MODULAR BRAKE LINE KITS

J064512021-10-14

GENERAL

NOTE

Diamondback™, Diamond-Black and Stock-Style upper brake lines are available in various master cylinder banjo angles, banjo diameters 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.

To complete the modular brake line assembly, a lower brake line assembly may also be required. Lower brake line assemblies are vehicle model dependent.

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)

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)

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)

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

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)

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

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 year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.

Harley-Davidson recommends using Harley-Davidson Platinum Label DOT 4 Brake Fluid because of its superior moisture and corrosion inhibiting properties.

Braided Upper Brake Line Kit Numbers

Table 1. Braided Upper Brake Line Kits - 7/16 Inch Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length	Banjo Angle
41800024A	-	508 mm (20 in)	0°
41800025A	-	533 mm (21 in)	0°

41800026A	-	559 mm (22 in)	0°

41800027A	-	584 mm (23 in)	0°

41800028A	-	610 mm (24 in)	0°

41800029A	41800341	635 mm (25 in)	0°

41800030A	-	660 mm (26 in)	0°

41800031A	41800104A	711 mm (28 in)	0°

41800042A	41800580	762 mm (30 in)	0°

41800043A	-	813 mm (32 in)	0°

41800044A	-	864 mm (34 in)	0°

41800051A	41800106A	483 mm (19 in)	35°

41800052A	-	508 mm (20 in)	35°

41800053A	41800108A	533 mm (21 in)	35°

41800054A	41800110A	559 mm (22 in)	35°

41800055A	-	584 mm (23 in)	35°

41800056A	-	610 mm (24 in)	35°

41800057A	-	635 mm (25 in)	35°

41800058A	-	660 mm (26 in)	35°

41800059A	41800112A	711 mm (28 in)	35°

41800060A	41800114A	762 mm (30 in)	35°

41800061A	41800116A	813 mm (32 in)	35°

41800062A	41800118A	864 mm (34 in)	35°
41800080A	41800120A	508 mm (20 in)	90°

41800082A	-	533 mm (21 in)	90°
41800084A	-	559 mm (22 in)	90°
41800088A	-	584 mm (23 in)	90°
41800090A	41800122A	610 mm (24 in)	90°
41800092A	-	635 mm (25 in)	90°

41800094A	-	660 mm (26 in))	90°
41800096A	-	711 mm (28 in)	90°

41800098A	-	762 mm (30 in)	90°

41800100A	-	813 mm (32 in)	90°
41800102A	-	864 mm (34 in)	90°

Table 2. Service Parts: Braided Upper Brake Line Kits - 7/16 Inch Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (2)	41733-88
Cable Strap (3)	10065
P-Clamp, Small (2)	10059A
P-Clamp, Cushioned (1)	42364-07

Table 3. Braided One-Piece Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length
-	41800178	864 mm (34 in)
46934-06	-	965 mm (38 in)
46936-06	-	1,024 mm (40 in)
46930-06	46779-09	1,054 mm (41.5 in)
41800283	46720-09	1,168 mm (46 in)

Table 4. Service Parts: Braided One-Piece Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (2)	41732-04
Cable Strap (3)	10065
P-Clamp (3)	10059A

Table 5. Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length
41800670	-	740 mm (29 in)

Table 6. Service Parts: Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (4)	41756-08

Table 7. Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length
41800671	-	380 mm (15 in)

Table 8. Service Parts: Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (4)	41756-08

Table 9. Braided Upper Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length	Banjo Angle
41800532	41800534	330 mm (13.0 in)	0°
41800234	41800248	381 mm (15.0 in)	0°
41800236	41800250	419 mm (16.5 in)	0°
41800464	-	470 mm (18.5 in)	0°
41800240	41800254	521 mm (20.5 in)	0°
41800424	41800440	572 mm (22.5 in)	0°
41800244	41800258	622 mm (24.5 in)	0°
41800246	41800260	673 mm (26.5 in)	0°
41800425	41800441	724 mm (28.5 in)	0°
41800453	41800456	775 mm (30.5 in)	0°
41800465	41800480	826 mm (32.5 in)	0°
41800466	-	876 mm (34.5 in)	0°
41800467	41800481	927 mm (36.5 in)	0°
41800818	-	381 mm (15.0 in)	35°
41800238	41800252	470 mm (18.5 in)	35°
41800452	41800455	521 mm (20.5 in)	35°
41800242	41800256	572 mm (22.5 in)	35°
41800420	41800436	622 mm (24.5 in)	35°
41800421	41800437	673 mm (26.5 in)	35°
41800422	41800438	724 mm (28.5 in)	35°
41800423	41800439	775 mm (30.5 in)	35°
41800468	41800551	826 mm (32.5 in)	35°
41800469	41800482	876 mm (34.5 in)	35°
41800470	-	927 mm (36.5 in)	35°
41800471	41800483	1,016 mm (40.0 in)	35°
41800472	41800484	1,117 mm (44.0 in)	35°
41800426	41800442	470 mm (18.5 in)	90°
41800427	41800443	521 mm (20.5 in)	90°
41800454	41800457	572 mm (22.5 in)	90°
41800473	41800553	622 mm (24.5 in)	90°
41800474	-	673 mm (26.5 in)	90°
41800475	-	724 mm (28.5 in)	90°
41800476	-	775 mm (30.5 in)	90°
41800477	41800485	826 mm (32.5 in)	90°
41800478	-	876 mm (34.5 in)	90°
41800479	-	927 mm (36.5 in)	90°
41800818	-	381 mm (15.0 in)	35°

Table 10. Service Parts: Braided Upper Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Sealing Washer, 10 mm (2)	41756-08
P-Clamp (1)	10059A
Cable Strap (3)	10065

Table 11. Braided Upper Brake Line Kits - 12mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length	Banjo Angle
41800726	-	876 mm (34.5 in)	0°
41800727	-	927 mm (36.5 in)	0°
41800725	-	673 mm (26.5 in)	35°
41800724	-	521 mm (20.5 in)	90°
41800806	-	826 mm (32.5 in)	0°
41800807	-	787 mm (31.0 in)	0°
41800826	-	724 mm (28.5 in)	35°

Table 12. Service Parts: Braided Upper Brake Line Kits - 12mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (4)	10600007
Cable Strap (3)	10065
Screw, Tapping (1)	4091
P-Clamp (1)	10059A

Table 13. Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Diamondback Kit	Diamond-Black Kit	Length
-	46791-09	1,080 mm (42.5 in)
46942-06	48962-09	1,120 mm (44 in)
-	48970-09	1,143 mm (45 in)

Table 14. Service Parts: Braided One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line (1)	Not sold separately
Washer, Sealing (2)	41733-88
Washer, Sealing (2)	41731-01
Cable Strap (3)	10065
P-Clamp (2)	10059A

Stock-Style Upper Brake Line Kit Numbers

Table 15. Stock-Style One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Kit	Length
41800326	1,049 mm (41 in)

Table 16. Service Parts: Stock-Style One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line (1)	Not sold separately
Washer, Sealing (4)	12300033
P-Clamp (1)	10053

Table 17. Stock-Style One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Kit	Flexible Length
41800610	331 mm (13 in)
41800611	429 mm (17 in)

Table 18. Service Parts: Stock-Style One-Piece Front Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line (1)	Not sold separately
Washer, Sealing (4)	12300033
Grommet (2)	12100087

Table 19. Stock-Style Upper Brake Line Kits - 10mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Kit	Length	Banjo Angle
41800656	847 mm (33 in)	10°
41800657	746 mm (29 in)	10°
41800667	557 mm (22 in)	10°
41800676	581 mm (23 in)	10°
41800678	699 mm (28 in)	10°
41800709	876 mm (34 in)	10°
41800710	787 mm (31 in)	10°
41800711	622 mm (24 in)	10°
41800652	496 mm (20 in)	56°
41800677	560 mm (22 in)	56°
41800704	521 mm (21 in)	56°
41800705	597 mm (24 in)	56°
41800653	674 mm (26.5 in)	56°
41800654	499 mm (20 in)	90°
41800655	601 mm (24 in)	90°
41800706	622 mm (24 in)	90°
41800707	546 mm (21.5 in)	90°
41800708	660 mm (26 in)	90°
41800802	432 mm (17 in)	10°
41800803	483 mm (19 in)	10°

Table 20. Service Parts: Stock-Style Upper Brake Line Kits - 10mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (2)	41756-08
Screw, Tapping (1)	10200422
P-Clamp (1)	10053

Table 21. Stock-Style Upper Brake Line Kits - 12mm Banjo Bolt

Fitments: See Handlebar Fitment Guide
Kit	Length	Banjo Angle
41800722	876 mm (34.5 in)	10°
41800723	787 mm (31 in)	10°
41800721	597 mm (23.5 in)	56°
41800720	499 mm (20 in)	90°
41800810	746 mm (29 in)	10°

Table 22. Service Parts: Stock-Style Upper Brake Line Kits - 12mm Banjo Bolt

Service Parts
Description (qty.)	Part Number
Brake Line, Upper (1)	Not sold separately
Washer, Sealing (2)	10600007
Screw, Tapping (1)	10200422
P-Clamp (1)	10053

Lower Brake Line Kit Numbers

Table 23. Lower Brake Line Kits - NON-ABS

Fitment	Diamondback Kits	Diamond-Black Kits	Stock Style	Length, Caliper Banjo Angle
See Handlebar Fitment Guide	41800226	41800228	-	48 cm (19 in) long, 10 mm x 65°
	41800412	41800413	-	53 cm (21 in) long, 10 mm x 65°
	41800590A	41800592A	-	43 cm (16.9 in) long, 10 mm x 65°
	42110-07	38116-10	-	54.6 cm (21 in) long, ⅜ in x 78°
	42110-07	38116-10	-	54.6 cm (21 in) long, ⅜ in x 78°
	42110-07	38116-10	-	54.6 cm (21 in) long, ⅜ in x 78°
	42366-07	48924-10	-	57.9 cm (23 in) long, ⅜ in x 78°
	42108-07	48926-10	-	61 cm (24 in) long, ⅜ in x 78°
	42112-08A	48928-10	-	61 cm (24 in) long, ⅜ in x 78°
	42371-07	48920-10	-	51.6 cm (20 in) long, ⅜ in x 78°
	41800374	41800375	-	51.6 cm (20 in) long, 10 mm x 60°
	45770-08	-	-	59.2 cm (23 in) long, ⅜ in x 78°
	42366-07	48924-10	-	57.9 cm (23 in) long, ⅜ in x 78°
	42110-07	38116-10	-	54.6 cm (21.5 in) long, ⅜ in x 78°
	41800634	-	41800636	49.3 cm (19 in) long, 10 mm x 90°
	45818-07	48938-10	-	40.6 cm (16 in) long, ⅜ in x 78°
	45820-07	-	-	40.6 cm (16 in) long, ⅜ in x 78°
	44907-08	48942-10	-	38.9 cm (15 in) long, 10 mm x 90°
	44905-08	41800280	-	38.9 cm (15 in) long, 10 mm x 90°
	41800336	41800338	-	54 cm (21 in) long, 10 mm x 65°
	41800336	41800338	-	54 cm (21 in) long, 10 mm x 65°
	83666-10	-	-	42.7 cm (17 in) long, 10 mm x 90°

Table 24. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 41800226, 41800228, 41800412, 41800413
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41756-08
P-Clamp, Cushioned (1)	42364-07

Table 25. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 41800590A, 41800592A
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41756-08

Table 26. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 42110-07, 38116-10, 42108-07, 48926-10, 42371-07, 48920-10, 41800374, 41800375, 45770-08, 42366-07, 48924-10, 41800634, 41800636
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41731-01
Cable Strap (3)	10065
Screw (45770-08 Only)	3594
Washer, Flat (45770-08 Only)	6703

Table 27. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 42112-08A, 48928-10
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (4)	41731-01
Screw (1)	923
P-Clamp (1)	10059A

Table 28. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 45818-07, 48938-10, 45820-07
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (4)	41731-011
Cable Strap (3)	10065

Table 29. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 44907-08, 48942-10, 44905-08, 41800280, 83666-10
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (4)	41751-06A
Cable Strap (3)	10065

Table 30. Service Parts: Lower Brake Line Kits - NON-ABS

Service Parts Kits 41800336, 41800338
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (4)	41751-06A
P-Clamp, Large (1)	Not sold separately
P-Clamp, Small (1)	Not sold separately
Cable Strap (3)	10006

Table 31. Lower Brake Line Kits - ABS

Fitment	Diamondback Kits	Diamond-Black Kits	Length, Caliper Banjo Angle
See Handlebar Fitment Guide	41800230A	41800232A	49 cm (19 in) long, 10 mm x 65°
	41800416A	41800417A	54 cm (21 in) long, 10 mm x 65°
	41800585	41800587	43 cm (17 in) long, 10 mm x 65°
	41800050	-	49.5 cm (19.5 in) long, ⅜ in x 78°
	41800032A	41800076A	55.4 cm (22 in) long, ⅜ in x 78°
	41800048	41800078	48.3 cm (19 in) long, ⅜ in x 78°
	41800032A	41800076A	55.4 cm (22 in) long, ⅜ in x 78°
	41800048	41800078	48.3 cm (19 in) long, ⅜ in x 78°
	38132-11A	38135-11A	47.8 cm (19 in) long, 10 mm x 65°
	41800370	41800369	47 cm (18.5 in) long, 10 mm x 60°
	41800370	41800369	47 cm (18.5 in) long, 10 mm x 60°
	38186-11A	-	51.6 cm (20 in) long, 10 mm x 65°
	41800308A	41800022B	53.8 cm (21 in) long, 10 mm x 65°
	41800370	41800369	47 cm (18.5 in) long, 10 mm x 60°
	38186-11A	-	51.6 cm (20 in) long, 10 mm x 65°
	41800308A	41800022B	53.8 cm (21 in) long, 10 mm x 65°
	41800632	-	42.1 cm (17 in) long, 10 mm x 90°
	41800632A	-	44.7 cm (17.6 in) long, 10 mm x 90°
	41825-09	48946-10	38.1 cm (15 in) long, 10 mm x 90°
	46049-09	-	35.6 cm (14 in) long, 10 mm x 90°
	41800332 / Mid-Brake Line	41800333 / Mid-Brake Line	37.8 cm (15 in) long, 10 mm x 90°
	41600094 Adapter (chrome)		2.5 cm (1 in) long, 12 mm x 80°
	41800292	-	42.7 cm (17 in) long, 10 mm x 60°

Table 32. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800230A, 41800232A, 41800416A, 41800417A
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41756-08
Cable Strap (3)	10065

Table 33. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800585, 41800587
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (4)	41756-08

Table 34. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800050, 41800032A, 41800076A
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41731-01
Screw (1)	4240
Lockwasher (1)	7118

Table 35. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800048, 41800078
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41731-01
Screw (1)	4240
Lockwasher (1)	7118

Table 36. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 38132-11A, 38135-11A, 38186-11A, 41800308A, 41800022B
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Brake Line, Intermediate (HCU to Upper Brake Line)	Not sold separately
Washer, Sealing (41800022B, 41800308A Only) (2)	41756-08
Washer, Sealing (All other kits)(4)	41731-01
Washer, Sealing (2)	41733-88
Cable Strap (2)	10006

Table 37. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800370, 41800369
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (2)	41731-01
Washer, Sealing (2)	41733-88
Washer, Sealing (2)	41756-08
Cable Strap (3)	10006

Table 38. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41825-09, 48946-10, 46049-09, Mid-Brake Line 41800332, 41800333
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Washer, Sealing (qty varies)	41751-06A
Cable Strap (qty varies)	10065

Table 39. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41600094 Adapter (Chrome), 41800292
Description (qty.)	Part Number
Brake Line, Linked Front Assembly (1)	Not sold separately
Brake Line, Linked Rear Assembly	Not sold separately
Washer, Sealing (2)	10600007
Washer, Sealing (10)	41756-08
Support Clip (2)	12200077
Screw (2)	4813A
Cable Strap (8)	10006

Table 40. Service Parts: Lower Brake Line Kits - ABS

Service Parts Kits 41800632, 41800632A
Description (qty.)	Part Number
Brake Line, Lower (1)	Not sold separately
Bushing, Manifold (1)	Not sold separately
Screw, Shoulder (1)	5004
Washer, Sealing (2)	41756-08

Mid-Brake Line Kit Numbers

Table 41. Stock-Style Upper Mid-Brake Line Kits

Fitment	Kit
See Handlebar Fitment Guide	41800321
See Handlebar Fitment Guide	41800738

Table 42. Stock-Style Lower Mid-Brake Line Kits

Fitment	Kit
See Handlebar Fitment Guide	41800323A
See Handlebar Fitment Guide	41800690

Brake Line Adapter Kit Numbers

Table 43. Upper Brake Line Adapters

Fitments: See Handlebar Fitment Guide
Use	Kit
Braided Upper Brake Line into Lower Brake Line	41600245
Stock-Style Upper Brake Line into Lower Brake Line	41600260

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.

NOTE

If brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water. DOT 4 BRAKE FLUID (41800219)

Cover painted parts to protect finish.

STOCK FRONT BRAKE LINE REMOVAL

For proper removal procedures, refer to the service manual for the vehicle being modified.

FRONT BRAKE LINE INSTALLATION

For proper installation procedures, refer to the service manual for the vehicle being modified.

NOTE

The front brake line setup designated for the handlebar being installed assumes replicating the stock line routing with an accessory handlebar mounted. It should be noted that in some cases, routing modifications may be needed, or a different length of brake line may be required. Contact a Harley-Davidson dealership if a different length is required.

In certain instances, the accessory brake line assembly deviates from the stock assembly. See below to ensure the application does not have any noted assembly differences.

2014 and Later Touring ABS Mid-Line and 2019 and Later FLHTCUTG/FLRT Mid-Line Installation and Routing

NOTE

2014 and later Touring models have a stock-style mid-brake line that runs from the Anti-lock Braking System (ABS) module to the fairing area. This allows for the use of the stock routing caddies and methods. The mid-brake lines have excess length so that the lines can be routed with as little stress on the connection points between the mid-line and the braided line as possible.

1.	Follow installation instructions in the service manual until the step where placing the new brake line onto the vehicle is reached.
2.	If installing braided lower brake lines, obtain the lower brake lines, the mid-lower right brake line, the mid-lower left brake line and four sealing washers.
3.	See Figure 1. Route the mid-lower brake lines (2) male swivel fittings from the front of the vehicle to locations shown behind the lower triple-clamp.
4.	Route the flexible mid-lower mid-brake lines: Avoid twisting the brake lines. a. Route brake line behind the wire bundle (6). b. Route in front of the steering head, under the radio (8) c. Route down the right side of the backbone to the ABS module.
5.	With MID-LOWER brake lines parallel and untwisted, install sealing washers on either side of the banjo fittings. Install the banjo bolts removed earlier from the ABS module. Leave fasteners loose.
6.	Attach the LOWER brake lines at the swivel fittings and route to the front calipers. Install sealing washers and banjo bolts removed earlier. Leave fasteners loose.
7.	If installing braided upper brake lines, obtain the UPPER brake line, the MID-UPPER brake line and two sealing washers.
8.	Position UPPER brake line. a. FLHT, FLHX, FLHTCUTG models: See Figure 1. Position the UPPER brake line (3) with the banjo fitting at the master cylinder and the swivel threaded end toward the front. Route the swivel threaded end in front of the steering head and the hydraulic clutch line (4). Join with the MID-UPPER line in front of the steer head and route counterclockwise behind the wire bundles, along the right side of the backbone to the ABS module. b. FLTR, FLRT models: See Figure 2. Position the UPPER brake line (7) with the banjo fitting at the master cylinder and the swivel threaded end toward the front. Route the line clockwise, down and around the frame member under the handlebar risers and heading down the left side of the fairing support structure. Join with the MID-UPPER line that is routed under the fairing structure in a counterclockwise direction, and down the right side of the backbone to the ABS module.
9.	Resume to following the service manual to complete the brake line installation procedure to seal all banjo fittings at both the master cylinder and ABS module.
10.	Tighten all swivel fittings. Making sure only the swivel nut turns, tighten the swivel nut past finger-tight by 45°, or: Torque: 5.1–7.3 N·m (45–65 in-lbs)

1	Mid-upper brake line (routed counter-clockwise)
2	Mid-lower brake lines (routed clockwise)
3	Upper brake line, braided
4	Hydraulic clutch line
5	Swivel nut upper brake line connection (cover with protective sleeve)
6	Brake lines routed behind wire harness bundle
7	Upper brake line fastened to right side fork tube
8	Radio and radio mount bracket
9	Lower brake line swivel nut (behind lower triple clamp)

Figure 1. Outer Fairing View - Brake Line Routing: FLHT, FLHX

1	Forward brake retention clip
2	Mid-lower brake line (2)
3	Unused slot (for OE upper brake line)
4	Slot for hydraulic clutch line
5	Mid-upper brake line
6	Secure mid-upper brake line here (under frame)
7	Braided upper brake line
8	Braided upper to mid-upper brake line connection. Cover with protective sleeve, secure to risers.

Figure 2. Outer Fairing View - Brake Line Routing: FLTR

2014 and later TOURING NON-ABS LOWER BRAKE LINE

1.	Follow installation instructions in service manual until the step where placing the new brake line onto the vehicle is reached.
2.	Some stock Touring models are equipped with a locating roll pin on the mounting surface for the lower brake line manifold. Remove the roll pin before installing the new brake line kit.
3.	Remove the plastic brake line mounting caddy located on the rear of the lower triple clamp. Retain the mounting screws for later use.
4.	NOTE The lower brake line manifold is mounted so the two lines to the calipers go to the rear and down. See Figure 3. Obtain the new UPPER (1) and LOWER (2) brake line assemblies.
5.	Position the LOWER brake line (2) to the backside of the lower triple clamp, and center the lower legs of the brake line between the forks oriented rearward and down.
6.	NOTE The brake lines must not contact the forks. If either brake line is touching the fork, loosen the p-clamps, reposition and re-tighten. Obtain the large (6) and small (7) brake line P-clamps and attachment screws removed earlier from the plastic brake line caddy. Attach the lower brake line assembly and fasten the P-clamps to the triple clamp. The right hand P-clamps will overlap. Tighten. Torque: 13.6–20.3 N·m (10–15 ft-lbs)
7.	Tighten the swivel fitting. Making sure only the swivel nut turns, tighten the swivel nut past finger-tight by 45°, or: Torque: 5.1–7.3 N·m (45–65 in-lbs)
8.	Resume to following the service manual to complete the brake line installation procedure to both master cylinder and front calipers.

1	Upper brake line assembly (master cylinder to female swivel nut fitting)
2	Lower brake line assembly (male fitting to calipers)
3	Master cylinder
4	Caliper
5	Swivel nut connection of upper and lower brake lines
6	P-clamp, large
7	P-clamp, small (2)

Figure 3. 2014 and later Front Non-ABS Brake Lines

2014 and later FLHTCUTG AND 2015 and later FLRT LOWER LINKED LINES

NOTE

All procedures for mounting these lower brake lines are the same as what is outlined in the service manual, with the exception of an additional plastic support clip.

See Figure 4. Install a support clip (1) 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.

1	Lower brake line support clip (2)

Figure 4. Lower Brake Line Support Clips

2011-2017 SOFTAIL ABS UPPER BRAKE LINE ROUTING ON FL MODELS WITH FORK COVERS

NOTE

All procedures for mounting these lower brake lines are the same as what is outlined in the service manual, with the exception of the use of the lower P-clamp on FL models with fork covers.

Remove the top screw on the fork cover. Get the small P-clamp (7) from the upper brake line kit. Route the upper brake line though the P-clamp and use the screw to attach it to the same location on the fork cover. DO NOT attach the brake line to the lower hole location on the fork cover. Adjust the position of the brake line to route smoothly from the manifold to the P-clamp. Rotation of the P-clamp may be necessary for some handlebars. Tighten.

Torque: 2.3–3.4 N·m (20–30 in-lbs)

2018 and later SOFTAIL UPPER BRAKE LINE ADAPTER

1.	NOTE All procedures for mounting these upper brake lines are the same as what is outlined in the service manual, with the exception of a brake line adapter between the lower brake line manifold (ABS) or lower brake line (non-ABS). The use of the proper adapter allows for ease of routing, and in some ABS cases, eliminates the need to replace the stock lower brake line. Follow installation instructions in service manual until the step where placing the new upper brake line onto the vehicle is reached.
2.	Prior to attaching the upper brake line to the vehicle, attach the proper adapter to the lower end of the upper brake line. Leave the connection loose to allow for adjustment prior to final routing.
3.	Once routing of upper brake line is completed, tighten banjo fittings and tube nut joints to the torque specification outlined in the service manual.
4.	Figure 5 Tighten swivel fittings. Making sure only swivel nut turns, tighten swivel nut past finger-tight by 45°, or: Torque: 5.1–7.3 N·m (45–65 in-lbs)

1	Swivel nut
2	Tube nut

Figure 5. Brake Line Adapters

1	Brake line
2	Tube nut

Figure 6. Brake Line Orientation

FINAL ASSEMBLY AND RETURN TO SERVICE (ALL MODELS)

Refer to the service manual for the proper final assembly procedure for the vehicle being serviced. This includes:

Proper securing of all brake lines and affected systems with the noted exceptions stated here
Torque values for all fasteners
Proper type of brake fluid to use
Proper brake bleeding procedures
Leak checks

2.	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.
3.	Once all steps in the service manual and above have been performed, slowly test ride the vehicle. If the brakes do not function as intended, repeat the bleeding procedure as outlined in the service manual.