Special Tools

Description	Part Number	Qty.
DOT 4 BRAKE FLUID MOISTURE TESTER	HD-48497-A	1

Inspect brake fluid level and check brake pads and discs for wear at proper intervals. Refer to Maintenance Scheduling → Service Records.

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.

Brake Fluid

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)

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

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)

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.

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

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. By replacing the pads, the fluid level will return to its normal level.
Use only DOT 4 brake fluid and replace the brake fluid every two years or sooner if moisture content is 3% or greater. See a Harley-Davidson dealer.

Place vehicle on a flat level surface.
1. Front brake: Level the master cylinder by turning the handlebar and/or standing the motorcycle upright (not leaning on jiffy stand).
2. Rear brake: Position the motorcycle so the master cylinder reservoir is level.
See Figure 1. View reservoir sight glass. Fluid level must be at or above the minimum mark on glass. If fluid level is below minimum mark, 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 master cylinder reservoir
2	Rear master cylinder reservoir

Figure 1. Sight Glass Minimum 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)

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)

Harley-Davidson has provided your new motorcycle with the most optimum brake pad friction material available. It is selected to give the best performance possible under dry, wet and high operating temperature conditions. It exceeds all regulatory requirements currently in effect. However, during some braking conditions you can hear a brake noise. This noise is normal for this friction material.

Table 1. Minimum Brake Pad Friction Material Thickness

in	mm
0.016	0.4

See Figure 2. Check the brake disc as it spins. The disc should run true in the brake caliper.
Measure the thickness of the brake pad friction material. The pads do not necessarily wear evenly. Check each pad. The grooves on the brake pads are no longer visible when the pads are near the end of service life.
Replace brake pads before friction material reaches mininum thickness. Always replace brake pads in pairs. See a Harley-Davidson dealer. Refer to Table 1.

1	Front brake (as viewed from front of vehicle)
2	Rear brake (as viewed from rear of vehicle)
3	Brake pad friction material thickness
4	Brake pad grooves

Figure 2. Brake Pad Friction Material