Special Tools
| Description | Part Number | Qty. |
|---|---|---|
| DOT 4 BRAKE FLUID MOISTURE TESTER | HD-48497-A | 1 |
Brake Fluid
WARNINGClean 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)
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
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)
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
- At every service, check moisture content of fluid using DOT 4 BRAKE FLUID MOISTURE TESTER (Part Number:HD-48497-A). Follow the instructions included with tool.
- Flush brake system and replace DOT 4 fluid every two years or sooner if brake fluid test shows moisture content is 3% or greater.
- Fluid should never need to be added or removed from the system during normal wear, except for fluid replacement as specified in the maintenance schedule.
- Fluid level in reservoir will decrease with brake wear. Reservoir volume is adequate to provide fluid to the wear limits of the pads and rotors.
Front brakes: Position motorcycle and handlebar so the master cylinder reservoir is level.
See Figure 1. View sight glass (1) to verify that fluid level is at or above the center of sight glass.
Rear brakes: Position motorcycle so the master cylinder reservoir is level. Verify that fluid level is visible within the window (2).
If the fluid level is below the minimum mark or not present in either the front or rear brake reservoir, see a Harley-Davidson dealer.
Verify front brake hand lever and rear brake foot pedal have a firm feel when applied. If brakes are not firm, the brake system must be bled. See a Harley-Davidson dealer.
| 1 | Front brake fluid sight glass |
| 2 | Rear brake fluid sight glass |
Figure 1. Brake Fluid Reservoirs
Brake Pads
WARNINGInspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a)
WARNINGAlways replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)
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)
WARNINGPerform routine scheduled brake maintenance. Lack of maintenance at recommended intervals can adversely affect brake performance, which could result in death or serious injury. (00055a)
Harley-Davidson has equipped your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry or wet conditions and at high operating temperatures. It exceeds all regulatory requirements currently in effect. However, during some braking you can experience noise. This noise is normal for this friction material.
WARNINGBe sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)
- Check the rear brake disc as it spins. The disc should run true in the brake caliper.
- See Figure 2. Measure the thickness of the brake pad friction material. For rear brakes, place the ruler against the brake disc through the space alongside the caliper.
| 1 | Front brake |
| 2 | Rear brake |
Figure 2. Brake Friction Material
NOTE
Always replace brake pads in pairs.
- Replace brake pads before friction material reaches minimum thickness. See a Harley-Davidson dealer. Refer to Table 1.
Table 1. Minimum Brake Pad Friction Material Thickness
in | mm |
|---|---|
0.040 | 1.020 |