Essential Information
- Use a measuring tape or ruler to measure the distance between the brake line’s banjo bolts (the ends that connect to the master cylinder and caliper).
- Use a measuring tape or ruler to measure the distance between the center of the master cylinder’s banjo bolt hole and the center of the caliper’s banjo bolt hole.
- You can use a bungee cord or zip tie to hold the brake line in place while you measure.
Maintaining a reliable and responsive braking system is crucial for the safety and performance of your Harley-Davidson motorcycle. One important aspect of brake maintenance is ensuring that your brake lines are the correct length. This blog post will provide you with a comprehensive guide on how to accurately measure Harley brake lines, empowering you to install or replace them with confidence.
Tools You’ll Need
Before you begin, gather the following tools:
- Measuring tape or ruler
- Pen or marker
- Helper (optional but recommended)
Measuring the Old Brake Line
If you have an old brake line that needs to be replaced, follow these steps:
1. Remove the brake line: Disconnect the brake line from the master cylinder and caliper.
2. Straighten the brake line: If the brake line is coiled or bent, straighten it out as much as possible.
3. Measure the length: Use a measuring tape or ruler to measure the distance between the brake line’s banjo bolts (the ends that connect to the master cylinder and caliper).
Measuring for a New Brake Line
If you’re installing a new brake line or replacing a line that doesn’t exist, follow these steps:
1. Measure the distance between the master cylinder and caliper: Use a measuring tape or ruler to measure the distance between the center of the master cylinder’s banjo bolt hole and the center of the caliper’s banjo bolt hole.
2. Add some slack: Brake lines need some slack to accommodate suspension movement. Add 2-3 inches of slack to your measurement.
3. Round up to the nearest inch: Brake lines are typically sold in whole inches. Round up your measurement to the nearest inch.
Considerations for Measuring
- Brake line routing: Consider the path the brake line will take, including any bends or curves.
- Handlebar position: If you have aftermarket handlebars, they may affect the length of the brake line needed.
- Brake caliper type: Some brake calipers may require a different length of brake line than others.
Installing the New Brake Line
Once you have measured and obtained the correct brake line, follow these steps to install it:
1. Route the brake line: Place the brake line along the intended path, making sure it doesn’t interfere with other components.
2. Connect the brake line: Tighten the banjo bolts to the specified torque.
3. Bleed the brake system: Remove any air from the brake system by bleeding the brake line.
Troubleshooting
If you encounter any issues during the measurement or installation process, consider the following troubleshooting tips:
- The brake line is too short: Measure the distance again, ensuring you’ve added the necessary slack.
- The brake line is too long: Recheck your measurements and ensure you’ve accounted for all bends or curves in the routing.
- The brake line is kinked or damaged: Replace the brake line immediately.
Wrapping Up: Ensure a Safe and Smooth Ride
By accurately measuring your Harley brake lines, you can ensure a proper fit and optimal braking performance. Remember to consider the factors discussed in this guide, and don’t hesitate to seek professional assistance if needed. By following these steps, you can maintain a reliable and responsive braking system, enhancing your riding experience.
Answers to Your Most Common Questions
Q: Can I measure the brake line while it’s still connected to the motorcycle?
A: Yes, but it’s easier to measure an old brake line that has been removed.
Q: How much slack should I add to the brake line measurement?
A: Typically 2-3 inches is sufficient.
Q: What if I don’t have a helper to assist me?
A: You can use a bungee cord or zip tie to hold the brake line in place while you measure.
Q: Can I use a flexible brake line instead of a fixed-length line?
A: Yes, flexible brake lines can accommodate various lengths, but they may not be as durable as fixed-length lines.
Q: How often should I inspect my brake lines?
A: Regularly inspect your brake lines for any signs of wear or damage, especially after riding in harsh conditions.
