SOFTAIL BRAIDED REAR BRAKE LINE KIT
J016352005-12-13
GENERAL
Kit Number
44803-00B, 44881-05, 46650-06, and 46652-06
Models
Kits 44803-00B and 44881-05 fit 2000 and later FL Softails and FXSTD (except FXSTDSE), and 2000-2005 FX Softails.
Kits 46650-06 and 46652-06 fit 2006 and later FX Softails (except FXSTD).
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)
NOTE
This instruction sheet covers motorcycle models that use either D.O.T. 4 Hydraulic Brake Fluid or D.O.T. 5 Silicone Hydraulic Brake Fluid. Your model motorcycle's Owner's Manual, Service Manual, and Master Cylinder Cover will all indicate which type of brake fluid should be used for your motorcycle.
Additional Parts Required
There are no additional parts required for this kit.
INSTALLATION
WARNINGContact 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
CAUTIONDirect 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)
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)
Drain Brake Fluid
| 1. | Pop off bleeder nipple cap on the rear brake caliper. | |
| 2. | Install one end of a length of plastic tubing over the caliper bleeder valve. Place the free end of the tubing into a suitable container. | |
NOTICE Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) | ||
| 3. | Open the bleeder valve about 1/2-turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not reuse brake fluid. |
Remove Existing Rear Brake Line
| 1. | Disconnect wiring harness connectors from brake light switch spade terminals. | |
NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) | ||
| 2. | Disconnect existing brake line from rear brake caliper and rear brake master cylinder assembly. Save banjo bolts, but discard brake line gaskets. NOTE This kit contains all gaskets needed for replacement. | |
| 3. | Carefully make note of rear brake line routing and orientation of banjo fittings, then remove existing brake line. Save hex head screw holding brake light switch manifold to tab on frame, but discard brake line and attaching parts. | |
| 4. | Unthread brake light switch from brake line. Save switch for later use. |
Install Braided Rear Brake Line Kit
NOTE
Before installing brake light switch into new braided brake line manifold, clean pipe threads and apply Loctite® PST 565 Pipe Sealant with Teflon (H-D part number 99818-97) to the threads. To prevent brake fluid contamination, be careful not to allow excess sealant to seep into the manifold (do not apply thread sealant too close to end of thread).
| 1. | See Figure 1. Install rear brake light switch as follows: 72023-51C Brake Light Switch (stock on 2000-2005 Softail
models): Install switch (1) into threaded hole in manifold of braided brake line. Tighten switch to 84-120 in-lbs (9.5-13.6 Nm). 72023-51D Brake Light Switch (stock on 2006-later Softail
models, or replacement on 2000-2005 Softail models): Install brake light switch (2) into threaded hole in manifold of braided brake line. Tighten switch to 12-15 ft-lbs (16.3-20.3 Nm). NOTE Make sure banjo fittings on braided brake line are oriented the same as fittings on existing brake line. | 
Figure 1. Rear Brake Light Switches | ||||||
| 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) | ||||||||
| 2. | See Figure 3. Run braided brake line (1) along the same route as existing brake line. a. Lubricate brake line gaskets (steel/rubber washers) (2) from kit with D.O.T. 4 Hydraulic Brake Fluid or D.O.T. 5 Silicone Hydraulic Brake Fluid, depending on the brake fluid used on your vehicle. See your Owner's Manual, Service Manual, or Master Cylinder Cover to determine the correct fluid. b. Use stock banjo bolts and new gaskets (one gasket on each side of brake line banjo fitting) to fasten braided rear brake line at rear brake master cylinder and rear brake caliper. c. Tighten banjo bolts to 17-22 ft-lbs (23-30 Nm). | |||||||
| 3. | The brake light switch manifold on the braided brake line has a 1/4-20 tapped hole and a 1/4 inch diameter rod. 2003 and earlier models: Line up tapped hole to top hole in frame mounting tab. Fit rod into bottom hole to orient brake line. Attach manifold to frame tab with original equipment screw (A). Tighten screw to 80-100 in-lbs (9.0-11.3 Nm). 2004 and later models: Obtain bracket (4) and screw (5) from kit. Line up tapped hole in brake light switch manifold to top hole in bracket. Fit rod into center hole to orient brake line. Attach manifold to bracket using screw from kit. Attach bracket to frame with the original equipment screw (A). Tighten screw to 80-100 in-lbs (9.0-11.3 Nm). | |||||||
| 4. | Connect wiring harness connectors [121] detached earlier onto brake light switch spade terminals. a. If connecting harness to the 72023-51D Rear Brake Light Switch (2006-later Softail models, or replacement on 2000-2005 Softail models) align female wiring harness connector with the brake light switch terminals so the flat side of the metal receptacle inside the connector housing faces the isolator wall. This will prevent interference with the switch terminal isolator wall ( Figure 1 , item 3). | |||||||
| 5. | Use cable straps (3) to secure brake line to lower frame tube. | |||||||
| 6. | See Figure 2. Place braided brake line under frame clips (1). | 
Figure 2. Frame Clip Locations |
Bleed and Test Rear Brake Line
| 1. | Remove rear brake master cylinder cover. | |
| 2. | Stand motorcycle upright so master cylinder is in a level position. NOTE This instruction sheet covers motorcycle models that use either D.O.T. 4 Hydraulic Brake Fluid or D.O.T. 5 Silicone Hydraulic Brake Fluid. Your model motorcycle's Owner's Manual, Service Manual, and Master Cylinder Cover will all indicate which type of brake fluid should be used for your motorcycle. | |
| 3. | Add D.O.T. 4 Hydraulic Brake Fluid or D.O.T. 5 Silicone Hydraulic Brake Fluid (check your Owner's Manual, Service Manual, or Master Cylinder Cover for correct type for your model motorcycle) only to master cylinder reservoir until fluid level is 1/8 in. (3.2 mm) 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. Actuate the brake pedal. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly. | |
| 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. | Depress and hold brake pedal to build up hydraulic pressure. | |
| 6. | Open bleeder valve about 1/2 turn. Brake fluid will flow from bleeder valve through tubing. Close bleeder valve when brake pedal has moved 1/2 to 3/4 of its full range of travel. Allow brake pedal to return slowly to its released position. | |
| 7. | Repeat steps 3, 5, and 6 above until all air bubbles are purged. | |
| 8. | Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm), then install bleeder cap. | |
| 9. | Add brake fluid to master cylinder reservoir until fluid level is about 1/8 in. (3.2 mm) from the top. | |
| 10. | Install master cylinder reservoir gasket, cover, and screws. Tighten screws to 6-8 in-lbs (0.7-0.9 Nm). | |
| WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 11. | Turn the Ignition Key/Light Switch to IGNITION and apply the rear brake foot pedal to test operation of the brake light. | |
| 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) | ||
| 12. | Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure. |
SERVICE PARTS
Figure 3. Service Parts: Softail Braided Rear Brake Line Kit
Table 1. Service Parts: Softail Braided Rear Brake Line Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Brake line, braided | Not Sold Separately |
2 | Gasket (4) | 41731-01 |
3 | Cable strap (4) | 10065 |
4 | Bracket | 45108-04 |
5 | Screw | 3588 |
Items mentioned in text, but not included in kit: | ||
A | Bracket mounting screw (original equipment) | |