SOFTAIL EXTENDED REACH BRAKE LINE KIT - Harley
Contents
1. MOTOR HARLEY DAVIDSON U J04400 INSTRUCTIONS REV 2007 05 07 SOFTAIL EXTENDED REACH BRAKE LINE KIT GENERAL Kit Number 44970 07 44972 08 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only Additional Parts NOTE These kits CANNOT be used with the following accessories e Engine guard Part Number 49200 07 e Rear master cylinder cover Part Number 45665 01 In addition to the parts from the kit LOCTITE 243 blue Threadlocker and Sealant Part Number 99642 97 Harley Davidson Wheel Bearing Grease Part Number 99855 80 and DOT 4 Brake Fluid Part Number 99953 99A is also required for installation For accessories and kit part numbers see your local Harley Davidson dealer www harley davidson com or your Harley Davidson Genuine Motor Accessories and Parts catalog NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 4 and Table 1 INSTALLATION Prepare the Motorcycle 1 If equipped with saddlebags remove the saddlebags fol lowing the instructions in the Service Manual 2 Remove the seat following the directions in the Owner s Manual WARNING To prevent accidental vehicle start up which could cause d2. 3 See Figure 2 Install the clamp 1 around the brake line and tighten fastener to 30 in Ib 3 4 Nm 4 Verify that the brake line runs parallel to the rear of the brake lever bracket and that the brake line does not rub against any part of the bracket 5 See Figure 3 Install the cable straps at locations 1 WARNING Be sure that no lubricants or fluids get on tires wheels or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047d NOTE Hydraulic brake fluid bladder type pressure equipment can be used to fill brake master cylinder through the bleeder valve Remove the master cylinder reservoir cover so that the system cannot pressurize Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place J04400 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 obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a NOTE The sight glass enables the rider to visually check the brake fluid level without removing the master cylinder cover When the reservoir is full the sight glass is da
3. eath or serious injury disconnect negative battery cable before proceeding 00048a 3 Disconnect the negative battery cable 4 Secure motorcycle in upright position 5 Disconnect the harness from the stoplamp switch 3 J04400 CAUTION Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a 6 Remove brake line following the instructions in the Service Manual Install Brake Line WARNING Be sure that no lubricants or fluids get on tires wheels or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047d 1 Connect the stoplamp switch and install the new rear brake line from the brake line kit following the instructions in the Service manual 1 Bleed the brakes following the instructions in the Service Manual soso M Rear brake line mounting fastener Rear brake line Stoplamp switch Terminals Alignment marks Se YS Figure 1 Brake Line Bracket and Stoplamp Switch 1 of 3 WARNING Use denatured alcohol to clean brake system components Do not use mineral based solvents such as gasoline or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a 1 Brake line clamp Figure 2 Brake Line Clamp
4. rk As the fluid level drops the glass lightens up to indicate this condition to the rider 6 Add brake fluid if necessary following the instructions in the Owner s Manual Return to Service 1 For models equipped with saddlebags Install the sad dlebags following the instructions in the Service Manual 2 Connect the negative battery cable WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 3 Install the seat following the instructions in the Owner s Manual WARNING The jiffy stand locks when placed in the full forward down position with vehicle weight on it If the jiffy stand is not in the full forward down position with vehicle weight on it the vehicle can fall over which could result in death or serious injury 00006a WARNING Be sure jiffy stand is fully retracted before riding If jiffy stand is not fully retracted it can contact the road surface causing a loss of vehicle control which could result in death or serious injury 00007a 4 Verify jiffy stand operation 5 With the ignition light key switch turned to IGNITION actuate the rear brake pedal to verify operation of the brake lamp WARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cau
5. se loss of control which could result in death or serious injury 00289a 6 Test ride the motorcycle If the brake feels soft repeat the rear brake bleeding procedure 20f3 1 Cable strap locations Figure 3 Cable Strap Location SERVICE PARTS is05040 Figure 4 Service Parts Extended Reach Forward Control Brake Line Table 1 Service Parts Item Description Quantity Part Number 1 Brake line assembly chrome 2007 models Not Sold Separately 2 Brake line assembly chrome 2008 models Not Sold Separately 3 Cable strap 2 10006 4 Gasket brake line 4 41731 01 5 Clamp brake line 2007 models 10106 Clamp brake line 2008 models 10059A 6 Lockwasher 8 7015 7 Screw 8 32x0 38 94634 99 J04400 3 of 3
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