ABS MID- AND LOWER-FRONT BRAKE LINE KITS

J057902026-04-21

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
41800321, 41800323A, 41800332, 41800333, 41800905, 41800906, 41800907, 41800933, 41801008, 41801039, 41801041, 41801042, 41801069, 41801071, 41801127, 41801129	Safety glasses, Torque wrench, Isopropyl alcohol, DOT 4 brake fluid, DTII

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

KIT CONTENTS

Figure 1. Kit Contents: ABS Mid- and Lower-Front Brake Line

Table 2. Kit Contents: ABS Mid- and Lower-Front Brake Line Kits

Verify that all contents are present in the kit before installing or removing items from vehicle.
Item	Qty	Description	Part No.	Notes
1	1	Kits 41800321, 41801127: Mid-Upper (includes items 2-5)
2	1	Brake line, ABS unit to master cylinder	Not sold separately	Banjo fitting is shaped differently: See Figure 3.
3	2	Copper sealing washer, M12	10600007
4	1	Protective sleeve	72162-02
5	2	Cable strap	10065
6	1	Kits 41800323A, 41801129: Mid-Lower (includes items 7-10)
7	1	Brake line, ABS unit to left caliper	Not sold separately	Banjo fitting is shaped differently. See Figure 3.
8	1	Brake line, ABS unit to right caliper	Not sold separately	Banjo fitting is shaped differently. See Figure 3.
9	4	Copper sealing washer, M10	41751-06A
10	2	Cable strap	10065
11	1	Kits 41800332, 41800333, 41800906, 41800907: Lower Kit, Diamondback (includes items 12-14) Kits 41801069, 41801071: (includes items 12, 13)
12	2	Lower brake line, braided	Not sold separately
13	4	Copper sealing washer, M10	41751-06A
14	3	Cable strap	10006
15	1	Kit 41800933: Mid Front Upper, ABS, FLT, Kit 41800905: FLH/FLHR (Batwing/Road King) Touring (includes items 16-19)
16	1	Mid brake line, front upper, ABS	Not sold separately	Banjo fitting is shaped differently. See Figure 4.
17	1	Protective sleeve	Not sold separately	Banjo fitting is shaped differently. See Figure 4.
18	1	Clip, brake line	41600320
19	2	Cable strap	10065
20	1	Kits 41801041, 41801042: Mid Front Lower, Trike (includes items 21-25)
21	2	Line clamp	10800211
22	1	Mid brake line, front lower, ABS	Not sold separately
23	3	Cable strap	10065
24	2	Copper sealing washer, M10	41751-06A
25	1	Banjo bolt, 10mm	11600001
26	1	Kits 41800905, 41801008: Mid-Lower (includes items 27-29)
27	1	Brake line, ABS unit to left caliper	Not sold separately	Banjo fitting is shaped differently. See Figure 4.
28	1	Brake line, ABS unit to right caliper	Not sold separately	Banjo fitting is shaped differently. See Figure 4.
29	2	Cable strap	10065

GENERAL

Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:

Go to h-d.com/isheets
Scan QR code in upper left corner of the instruction sheet

NOTE

This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.

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.

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

Installation Requirements

WARNING

Brakes 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)

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

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)

WARNING

Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a)

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)

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

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.

These items are available at your local Harley-Davidson dealership.

Separate purchase of new, uncontaminated DOT 4 Brake Fluid is required for this installation.
Kits 41800321 and 41800933: Separate purchase of Upper Brake Line Kit is required for installation.

NOTE

Upper Brake Line Kits are available in various master cylinder banjo angles and brake line lengths. Shorter or longer lines could be necessary when modifications (such as optional handlebars) have been made to the vehicle.

PREPARE

WARNING

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

Remove main fuse. See service manual.

REMOVE

1.	Remove following items as necessary to access brake components. See service manual. a. Seat b. Outer fairing or headlamp nacelle c. Dash panel or ignition switch cover d. Spot lamp and turn signal brackets e. Fuel tank f. Right side cover
2.	Fork mounted fairing models: a. Remove upper screw pair that mounts the front fairing. See service manual. b. Loosen lower screw pair. See service manual. c. Some installations may require full fairing removal for wire harness extensions and brake line routing. See service manual.
3.	Frame mounted fairing models: a. Remove instrument cluster. See service manual. b. Remove fairing assembly. See service manual.
4.	Touring models: Open brake line retention bracket at the rear of the lower triple clamp. See service manual.
5.	Trike models: Remove screws securing brake line clamps at the rear of the lower triple clamp. See service manual. NOTE If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water. Cover painted parts to protect finish.
6.	Drain brake fluid from front brake reservoir.
7.	Carefully compare new brake line assembly to old lines before removing old lines.
8.	Make sure that banjo fittings on new brake line(s) are oriented same as fittings on old lines.
9.	Note brake line routings and cable strap locations before removing brake lines.
10.	Remove and retain alignment bracket attached to all five brake lines at top of Anti-lock Braking System (ABS) unit. a. Touring models: See Figure 2 for alignment bracket (4). b. Trike models: See Figure 5 for alignment bracket (3).
11.	Touring models: Remove front brake lines that are being replaced. See service manual. a. See Figure 2. If installing new UPPER MID brake line, remove stock upper brake line (1). b. If installing new LOWER MID brake lines, remove stock lower brake lines (2, 3). c. See Figure 13. Remove all brake lines from retention clips (5, 6).
12.	Trike models: Remove front brake lines that are being replaced. See service manual. a. See Figure 5. If installing new UPPER MID brake line, remove stock upper brake line (1). b. If installing new LOWER MID brake line, remove stock lower brake line (2). c. See Figure 13. Remove all brake lines from retention clips (5, 6).
13.	Save all alignment brackets and retention clips, ABS unit banjo bolts, master cylinder banjo bolt (8) and caliper banjo bleeder bolts (10) for assembly. Discard all sealing washers and gaskets.

1	Banjo bolt, M12, mid-upper brake line
2	Banjo bolt, M10, mid-lower, left brake line
3	Banjo bolt, M10, mid-lower, right brake line
4	Alignment bracket

Figure 2. Touring-ABS Control Unit

NOTE

See Figure 3 and Figure 4. Old and New banjo fittings CANNOT be intermixed.

1	Old style banjo fittings

Figure 3. ABS Banjo Fittings on 2023 and Earlier Models

1	New style banjo fittings

Figure 4. ABS Banjo Fittings on 2024 and Later Models

1	Banjo bolt, M12, front mid-upper brake line
2	Banjo bolt, M10, front mid-lower brake line
3	Alignment bracket

Figure 5. Trike-ABS Control Unit

1	Brake line mount bracket
2	Mid-lower, left brake line
3	Mid-lower, right brake line
4	Lower brake line, left
5	Lower brake line, right
6	Swivel nut connections (if installing accessory lower brake line kit)

Figure 6. Touring-Lower Brake Line Mount Bracket (Mid-Lower Kits: 41801129, 41800905, 41801008, Front-Lower Kits: 41800332, 41800333, 41800906)

1	Brake line mount bracket
2	Mid-lower, left brake line
3	Mid-lower, right brake line
4	Lower brake line, left
5	Lower brake line, right
6	Swivel nut connections (if installing accessory lower brake line kit)

Figure 7. Touring-Lower Brake Line Mount Bracket (Kits 41800905, 41800906, 41800907, 41800933, 41801008)

1	Brake line mount clamps (2)
2	Front mid-lower brake line
3	Lower brake line, left
4	Lower brake line, right
5	Swivel nut connections (if installing accessory lower brake line kit)

Figure 8. Trike-Front Mid Lower Brake Line Mount Clamps (Kits 41801041, 41801042)

1	Forward brake line retention clip
2	Mid brake line retention clip
3	Snap feature of electrical caddy under fuel tank

Figure 9. Touring-Forward and Mid Brake Line Retention (Stock and Accessory)

1	Mid-upper brake line (routed counterclockwise)
2	Mid-lower brake lines (routed clockwise)
3	Upper brake line, braided
4	Hydraulic clutch line
5	Swivel nut upper brake line connection
6	Brake lines routed behind wire harness bundle
7	Upper brake line fastened to right side fork tube
8	Radio and radio mount bracket

Figure 10. FLH Outer Fairing View-Brake Line Routing (Kits 41801127, 41801129, and 41801039, 41800905)

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	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 11. FLT Outer Fairing View-Brake Line Routing

1	Female swivel nut
2	Male fitting from mid line

Figure 12. Connection from Mid Lines to Upper or Lower Brake Line Fittings

1	ABS control unit
2	ABS unit to master cylinder upper brake line
3	ABS unit to left caliper lower left brake line
4	ABS unit to right caliper lower brake line
5	Forward brake retention clip
6	Mid brake retention clip
7	Master cylinder
8	Banjo bolt, M10 master cylinder
9	Caliper, left and right
10	Banjo bleeder bolt, M10 caliper (2)

Figure 13. ABS Brake System (Original Touring routing shown, to illustrate routing and component terminology, does not fully represent all models)

INSTALL

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)

NOTE

In general, begin installation at the ABS unit. Work forward on vehicle. Instructions are written as if BOTH upper and lower brake lines are being installed. If installing only one brake line circuit, ignore instructions that do not apply.

Identify individual lines and differences in sealing washer size and type.

See Figure 1. Touring Models: Obtain LOWER MID RIGHT brake line (8), LOWER MID LEFT brake line (7) and four copper sealing washers (9).

NOTE

Keep any protective caps on the male threads (if present) or protect the threads while routing the lines.

See Figure 6 and Figure 7. Route brake lines following original brake line path. Place swivel fittings behind lower triple-clamp. See Service manual.

See Figure 1. Trike Models: Obtain LOWER brake line (22) and two copper sealing washers (24).

NOTE

Keep any protective caps on the male threads (if present) or protect the threads while routing the lines.

See Figure 8 and Figure 9. Route brake lines following original brake line path. Place swivel fittings behind lower triple-clamp. See service manual.

Avoid twisting LOWER brake lines. Route flexible LOWER brake lines:

a. Behind wire bundle (6).

b. In front of steering head.

c. Down right side of backbone to ABS unit.

See Figure 2. With LOWER brake lines parallel and untwisted:

NOTE

Some models may have slight visual differences to fittings.

a. Touring Models: See Figure 2. Install M10 banjo bolts removed earlier with new seal washers in locations shown (2, 3). Leave fasteners loose.

b. Trike Models: See Figure 5. Install M10 banjo bolts removed earlier with new seal washers in locations shown (1, 2). Leave fasteners loose.

Locate UPPER brake line and two new copper sealing washers.

Fork Mounted Fairing Models:

a. See Figure 10. Position UPPER brake line (1) with banjo fitting at ABS unit and male swivel threaded end toward front.

b. Route swivel threaded end between steering head and clutch line (4).

10.

Frame Mounted Fairing Models:

a. See Figure 11. Position UPPER brake line (1) with banjo fitting at ABS unit and male swivel threaded end toward front.

b. Route line counterclockwise, down and around frame member (opposite direction of LOWER mid lines).

11.

ALL models:

a. Touring Models: See Figure 2. Install new M12 copper sealing washers on both sides of banjo fitting.

b. Install M12 banjo bolt removed earlier in location shown (1). Leave fasteners loose.

c. Install alignment bracket (4). Make sure bracket (4) is installed to all brake lines.

d. Trike Models: See Figure 5. Install new M12 copper sealing washers on both sides of banjo fitting.

e. Install M12 banjo bolt removed earlier in location shown (1). Leave fasteners loose.

f. Install alignment bracket (3). Make sure bracket (3) is installed to all brake lines.

12.

Tighten M10 banjo bolt(s).

Torque: 23–26 N·m (17–19 ft-lbs)

13.

Tighten M12 banjo bolt(s).

Torque: 38–41 N·m (28–30 ft-lbs)

14.

See Figure 9 and Table 2 for mid brake line retention clip installation.

a. Make sure brake lines are routed parallel to each other from ABS unit to mid-retention clip location.

b. If installing ONLY the LOWER brake line kits, follow "Stock and Lower Configuration" column to snap brake lines into proper mid-retention clip position.

c. If installing ONLY the UPPER brake line kit OR installing BOTH UPPER and LOWER brake line kits, follow "Upper Only or Both Configuration" column to snap brake lines into proper mid-retention clip position.

d. Snap mid-retention clip (2) into tabs (3) of backbone wire caddy.

e. Kit 41800933: Apply a 50/50 isopropyl alcohol/water solution to lubricate install of diamondback and Diamondback lines into clip (Item 18 in Figure 1 ).

f. Secure retention clip onto vehicle using cable strap.

15.

See Figure 9 and Table 2 for forward brake line retention clip installation.

NOTE

If kit contains a separate retention clip, discard Original Equipment (OE) retention clip and use provided new clip.

a. Make sure brake lines are routed parallel to each other from mid-retention clip to forward-retention clip location.

b. If ONLY installing LOWER brake line kits, follow "Stock and Lower Configuration" column to snap brake lines into proper forward-retention clip position.

c. If ONLY installing UPPER brake line kit OR installing BOTH UPPER and LOWER brake line kits, follow "Upper Only or Both Configuration" column to snap brake lines into proper forward-retention clip position.

d. Snap forward-retention clip (1) into steering head caddy and fasten clutch cable/line if removed.

16.

Touring Models: See Figure 6 and Figure 7. With LOWER brake lines located behind lower triple clamp, snap left (2) and right (3) brake lines into retention bracket (1).

a. If equipped, close retention bracket by rotating cover upward. Snap into place. Secure with two cable straps.

17.

Trike Models: See Figure 8. With LOWER brake lines located behind lower triple clamp, secure two clamps (1) to lower fork bracket using screws removed earlier. Tighten.

Torque: 7–9 N·m (62–80 in-lbs)

18.

Obtain two LOWER braided brake lines (12) and four new sealing washers (13).

19.

Install new M10 sealing washers on both sides of LOWER braided brake line banjo fitting.

a. Thread into caliper using banjo bleeder bolt removed earlier.

b. Align banjo fitting against anti-rotation feature of caliper.

20.

Tighten banjo bleeder bolt.

Torque: 23–25.8 N·m (17–19 ft-lbs)

21.

See Figure 6. Position swivel nut female fitting (6) of LOWER braided brake line (4 or 5) to male swivel threaded fitting of MID-LOWER brake line (2 or 3, respectively).

NOTE

When tightening swivel nut fitting, turn only swivel nut. Do not allow male fitting, manifold tubing or lower braided brake line to turn.

a. Thread nut onto male fitting finger-tight. Do not twist brake lines.

22.

Tighten swivel nut (1) past finger-tight by 45 degrees (1/8 turn) relative to male fitting (2) or tighten.

Torque: 5.1–7.3 N·m (45–65 in-lbs)

23.

Repeat steps 17-20 for opposite caliper.

24.

Locate three new cable straps (Item 14 in Figure 1 , from LOWER braided brake line kit).

a. Spacing straps evenly, secure wheel speed sensor wire to left side LOWER braided brake line.

25.

Locate UPPER brake line and new sealing washers from UPPER brake line kit (purchased separately).

26.

See Figure 13. Route upper portion of brake line:

a. From master cylinder (7).

b. Through fairing or headlamp nacelle area.

c. To male fitting at front of vehicle.

27.

Install new sealing washers from UPPER brake line kit on both sides of upper brake line banjo fitting.

a. Install to master cylinder using M10 banjo bolt removed earlier.

28.

Install banjo bolt, but do not fully tighten now.

29.

FLHR Models: Route upper brake line same as OE brake line along handlebar to fit under riser cover into headlamp nacelle.

30.

Fork Mounted Fairing Models: Route upper brake line same as OE brake line along handlebar between inner fairing and inner fairing cap.

31.

Frame Mounted Fairing Models: Route upper brake line same as OE brake line along handlebar, exiting out of instrument cluster cover.

32.

All Models: Secure as needed using cable straps from UPPER brake line kit.

33.

Review routing of upper brake line. Verify that routing of brake line is smooth and does not interfere with vehicle components. If necessary, adjust position of cable straps:

a. From master cylinder.

b. Through fairing or headlamp nacelle area.

c. To junction of upper and lower brake lines.

34.

Tighten master cylinder banjo bolt.

Torque: 23–25.8 N·m (17–19 ft-lbs)

35.

See Figure 10 or Figure 11. Kits 41801008, 41800905, 41800933: Route brake lines same as OE. See service manual.

a. Route UPPER brake line (3) along right fork tube. Route upward in front of steering head.

b. Route MID-LOWER brake line (1).

c. Rotate lines clockwise around frame neck, down to caddy mounted on back side of lower triple clamp.

d. Counterclockwise, but parallel with other LOWER brake lines (2).

e. Behind wire bundle (6) until MID-LOWER brake line forms a loop mating with UPPER brake line (5).

f. Through steering head caddy (same as OE).

g. Up over frame neck.

36.

All Models: Install protective sleeve from MID-LOWER brake line kit over and past male swivel threaded fitting.

37.

Position swivel nut female fitting of UPPER braided brake line to male swivel threaded fitting of MID-LOWER brake line.

a. Thread nut onto male fitting finger-tight. Do not twist upper or lower braided brake lines.

38.

Tighten swivel nut past finger-tight by 45 degrees (1/8 turn) relative to male fitting or torque.

Torque: 5.1–7.3 N·m (45–65 in-lbs)

39.

Position protective sleeve over mated swivel nut connection. Affix with tape or cable strap.

40.

See Figure 14. Verify MID-LOWER and MID-UPPER lines (1) are under tab (2). Secure with cable straps (3).

1	Mid-Upper and Mid-Lower brake lines
2	Tab
3	Cable strap

Figure 14. ABS Brake Line Cable Straps

41.

Fork Mounted Fairing Models: See Figure 10. Using any remaining cable straps, secure UPPER brake line to right fork tube approximately where shown (7).

42.

Frame Mounted Fairing Models: See Figure 11. Using any remaining cable straps, secure UPPER brake line to handlebar risers (8).

1	4 Place retention clip
2	3 Place retention clip

Figure 15. Retention Clips

Table 3. Retention Clip Brake Line Configuration

Item	Retention Clip	Position	Stock/Lower Only Configuration	Upper Only or Both Configuration
1	Forward	a	Upper	Lower left
		b	Lower left	Lower right
		c	Lower right	Upper
		d	Hydraulic clutch
2	Mid	a	Upper	Lower left
		b	Lower left	Lower right
		c	Lower right	Upper

Brake Line Routing Check

1.	Using a proper lift, raise vehicle frame so front forks reach maximum extension. a. Verify that lower brake lines are not pulled tight when forks are fully extended.
2.	Fully compress forks to check that lower brake lines do not interfere with vehicle components.
3.	Turn handlebars to full-left and full-right fork stops. a. Verify smooth routing and proper slack in brake lines. b. Verify brake lines do not contact any vehicle components.
4.	Adjust brake lines and / or banjo fitting orientation if brake lines interfere or catch on vehicle components, or if routing does not appear correct.

FINAL ASSEMBLY

WARNING

Clean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury. (00504d)

NOTICE

NOTE

Do not mix grades of brake fluid as they are not compatible.
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
Cover nearby vehicle surfaces to help protect against damage to finish caused by spillage or splash of DOT 4 brake fluid.

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)

1.	Add brake fluid to master cylinder reservoir. See service manual. a. NEVER reuse old brake fluid. b. Only use brake fluid from a sealed container.
2.	Bleed brake system per service manual instructions. a. ABS models: connect Digital Technician II (DT II) and perform ABS Service procedure. Special Tool: DIGITAL TECHNICIAN II (HD-48650)
3.	Verify proper operation of brake system per service manual.
4.	Check ABS unit, master cylinder and caliper banjo fittings, and male/female swivel nut connections for any signs of leakage. Verify torques as necessary.

COMPLETE

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)

1.	Install items removed earlier. See service manual. a. Main fairing b. Spot lamp and turn signal brackets c. Dash panel or ignition switch cover d. Outer fairing or headlamp nacelle e. Fuel tank f. Right side cover g. Seat. After installing seat, pull up on seat to verify that it is secure.
2.	Install main fuse. See service manual.
3.	Turn ignition switch to IGNITION, but do not start motorcycle. Actuate front brake hand lever to verify operation of brake lamp.
4.	Test ride vehicle at low speed. Repeat bleeding procedure if brakes feel spongy.