Brake Fluid
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)
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
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)
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)
NOTE
  • If the brake system is not leaking, there should never be a need to add fluid. If the fluid level is low, the pads are probably worn and need to be replaced. By replacing the pads, the fluid level will rise.
  • Replace the brake fluid every two years. Use only DOT 4 BRAKE FLUID. See a Harley-Davidson dealer.
Front brakes: Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface. Turn handlebar so the top of the brake master cylinder is level.
See Figure 1. Compare the fluid level in the reservoir sight glass to the low-level mark (1).
Rear: Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface. Compare the fluid level in the reservoir sight glass to the low-level mark (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 that the front brake lever and the rear brake pedal have a firm feel when applied. If brakes are not firm, the brake system must be bled. See a Harley-Davidson dealer.
1Front
2Rear
Figure 1. Brake Fluid Low Level Marks
Brake Pads
WARNING
Inspect 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)
WARNING
Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)
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
Perform 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 conditions you may experience noise. This noise is normal for this friction material.
WARNING
Be 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)
  1. Check the rear brake disc as it spins. The disc should run true in the brake caliper.
  2. See Figure 2. Using a thin plastic ruler, 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.
1Front, from below
2Rear, from above
3Pad thickness
Figure 2. XL Brake Pad Thickness
NOTE
Always replace brake pads in pairs.
  1. If the brake pad friction material is at the minimum thickness or less, replace the pads. See a Harley-Davidson dealer. Refer to Table 1.
Table 1. Minimum Brake Pad Friction Material Thickness
in
mm
0.040
1.02