OE MATCH BRAKE LINE - REACH/TRACKER FITMENT

941002932024-01-23

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
41701145, 41800874, 41800877	Safety Glasses, Torque Wrench

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Brake Line

Table 2. Kit Contents: Brake Line Kit

Verify that all contents are present in the kit before installing or removing items from vehicle.
Item	Qty	Description	Part No.	Notes
1	1	Brake line	Not sold separately
2	4	Gasket, brake line	41751-06A
2	3	Cable strap	10065

GENERAL

Models

For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.

Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

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 the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

REMOVE

1.	Remove airbox. See service manual.
2.	Relocate electrical caddy to access brake line connections.
3.	Disconnect Original Equipment (OE) brake line. See service manual.

INSTALL

1.	Install new brake line.
2.	Figure 2 Connect front brake line (1), gaskets (4) and OE screw (3).
3.	Attached front brake line (1) to vehicle frame with OE P-clips (5) and OE screws (3).
4.	Figure 3 Attach front brake line (1), gaskets (3) and OE screw (4) to master cylinder (2).

1	Front brakeline
2	Front brakeline connector
3	OE Screw (3)
4	Gasket (2)
5	OE P-clip (2)

Figure 2. Front Brakeline Connection

1	Front brakeline
2	Master cylinder
3	Gasket (2)
4	OE Screw

Figure 3. Front Brakeline Connection to Master Cylinder

COMPLETE

1.	Install electrical caddy. See service manual.
2.	Install airbox. See service manual.

RETURN TO SERVICE

1.	Refer to service manual for proper final assembly procedure for vehicle being serviced. This includes: a. Proper securing of all brake lines and affected systems with noted exceptions stated here b. Torque values for all fasteners c. Proper type of brake fluid to use d. Proper brake bleeding procedures e. Leak checks
2.	NOTE When routing accessory brake lines, the intention is: a. Gentle routing without any sharp bends or kinking b. Free uninhibited movement from steer lock to steer lock c. Clearance to any pinch-points throughout steering motion d. Clearance to any potential snags such as ignition switch with key installed e. Avoid any contact with painted surfaces throughout steering motion (fender, gas tank, miscellaneous body components) f. Light structure contact with frame, downtubes or triple clamp may occur but only at full extents of steering motion
3.	Adjustments to brake line routing can include: a. Use of P-clamp in place of stock wire-form retention (on some models) b. Lower manifold adapter fitting orientation (on some models) c. Line lengths between mounting locations and banjo fitting angles d. P-clamp orientation e. Banjo fitting orientation
4.	Make sure all brake lines are routed properly. This includes turning 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 routing of brake lines and adjust as necessary.
5.	Once all steps in service manual and above have been performed, slowly test ride vehicle. If brakes do not function as intended, repeat bleeding procedure as outlined in service manual.