HARLEY DAVIDSON XL PULLBACK HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Installation Removing the Existing Front Brake Line To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware. 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) 2. See Figure 1. Open the bleeder nipple cap on the front brake caliper. Obtain a length of plastic tubing. Install one end of the tubing over the caliper bleeder valve (1). Place the free end of the tubing into a suitable container. Open the bleeder valve about 1/2-turn and pump the front-brake hand lever to drain the fluid out of the front brake system. Do not reuse brake fluid. 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. Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch line are clean and undamaged before assembly. (00329a) 3. Disconnect the brake line from the front brake caliper and the front brake master cylinder assembly. Discard the brake line sealing washers, but retain the banjo bolts. The brake line kit contains all new sealing wash- ers. CAUTION 1 CAUTION 1 WARNING 1 WARNING 1 WARNING ® Kit Number 56021-04B 1 of 6 Figure 1. Draining Brake Fluid i01986 i05811.tif 1 1. Caliper bleeder valve NOTE Carefully compare the new brake line to the old line before removing the old linefrom the motorcycle. Make sure the banjo fittings on the new brake line will be oriented the same as the fittings on the old line. 4. Make note of the front brake line routing and the orientation of the banjo fittings, then unfasten the brake line clamps at the right side of the front fork upper bracket and the underside of the front fork lower bracket, and remove the brake line assembly from the vehicle. Save the upper clamp and all attaching parts, but discard the brake line.

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HARLEY DAVIDSON SPORTSTER BRAIDED REAR BRAKE LINE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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This kit fits 1988-2003 XL models. INSTALLATION 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) Drain Brake Fluid 1. Remove bleed screw cap on rear brake caliper. 2. Install one end of a length of plastic tubing over caliper bleeder valve. Place free end of the tubing in a suitable container. 3. Open the bleeder valve about one-half turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not re-use brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. 2. See Figure 1. Remove screws from the three P-clamps and one bracket used to secure brake line to motorcycle. a. Save all screws except bracket screw and save stock P-clamp, located at the right side sprocket cover, for later use. b. Do not mix up the screws. The screws must go back into the same threaded hole in which they were removed. c. Discard remaining two P-clamps. 3. Note brake line routing, then remove existing brake line. NOTE This kit contains clamps to replace the original equipment clamps removed, except for the small clamp on the right side sprocket cover.

HARLEY DAVIDSON SOFTAIL BRAIDED REAR BRAKE LINE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION 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 attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) 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) 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 performed. Failure to comply can result in cosmetic damage. (00239b) Drain Brake Fluid 1. Pop off bleeder nipple cap on the rear brake caliper. 2. Install one end of a length of plastic tubing over the caliper bleeder valve. Place the free end of the tubing into a suitable container. 3. Open the bleeder valve about 1/2-turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not reuse brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 2. Disconnect existing brake line from rear brake caliper and rear brake master cylinder assembly. Save banjo bolts, but discard brake line gaskets. NOTE This kit contains all gaskets needed for replacement. 3. Carefully make note of rear brake line routing and orientation of banjo fittings, then remove existing brake line. Save hex head screw holding brake light switch manifold to tab on frame, but discard brake line and attaching parts. 4. Unthread brake light switch from brake line. Save switch for later use.

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