MODULAR BRAKE LINE KITS - Harley
Contents
1. area to the male fitting on the upper end of the lower brake line 5 8 Install the banjo fitting of the new upper brake line at the master cylinder using new copper gaskets from the Upper Brake Line Kit on each side of the fitting 9 Install the banjo bolt removed earlier snug but do not fully tighten at this time is07694 1 Upper brake line assembly master cylinder to female swivel nut fitting 2 Lower brake line assembly male fitting to cal ipers 3 Master cylinder 4 Caliper 5 Swivel nut connection of upper and lower brake lines 6 P clamp large 7 P clamp small 2 Figure 2 2014 Later Front Non ABS Brake Lines 10 For Road King models Route the upper brake line the same as the original equipment brake line along the handlebar to fit under the riser cover into the headlamp nacelle and secure as needed using cable straps from the Upper Brake Line Kit For Electra Glide models Route the upper brake line the same as the original equipment brake line along the handlebar between the inner fairing and the inner fairing cap and secure as needed using cable straps from the Upper Brake Line Kit For ALL models Review the routing of the upper brake line from the master cylinder through the fairing or head lamp nacelle area to the junction of the upper and lower brake lines Verify that the routing of the brake line is smooth and does not interfere with any vehicle components If necess2. Banjo Angle 0 Straight Diamond Black Diamondback Length Kit Kit N A 42393 08 18 inch N A 42396 08 19 inch N A 42399 08 20 inch N A 42428 08 21 inch 41800279A 42439 08A 22 inch N A 42461 08 23 inch N A 42484 08A 24 inch N A 42527 08A 26 inch 41800348 42548 08A 28 inch N A 42599 08 30 inch 41800350 44081 09A 32 inch N A 46336 09 34 inch 41800281 46566 09 36 inch Table 2 Upper Brake Line Kits Banjo Angle 35 Please dispose of materials responsibly Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Diamond Black Diamondback Length Kit Kit N A 44106 08 18 inch N A 44138 08 19 inch 48940 10 44206 08 20 inch N A 44213 08 21 inch N A 44250 08A 22 inch 38118 10 44259 08 23 inch N A 44306 08A 24 inch 38120 10 44340 08 26 inch 38139 10 44355 08A 28 inch 38141 10 44461 08 30 inch N A 40958 09 32 inch 41800282 46711 09 34 inch N A 46727 09 36 inch 38143 10 38147 10 40 inch 38145 10 38149 10 44 inch 1 of 6 Table 3 Upper Brake Line Kits Banjo Angle 90 Diamond Black Diamondback Length Kit Kit 48931 10 44790 08 18 inch 48929 10 45007 08 19 inch N A 45082 08 20 inch 48944 10 45094 08 21 inch N A 45131 08 22 inch N A 45134 08 23 inch N A 45150 08 24 inch N A 45223 08 26 inch N A 45251 08 28 i
3. any brake fluid spillage with a clean dry soft cloth Follow up by thoroughly wiping affected area with a clean damp soft cloth small spills or washing with a large quantity of soapy water large spills 2 Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching Damage to the finish could result 3 Disconnect the front brake lines following the instructions in the appropriate service manual Save the master cylinder banjo bolt the caliper banjo bolts for 1994 2007 models the caliper banjo bleeder bolts for 2008 later models the brake line tee attaching screw for 2008 2013 models and the hardware mounting the plastic brake line mount bracket at the rear of the lower triple clamp for 2014 later models for later assembly Discard all sealing washers and the plastic brake line mount bracket for 2014 later models 4 Some stock Touring models are equipped with a locating roll pin on the mounting surface for the lower brake line J04431 manifold Remove the roll pin before installing this brake line kit INSTALLATION 2013 EARLIER MODELS 1 Verify that the correct upper and lower Brake Line Kits have been obtained e In some cases the Upper Brake Line Kit has already been specified e Inother cases the proper Upper Brake Line Kit see Table 1 Tabl
4. 007 Models At each front brake caliper posi tion a new sealing washer steel rubber from the Lower Brake Line Kit on each side of the brake line banjo fitting Insert the banjo bolt removed earlier through the washers and fitting Thread the bolt into the caliper and tighten to 17 22 ft lb 23 0 29 8 Nm 3 of 6 1S04622a one N Ondi Upper brake line assembly Lower brake line assembly Brake line tee Screw Upper brake line female fitting swivel nut Lower brake line male fitting OaPpenna Figure 1 2013 Earlier Front Brake Lines Road King Model Shown 6 Obtain the new upper brake line assembly 1 Route the upper brake line from the master cylinder through the fairing or headlamp nacelle area to the male fitting on the upper end of the lower brake line 7 Install the banjo fitting of the new upper brake line at the master cylinder using a new copper gasket from the Upper Brake Line Kit on each side of the fitting 8 Install the banjo bolt removed earlier snug but do not fully tighten at this time 9 For Road King and Road Glide models Using cable straps from the Lower Brake Line Kit tie the brake line to the handlebar riser For Electra Glide models Route the upper brake line the same as the original equipment brake line along the handlebar between the inner fairing and the inner fairing cap For ALL models Review the routing of the upper brake line from the master cylinder thr
5. A Not Sold Separately Copper gasket 4 P clip large P clip small 2 Cable strap 3 Not Sold Separately 10006 oo AeA Ww 6 of 6
6. ary adjust the position of the cable straps 11 See Figure 3 Position the upper brake line female fitting swivel nut 2 to the male fitting 4 on the lower brake line J04431 Thread the nut onto the male fitting finger tight Do not twist the upper or lower brake lines while tightening 12 Using two 7 16 inch open end wrenches tighten the swivel nut 2 past finger tight by 45 degrees 1 8 turn relative to the male fitting 4 or torque to 45 65 in lbs 5 1 7 3 Nm is07597 Upper brake line Female swivel nut Lower brake line 1 2 3 4 Male fitting Figure 3 Upper to Lower Brake Line Fittings BRAKE LINE ROUTING CHECK 1 Using a motorcycle lift raise the vehicle frame so that the front forks reach maximum extension Verify that the lower brake lines are not pulled tight when forks are fully extended 2 Fully compress the forks to check that the lower brake lines do not interfere with motorcycle components 3 Turn the handlebars to the full left and full right fork stops to verify smooth routing and proper slack in the brake lines and to verify the brake lines do not contact any vehicle components 4 Adjust the brake lines and or banjo fitting orientation if the brake lines interfere or catch on motorcycle components or if the routing does not appear correct See Table 5 When all adjustments are complete tighten the master cylinder banjo bolt to specification Table 5 Banjo Bol
7. cMOTOR HARLEY DAVIDSON WY J04431 MODULAR BRAKE LINE KITS GENERAL For ABS Models AWARNING The rider s safety depends upon the correct installation of this kit Dealer installation is required for vehicles equipped with ABS brakes Proper installation of this kit requires the use of special tools available only through a Harley Davidson Dealer An improperly serviced brake system can adversely affect brake performance which could result in death or serious injury 00578b NOTE ABS and NON ABS models share upper brake line kits how ever ABS model installation instructions are found with the ABS Lower Brake Line Kit instructions J04652 or JO5790 For Non ABS Models These instructions describe the installation of upper and lower brake lines on non ABS Electra Glide Street Glide Road King Road Glide Tri Glide Ultra Classic and Street Glide Trike models ONLY For installation of the upper brake line on any other model including ABS refer to the instruction sheet included in the Lower Brake Line Kit for that model For 2014 later Trike Models 2014 later Trike models and earlier NON ABS Trike models share upper brake line kits however 2014 later linked brake model installation instructions are found with the Linked Lower Brake Line and Linked Adapter Kit instructions J05690 or J05691 J04431 Kit Numbers INSTRUCTIONS REV 2013 06 14 Table 1 Upper Brake Line Kits
8. e 2 or Table 3 needs to be determined using the Cable and Brake Line Measurement Tool Kit See a Harley Davidson dealer for assistance e See Table 4 to determine the correct Lower Brake Line Kit for your model motorcycle NOTICE Avoid leakage Be sure gaskets banjo bolt s and brake line are clean and undamaged before assembly 00323a 2 See Figure 1 Obtain the new lower brake line assembly 2 NOTE The lower brake line manifold tee is mounted so the two lines to the calipers go to the rear and down 3 Position the brake line tee 3 to the underside of the fork stem and center the lower legs of the brake line between the forks 4 Install the brake line tee attaching screw 4 removed earlier and fasten the tee to the fork stem Tighten the screw to 10 15 ft lbs 13 6 20 3 Nm NOTE The brake lines must not contact the forks If either brake line is touching the fork loosen the brake tee reposition and re tighten WARNING Replace brake line gaskets Re using original gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a 5 For 2008 Later Models At each front brake caliper position a new copper gasket from the Lower Brake Line Kit on each side of the brake line banjo fitting Insert the banjo bleeder bolt removed earlier through the washers and fitting Thread the bolt into the caliper and tighten to 17 19 ft lb 23 0 25 8 Nm For 1994 2
9. ervice manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is required for this installation and is available from a Harley Davidson dealer Additional Parts Required NOTE This instruction sheet covers motorcycle models that use either DOT 4 Hydraulic Brake Fluid or DOT 5 Silicone Hydraulic Brake Fluid The motorcycle s owner s manual service manual and the master cylinder cover will all indicate which type of brake fluid should be used for this motorcycle ACAUTION Direct contact of D O T 5 brake fluid with eyes can cause eye irritation swelling and redness Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 5 brake fluid can cause digestive discomfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00144a CAUTION Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtai
10. ever to verify operation of the brake lamp 8 Install any other removed components following the instructions in the service manual 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 9 Test ride the motorcycle If the brake feels spongy repeat the bleeding procedure SERVICE PARTS Table 6 Service Parts Upper Brake Line Kits Purchase Separately Item Description Quantity Part Number 1 Brake line assembly upper Not sold separately 41751 06A 10006 2 Copper gasket brake line 2 3 Cable strap 3 Table 7 Service Parts Lower Brake Line Kits 44905 08 44907 08 48942 10 83666 10 and 41800280 Item Description Quantity Part Number 1 Brake line assembly lower Not sold separately 41751 06A 10006 2 Copper gasket brake line 4 3 Cable strap 3 Table 8 Service Parts Lower Brake Line Kits 45818 07 45820 07 and 48938 10 Item Description Quantity Part Number 1 Brake line assembly lower Not sold separately 41731 01 10006 2 Sealing washer 4 3 Cable strap 3 Table 9 Service Parts Lower Brake Line Kits 41800336 and 41800338 Item Description Quantity Part Number 1 Brake line assembly lower Not sold separately 41751 06
11. n medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a Fresh uncontaminated DOT 4 H D Part No 99953 99A or DOT 5 brake fluid H D Part No 99902 77 from a sealed container is required See the service manual 2of6 WARNING Install proper length brake lines Incorrect brake line length can adversely affect motorcycle operation which could cause loss of control resulting in death or serious injury 00325a e If installing different handlebars measure the change in distance that will be required from the end of the stock brake line to the brake master cylinder e Compare this revised length to the brake line provided in your kit e Ifthe line is more than 2 0 in 50 8 mm longer or more than 1 0 in 25 4 mm shorter than the above measured distance see a Harley Davidson dealer for the correct brake line length Kit Contents See Table 6 Table 7 Table 8 and Table 9 REMOVAL WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 Refer to the service manual and follow the instructions given to remove the main fuse NOTICE D O T 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 per formed Failure to comply can result in cosmetic damage 00239b NOTE Immediately wipe up
12. nch N A 45260 08 30 inch 48995 10 44162 09 32 inch N A 46743 09 34 inch N A 46747 09 36 inch NOTE Diamondback and Diamond Black Upper Brake Line Kits are available in a variety of master cylinder banjo angles and brake line lengths Shorter or longer lines may be necessary when modifications i e optional handlebars have been made to the motorcycle See the P amp A retail catalog or a Harley Davidson dealer for more information Table 4 Lower Brake Line Kits Diamond Diamondback Models Black Kit Kit 41800280 44905 08 2008 2013 Electra Glide and Street Glide 48942 10 44907 08 2008 2013 Road King and Road Glide 48938 10 45818 07 1994 2007 Road King and Road Glide N A 45820 07 1996 2007 Electra Glide and Street Glide N A 83666 10 2008 2013 Street Glide Trike and Tri Glide Ultra Classic 41800338 41800336 2014 Later Electra Glide Street Glide and Road King Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only J04431 IWIN NIN Brakes are a critical safety component Contact a Harley Davidson dealer for brake repair or replacement Improp erly serviced brakes can adversely affect brake perform ance which could result in death or serious injury 00054a WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate s
13. of vehicle control which could result in death or serious injury 00317a 2 Verify proper operation of the master cylinder relief port Actuate the brake hand lever A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly 3 Bleed the brake system following the instructions in the appropriate service manual NOTE Before installing the master cylinder cover verify that the cover gasket bellows is not expanded If bellows is expanded brake fluid will be ejected from the reservoir during cover installation which could damage the vehicle finish 4 Note that the shape of the master cylinder cover has one end thinner than the other For 2008 Models Install the cover with gasket com pressed on the master cylinder reservoir so the thinner end is positioned above the brake line fitting For 1994 2007 Models Install the cover with gasket compressed on the master cylinder reservoir so the thicker end is positioned above the brake line fitting For All Models Install two screws to fasten the cover to the reservoir Tighten the screws to 6 8 in Ib 0 7 0 9 Nm 5 Verify that the ignition key switch is turned to the OFF position 6 Refer to the service manual and follow the instructions to install the main fuse or connect the battery cable J04431 7 Turn the ignition key switch to IGNITION but do not start the motorcycle Actuate the front brake hand l
14. ough the fairing or head lamp nacelle area to the junction of the upper and lower brake lines Verify that the routing of the brake line is smooth and does not interfere with any vehicle components If necessary adjust the position of the cable straps NOTE When tightening the fitting turn only the swivel nut Do not allow the male fitting or manifold tubing to turn J04431 10 See Figure 1 Position the upper brake line female fitting swivel nut 5 to the male fitting 6 on the lower brake line Thread the nut onto the male fitting finger tight do not twist the upper or lower brake lines while tightening 11 See Figure 3 Using two 7 16 inch open end wrenches tighten the swivel nut 2 past finger tight by 45 degrees 1 8 turn relative to the male fitting 4 or tighten to 45 65 in Ibs 5 1 7 3 Nm INSTALLATION 2014 LATER MODELS 1 Verify that the correct upper and lower Brake Line Kits have been purchased e In some cases the Upper Brake Line Kit has already been specified e Inother cases the proper Upper Brake Line Kit see Table 1 Table 2 or Table 3 needs to be determined using the Cable and Brake Line Measurement Tool Kit See a Harley Davidson dealer for assistance e See Table 4 to determine the correct Lower Brake Line Kit for your model motorcycle NOTICE Avoid leakage Be sure gaskets banjo bolt s and brake line are clean and undamaged before assembly 00323a 2 See Figure 2 Obtain
15. t Torque Values Models Master Cylinder Banjo Bolt Torque 1994 2007 Models 17 22 ft lbs 23 0 29 8 Nm 2008 Later Models 12 5 14 5 ft lbs 17 20 Nm FINAL ASSEMBLY NOTE This instruction sheet covers motorcycle models that use either DOT 4 Hydraulic Brake Fluid or DOT 5 Silicone Hydraulic Brake Fluid The specific model s owner s manual service manual 5 of 6 and the master cylinder cover will all indicate which type of brake fluid should be used for this motorcycle AWARNING Clean filler cap before removing Use only D O T 4 brake fluid from a sealed container Contaminated fluid can adversely affect braking which could result in death or serious injury 00504c NOTES Do not mix grades of brake fluid as they are not compatible Immediately wipe up any brake fluid spillage with a clean dry soft cloth Follow up by thoroughly wiping affected area with a clean damp soft cloth small spills or washing with a large quantity of soapy water large spills Cover nearby motorcycle surfaces to help protect against damage to finish caused by spillage or splash of DOT 4 brake fluid 1 Add the appropriate brake fluid to the master cylinder reservoir following the instructions in the service manual Do not reuse old brake fluid Only use fluid from a sealed container WARNING Be sure the master cylinder relief port is not plugged A plugged relief port can cause brake drag or lockup and loss
16. the new upper 1 and lower 2 brake line assemblies NOTE The lower brake line manifold is mounted so the two lines to the calipers go to the rear and down 3 Position the lower brake line 2 to the backside of the lower triple clamp and center the lower legs of the brake line between the forks oriented rearward and down 4 Obtain the large 6 and small 7 brake line P clamps and attachment screws removed earlier from the plastic brake line mount bracket Attach the lower brake line assembly and fasten the P clamps to the triple clamp The right hand p clamps will overlap Tighten the screw to 10 15 ft lbs 13 6 20 3 Nm NOTE The brake lines must not contact the forks If either brake line is touching the fork loosen the p clamps reposition and re tighten AWARNING Replace brake line gaskets Re using original gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a 5 At each front brake caliper 4 position a new copper gasket from the Lower Brake Line Kit on each side of the brake line banjo fitting Insert the banjo bleeder bolt removed earlier through the gaskets and banjo fitting 6 Orient the banjo fitting against the rotation stop on the caliper and thread the bolt into the caliper Tighten to 17 19 ft lb 23 0 25 8 Nm 7 Route the upper portion of the brake line 1 from the master cylinder 3 through the fairing or headlamp nacelle 4of6
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