to:
Torque: 19–24.4 N·m (14–18 ft-lbs) Banjo bolt
b. While holding the P-clamps in the proper orientation, tighten the P-clamp screw at the fork clamp to:
Torque: 4–5.4 N·m (3–4 ft-lbs) Banjo bolt
c. Install cable straps at the same locations as the original cable straps or as necessary to maintain proper brake line routing.
d. Turn the cushioned clamp under the lower fork clamp toward the left side of the vehicle. Move the vertical portion of the brake line between the upper and lower clamps as far to the right as possible. This adjustment keeps the brake line away from the ignition key.
e. If the brake line contacts the lower fork clamp, turn the cushioned clamp toward the right side of the vehicle.
FINAL ASSEMBLY
Bleed and Test Front Brake Line
NOTE
Cover painted and chrome parts to protect finish.
1. Remove the front brake master cylinder cover, unless already done.
2. Stand motorcycle upright (not leaning on jiffy stand) on a level surface.
WARNING
Use only DOT 4 hydraulic brake fluid in the brake master cylinder. Use of other types of fluid can cause brake system damage and adversely affect braking, which could result in death or serious injury. (00597c)
3. Add DOT 4 hydraulic brake fluid only to the master cylinder reservoir until fluid level is 3.2 mm (1/8 in) from the top. Do not reuse brake fluid. Use only brake 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)
4. Verify proper operation of the master cylinder relief port by actuating the brake pedal or lever. A slight spurt of fluid will break the fluid surface in the reservoir if internal components are working properly.
NOTE
ABS Models: ABS models require special tools to bleed the brakes that are only available to Harley-Davidson dealers.
WARNING
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
5. Bleed the brake system following the instructions in the service manual.
6. Check the master cylinder and caliper banjo fittings and male/female connection under the lower fork clamp for any signs of leakage.
7. Tighten the bleeder screw. Install the bleeder cap.
Torque: 3.9–6.9 N·m (34.5–61 in-lbs) hex nut
8. Add brake fluid to the master cylinder reservoir until the fluid level is about 3.2 mm (1/8 in) from the top.
NOTE
Before installing the master cylinder cover, verify that the cover gasket bellows is not expanded. If bellows is expanded, brake fluid is ejected from the reservoir during cover installation, which could damage the vehicle finish.
9. One end of the master cylinder cover is thinner than the other. Install the cover (with gasket compressed) on the master cylinder reservoir, with the thicker end positioned above the brake line fitting. Tighten screws to:
Torque: 1–2 N·m (8.8–17.7 in-lbs) screws
COMPLETION
NOTE
To prevent possible damage to the sound system, verify that the ignition is OFF before installing the main fuse.
1. See the service manual. Install main fuse.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
2. See the service manual. Install seat.
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)
3. Test ride motorcycle at low speed. Repeat the bleeding procedure if brakes feel spongy.
SERVICE PARTS
Figure 9. Service Parts: Upper Brake Line Kit
Table 5. Service Parts: Upper Brake Line Kit
Item
Description (Quantity)
Part Number
1
Upper brake line
Not Sold Separately
2
Sealing washer, 10 mm (2)
41756-08
3
P-clamp
10059A
4
Cable strap (3)
10065
Figure 10. Service Parts: Sportster Non-ABS Lower Brake Line Kit
Table 6. Service Parts: Sportster Non-ABS Lower Brake Line Kit
Item
Description (Quantity)
Part Number
1
Lower brake line, non-ABS
Not Sold Separately
2
Sealing washer, 10 mm (2)
41756-08
3
P-clamp, cushioned
42364-07
Figure 11. Service Parts: Sportster ABS Lower Brake Line Kit
Table 7. Service Parts: Sportster ABS Lower Brake Line Kit
Item
Description (Quantity)
Part Number
1
Lower brake line, ABS
Not Sold Separately
2
Sealing washer, 10 mm (2)
41756-08
3
Cable strap (3)
10065
SERVICE PARTS
Figure 12. Service Parts: Non-ABS Dual Disk Lower Brake Line
Table 8. Service Parts: Non-ABS Dual Disc Lower Brake Line Kit
Item
Description (Quantity)
Part Number
1
Lower brake line, Non-ABS
Not Sold Separately
2
Sealing washer, 10 mm (4)
41756-08
3
Cable strap (6)
10065
Figure 13. Service Parts: ABS Dual Disk Lower Brake Line
Table 9. Service Parts: ABS Dual Disc Lower Brake Line
Item
Description (Quantity)
Part Number
1
Lower brake line, ABS
Not Sold Separately
2
Sealing washer, 10 mm (4)
41756-08
3
Cable strap (6)
10065