Special Tools

Description	Part Number	Qty.
BASIC VACUUM BRAKE BLEEDER	BB200A	1
DIGITAL TECHNICIAN II	HD-48650	1

Consumables

Description	Part Number	Size
Harley-Davidson Platinum Label DOT 4 Brake Fluid	41800xxx	-

If brake system was drained, use BASIC VACUUM BRAKE BLEEDER (Part Number:BB200A). If a vacuum brake bleeder is not available, use the following procedure.

WARNING

When any hydraulic brake component, line or connection is loosened or replaced on an ABS motorcycle, Digital Technician II must be used during the brake bleeding procedure to verify all air is removed from the system. Failure to properly bleed the brake system could adversely affect braking, which could result in death or serious injury. (00585c)

WARNING

Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury. (00291a)

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)

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

Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c)

NOTE

Procedure for filling and bleeding brake fluid is the same for both the front and the rear brake systems.

NOTE

Bleeding Anti-lock Braking System (ABS) systems requires the use of Digital Technician II (DT II).DIGITAL TECHNICIAN II (Part Number:HD-48650)

1.	Verify brake system operation. a. Verify that master cylinder is level. b. Remove master cylinder reservoir cover. c. Check for moisture content in brake fluid. See Maintenance → CHECK AND REPLACE BRAKE FLUID. d. Fill reservoir with appropriate brake fluid until fluid reaches max fill level.Harley-Davidson Platinum Label DOT 4 Brake Fluid (41800xxx) NOTE Verify proper master cylinder relief port operation by actuating brake pedal or lever. Fluid will break fluid surface if internal components are working properly. NOTE Monitor fluid level in master cylinder reservoir. Add fluid before it empties to avoid drawing air into brake lines.
2.	NOTE When bleeding front brakes: Repeat procedure for both calipers. Bleed brake system. a. See Chassis → BLEED BRAKES → Drain → Bleeder Screw (Typical). Remove cap (1) from bleeder screw (2). b. Install end of clear plastic tubing over bleeder screw. c. Place opposite end of clear plastic tubing in a clear container. d. Operate brake lever or pedal to build pressure. e. Hold pressure with brake lever or pedal. f. Open bleeder screw three-quarters of a turn. g. Close bleeder screw as soon as brake lever or pedal has moved full range of travel. h. Allow brake lever or pedal to return slowly to released position.
3.	Repeat until all air bubbles are purged and a solid column of fluid is observed in bleeder tube.
4.	Tighten bleeder screw. Torque: 12–16 N·m (106–142 in-lbs) Brake caliper bleeder screw
5.	Fill reservoir with brake fluid to max fill level.Harley-Davidson Platinum Label DOT 4 Brake Fluid (41800xxx)
6.	Verify master cylinder cover gasket bellows is not extended or brake fluid will be ejected from the reservoir.
7.	Install rear master cylinder reservoir cap.
8.	Install front master cylinder reservoir cover. a. Position cover with vent holes facing rear of vehicle. b. Install cover screws. Tighten. Torque: 1.3–1.7 N·m (12–15 in-lbs) Brake master cylinder, front reservoir cover screw
	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)
9.	Check operation of stoplamp.
	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 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)
10.	Test ride motorcycle. Repeat the bleeding procedure if brakes feel spongy.