1984-1995 TOURING MODEL FRONT BRAKE LINE KIT
J001092009-03-13
GENERAL
Kit Number
43349-84D
Models
This kit fits 1984-1995 FL Touring models (except Road King) with dual front disc brakes.
Additional Parts Required
WARNINGReplace 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)
New brake line gaskets (banjo washers) must be installed. These gaskets are available separately from a Harley-Davidson dealer. Refer to the parts catalog for your year/model vehicle for the correct part numbers, or see Table 1.
Table 1. Brake Line Gaskets (Banjo Washers)
Part Number | Description | Usage |
|---|---|---|
41731-82 | Zinc-plated copper | 1984-1989 models |
41731-88A | Steel with rubber ring | 1990-1995 models |
Tools and Supplies Required
Fresh, uncontaminated DOT 5 brake fluid is required for installation of this kit.
WARNINGBrakes 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)
WARNINGRider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
Kit Contents
Table 2. Kit Contents
Description (Quantity) | Part Number |
|---|---|
Brake line assembly | Not sold separately |
Speedometer cable P-clamp | 9990W |
Spacer | 52103-31 |
REMOVAL
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Refer to the owner's manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. | |||||||||||||
| CAUTION Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b) | ||||||||||||||
| 2. | See Figure 1. Turn handlebar so one front brake caliper bleeder valve (1) is near vertical. Open bleeder nipple cap on that caliper. Install end of a length of plastic tubing over caliper bleeder valve while placing free end in a suitable container. Open bleeder valve about one-half turn. Pump brake lever to drain brake fluid from brake line. Turn handlebar so the opposite front brake caliper bleeder valve is near vertical. Repeat the bleeding procedure for second brake line. | 
Figure 1. Draining Brake Fluid | ||||||||||||
| 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) | ||||||||||||||
| 3. | Remove bolt and two brake line gaskets to disconnect brake line fitting from master cylinder. Save bolt and discard gaskets. | |||||||||||||
| 4. | See Figure 2. Remove screw (2) and washer (3) (and speedometer cable clip, item 4 on earlier models) to disconnect front brake line (1) tee from underside of fork stem. Remove spacer (5) from under tee. Discard speedometer cable clip, but save screw, washer and spacer for later assembly. | 
Figure 2. FLT Front Brake Line (Typical) | ||||||||||||
| 5. | Remove bolt and two brake line gaskets to disconnect brake line fitting from each brake caliper. Save bolts and discard gaskets. | |||||||||||||
| 6. | Carefully make note of brake line routing, then remove brake line from motorcycle. |
INSTALLATION
| 1. | Position new front brake line to vehicle, following routing of the original. NOTE On earlier models, brake line gaskets (banjo washers) were zinc-coated copper. Later gaskets were steel with a rubber ring in the inside diameter. It is important that the new gaskets are the same type as the original. The banjo bolt is designed for a specific type of gasket and interchanging gaskets can cause brake line leakage. See Table 1. | |
NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) | ||
| 2. | Position a new brake line gasket on each side of upper hydraulic brake fitting (banjo fitting). Insert banjo bolt (removed earlier) through gaskets and fitting. Hold new brake line in position and install bolt into master cylinder and caliper. Tighten only enough to keep banjo fitting in the correct orientation. | |
| 3. | Position a new brake line gasket on each side of lower hydraulic brake fittings (banjo fittings). Insert banjo bolts (removed earlier) through gaskets and fittings. Hold new brake line in position and install bolt into each caliper. Tighten only enough to keep banjo fitting in the correct orientation. | |
| 4. | See Figure 2. Position brake line (1) tee to fork stem with OE spacer (5) under tee as shown. Insert OE screw (2) through OE washer (3). For 1984-1987 models, place speedometer cable in new speedometer cable clamp (4) from kit. Insert screw (2) through new spacer (6) from kit and speedometer cable clip (4). For ALL models, install screw (2) through tee and spacer (5), and tighten screw to 13.6–20.3 N·m (120–180 in-lbs). | |
| 5. | Check entire length of brake lines to make sure line is not twisted or in contact with any vehicle components . Make adjustments as necessary. | |
| 6. | For models using zinc/copper brake line gaskets: Tighten bolts at banjo fittings at master cylinder and calipers to 41–47 N·m (30–35 ft-lbs). For models using steel/rubber brake line gaskets: Tighten bolts at banjo fittings at master cylinder and calipers to 23–30 N·m (17–22 ft-lbs). | |
| 7. | Remove master cylinder cover. Position motorcycle upright so master cylinder is in a level position. | |
| 8. | Following the instructions in the owner's manual, add new DOT 5 brake fluid to the master cylinder reservoir until the fluid level is 3.2 mm (0.12 in) from the top. Do not reuse old brake fluid. | |
| WARNING A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) | ||
| 9. | Verify proper operation of the master cylinder relief port. Actuate the brake hand lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly. | |
| 10. | Add DOT 5 brake fluid to the master cylinder reservoir until the fluid level is 3.2 mm (0.12 in) from the top. | |
| 11. | Activate and hold brake lever to build up hydraulic pressure. | |
| 12. | Open bleeder valve about one-half turn. Brake fluid will flow from bleeder valve through tubing. Close bleeder valve when brake lever has moved one-half to three-quarters of its full range of travel. Allow brake lever to return slowly to its released position. | |
| 13. | Repeat steps 10-12 until all air bubbles are purged. | |
| 14. | Final tighten bleeder valve to 9–11.3 N·m (80–100 in-lbs). Install bleeder cap. | |
| 15. | Repeat steps 12-14 with the bleeder valve on the opposite-side caliper. | |
| 16. | Add brake fluid to master cylinder reservoir until fluid level is about 3.2 mm (0.12 in) from the top. Final tighten master cylinder reservoir cover screws to 0.7–0.9 N·m (6–8 in-lbs). NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cable. | |
| 17. | Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (Part Number 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal. Refer to the owner's manual and follow the instructions given to attach the negative battery cable. | |
| 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) | ||
| 18. | Refer to the owner's manual, and follow instructions to install the 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) | ||
| 19. | Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure. |