BRAIDED FRONT BRAKE LINE KITS

J017352009-06-18

GENERAL

Kit Numbers

Table 1. Braided Front Brake Line Kits

Stainless Steel Kits	Diamondback^™ Kits	Diamond-Black Kits
43350-96C	44877-05	N/A
44793-01	44899-05	N/A
44813-00A	44897-05	N/A
44815-00A	44885-05	N/A
44890-04A	46689-06	N/A
45201-97B	N/A	N/A
45202-00A	N/A	N/A
45202-97B	N/A	N/A
45203-97B	N/A	N/A
45205-97B	N/A	N/A
45206-97B	44887-05	N/A
45207-97B	N/A	N/A
45208-97B	N/A	N/A
45209-97B	44901-05	N/A
45210-97B	N/A	N/A
45212-97B	44877-05	N/A
45264-98B	44903-05	46791-09
45781-02	46691-06	N/A
45783-02	46693-06A	N/A
46011-01	44883-05	N/A
46378-05	N/A	N/A
N/A	46708-06	N/A
N/A	46715-06	N/A
N/A	46724-06	N/A
N/A	46726-06	46740-09
N/A	46654-06	N/A
N/A	N/A	48972-09
45119-00B	44885-05	N/A
45112-96A	44887-05	N/A
45291-00A	N/A	N/A
45250-98B	44903-05	N/A
45199-99B	44897-05	N/A

Table 2. Braided Front Brake Line Kits (continued)

Stainless Steel Kits	Diamondback^™ Kits	Diamond-Black Kits
45121-96A	N/A	N/A
45115-95B	44901-05	N/A
45110-96A	N/A	N/A
44794-01A	44899-05	N/A
42317-06A	44883-05	N/A

Models

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

These instructions describe the installation on non-ABS models only. For ABS models, contact a Harley-Davidson dealer.

Tools and Supplies Required

Fresh, uncontaminated DOT 5 or DOT 4 brake fluid is required for installation of this kit. Refer to the service manual or contact a Harley-Davidson dealer for the correct type of brake fluid required.

A service manual is available from a Harley-Davidson dealer.

WARNING

Rider 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

See Service Parts tables for kit contents.

REMOVAL

Models with main fuse:

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

Refer to the owner's manual and follow the instructions given to remove the main fuse.

Models with main circuit breaker:

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

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)

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

Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).

See Figure 1. Open bleeder nipple cap on front brake caliper. Install end of a length of plastic tubing over caliper bleeder valve (1), while placing free end in a suitable container. Open bleeder valve about one-half turn. Pump brake lever to drain brake fluid.
Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Save bolt and discard washers.
Remove bolt and two sealing washers to disconnect brake line fitting from each brake caliper. Save bolt(s) and discard washers.
On dual disk systems, the right and left side brake lines are similar, but not identical. To distinguish between them, carefully mate the new brake lines up to the old brake lines before removing the old lines from the motorcycle. Verify the banjo fittings on the new brake lines are oriented the same as the ones on the old brake lines.
Carefully make note of brake line routing, then remove brake line from motorcycle. Some kits contain new clamps to replace the original equipment (OE) clamps being removed.

INSTALLATION

For dual disk systems, install the brake line tee to the fork stem. Tighten the screw to 13.6–20.3 N·m (10–15 ft-lbs).

Thread flare nut ends on braided brake lines into brake line tee. Do not tighten at this time.

For single or dual disk systems, Position new sealing washers from the kit on each side of hydraulic brake fittings (banjo fittings). Insert bolts (removed earlier) through washers and fittings. Hold new braided brake line(s) in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the correct orientation. Verify there is no twist in the brake line(s). Adjust if necessary.

1	Caliper bleeder valve

Figure 1. Draining Brake Fluid

Install clamps from kit by wrapping clamp around brake line at each of the clamp mounting locations. Verify the clamp is oriented the same as the OE clamps. Install clamp screws but leave loose for now.

Check entire length of brake lines to make sure line is not twisted, line is not in contact with any vehicle components, and the brake line lengths between clamps is sufficient. Make adjustments as necessary.

For dual disk systems, tighten flare nut fittings at the tee to 13.6–20.3 N·m (10–15 ft-lbs).

Tighten bolts at banjo fittings at the master cylinder and the caliper(s) to 23–30 N·m (17–22 ft-lbs).

Tighten all clamp screws being careful to hold clamps in correct orientation while tightening and install cable straps at same locations as OE cable straps (if present) were located.

NOTE

For 2006 and later Dyna models with ignition switch/key location at front of frame directly behind steering head, turn clamp located below lower triple tree toward left side of vehicle to move vertical portion of brake line between upper and lower clamps as far right as possible in order to keep brake line away from ignition key during a full-right turn of the handle bars.

Remove the master cylinder cover. Position the motorcycle upright so the master cylinder is in a level position.

10.

Add the correct brake fluid following the instructions in the owner's manual to the master cylinder reservoir until the fluid level is 3.2 mm (0.12 in) from the top. Do not reuse 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)

11.

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.

12.

Add brake fluid to the master cylinder reservoir until the fluid level is 3.2 mm (0.12 in) from the top.

13.

Activate and hold brake lever to build up hydraulic pressure.

14.

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.

15.

Repeat steps 12-14 until all air bubbles are purged.

16.

Final tighten bleeder valve to 9–11.3 N·m (80–100 in-lbs). Install bleeder cap. 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 installing the main fuse/attaching the battery cables.

17.

Verify that the ignition/key switch is turned to the OFF position. Models with main fuse: Refer to the owner's manual and follow the instructions given to install the main fuse. Models with main circuit breaker : 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 service 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.

SERVICE PARTS

Table 3. Kits 44793-01, 44813-00A, 44815-00A, 44885-05, 44887-05, 44897-05, 44899-05, 44903-05, 45201-97B, 45202-00A, 45202-97B, 45203-97B, 45206-97B, 45264-98B, 46654-06, 46689-06, 46791-09, 48972-09

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (2)	10059A

Table 4. Kits 45204-97B, 45205-97B, 45207-97B, 45287-99B

Item	Description (Qty)	Part Number
1	Braided brake line (master cylinder to tee)	Not Sold Separately
2	Braided brake line (tee to right side caliper)	Not Sold Separately
3	Braided brake line (tee to left side caliper)	Not Sold Separately
4	Cable strap (3)	10065
5	Gasket, banjo (6)	41731-01
6	Brake line tee	Not Sold Separately
7	Clamp	71795-63A

Table 5. Kits 44883-05, 46011-01, 42317-06A

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (3)	68562-84

Table 6. Kits 44901-05, 45208-97B, 45209-97B, 45110-96A, 45115-95B

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Clamp (2)	10209
4	Gasket, banjo (2)	41733-88
5	Gasket (2)	41731-01
6	Clamp	68562-84

Table 7. Kit 45210-97B

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (3)	68562-84

Table 8. Kits 43350-96C, 44877-05, 45212-97B, 45781-02

Item	Description (Qty)	Part Number
1	Braided brake line (master cylinder to tee)	Not Sold Separately
2	Braided brake line (tee to right hand caliper)	Not Sold Separately
3	Braided brake line (tee to left hand caliper)	Not Sold Separately
4	Cable strap (3)	10065
5	Gasket (6)	41731-01
6	Brake line tee	Not Sold Separately

Table 9. Kits 46708-06, 46715-06, 46724-06, 46726-06, 46740-09

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (2)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (2)	10059A

Table 10. Kits 46693-06A, 45783-02

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (3)	68562-84
6	Clamp	71795-63A
7	Clamp	10209

Table 11. Kits 44890-04A, 46689-06, 45119-00B, 45112-96A, 45121-96A, 45291-00A, 45250-98B, 45199-99B, 44794-01A

Item	Description (Qty)	Part Number
1	Braided brake line	Not Sold Separately
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (3)	68562-84
6	Clamp	71795-63A

Table 12. Kit 46378-05

Item	Description (Qty)	Part Number
1	Braided brake line	45191-05
2	Cable strap (3)	10065
3	Gasket, banjo (2)	41733-88
4	Gasket (2)	41731-01
5	Clamp (3)	68562-84