Special Tools
DescriptionPart NumberQty.
DOT 4 BRAKE FLUID MOISTURE TESTER
HD-48497-A
1

Inspect brake fluid level and check brake pads and discs/rotors 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)
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)
  1. See Figure 1 and Figure 2. Check fluid level in brake master cylinder reservoir. Place vehicle on a flat level surface. Turn handlebar so master cylinder is level.
    1. Sight glass appears dark if fluid is present. If the front sight glass remains clear, see a Harley-Davidson dealer.
    2. FLHTCUTG: The rear fluid level must be between the MIN and MAX lines.
    3. FLRT: Check level in rear sight glass. Level must be above MIN mark. If the rear sight glass remains clear, see a Harley-Davidson dealer.
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 must be replaced. By replacing the pads, the fluid level rises.
  • 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.
  1. 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.
1Front master cylinder reservoir
2Rear master cylinder reservoir
Figure 1. Brake Fluid Sight Glass: FLHTCUTG
1Front master cylinder reservoir
2Rear master cylinder reservoir
Figure 2. Brake Fluid Sight Glass: FLRT
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 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 may experience noise. This is normal for this friction material.
  1. Inspect for grit and debris buildup at caliper piston areas. Clean if necessary.
    1. Rinse area with warm soapy water.
    2. Dry using low-pressure compressed air.
  2. See Figure 3. Check the brake disc or rotor as it spins. The disc/rotor should run true in the brake caliper.
  3. Measure the thickness of the brake pad friction material. The pads may not necessarily wear evenly. Check each pad.
    4. NOTE
    The rear brake pads have tabs to indicate brake pad wear. Rear pads can be visually inspected for wear without rear wheels removed.
  4. See Figure 4. Compare the end of tabs (2) to the surface of the outboard caliper bracket (1). If tab is flush or below surface, see a Harley-Davidson dealer.
  5. Replace brake pads before friction material reaches mininum thickness. Always replace brake pads in pairs. See a Harley-Davidson dealer. Refer to Table 1.
1Front brake
2Rear brake
3Brake pad friction material thickness
Figure 3. Brake Friction Material
1Caliper bracket surface
2Tabs
Figure 4. Rear Brake Pad Inspection
Table 1. Minimum Brake Pad Friction Material Thickness
BRAKE
in
mm
Front
0.040
1.02
Rear
0.040
1.02