Discover the Proven Method for Safely Extending Your Harley Brake Line

Do you feel your Harley’s brake lines are holding you back? Maybe you’ve installed new handlebars, lowered the suspension, or simply need a bit more slack for those tight turns. Whatever the reason, knowing how to extend Harley brake lines is a valuable skill for any motorcycle enthusiast. This guide will walk you through the process, providing step-by-step instructions and helpful tips to ensure a safe and successful extension.

Why Extend Harley Brake Lines?

Before we dive into the how-to, let’s understand why extending brake lines is necessary in the first place. Here are some common scenarios:

• Aftermarket Handlebars: Switching to taller or wider handlebars often requires longer brake lines to avoid stretching or kinking.
• Lowered Suspension: If you’ve lowered your Harley’s suspension, the stock brake lines might become too short, limiting their flexibility and potentially causing braking issues.
• Custom Modifications: Any significant changes to your bike’s geometry, like adding a custom swingarm or relocating the master cylinder, could necessitate brake line extension.
• Increased Comfort: Some riders simply prefer the extra length for added comfort and maneuverability.

Choosing the Right Brake Line Extension Kit

The first step is choosing the right brake line extension kit. You have two main options:

• Pre-Made Kits: These kits come with pre-cut lines and fittings, making installation easier. However, you might need to find a kit specifically designed for your Harley model and the modifications you’ve made.
• Custom-Made Kits: You can purchase individual components like braided stainless steel lines, banjo bolts, and fittings to create a custom extension. This gives you more flexibility but requires a bit more technical knowledge and assembly.

Key Considerations When Choosing a Kit:

• Compatibility: Ensure the kit is compatible with your specific Harley model and brake system.
• Material: Opt for high-quality braided stainless steel lines for durability and performance.
• Length: Choose the correct extension length based on your modifications.
• Fittings: Make sure the banjo bolts and fittings are compatible with your existing brake system.

Essential Tools and Supplies

Before starting the extension process, gather the following tools and supplies:

• Brake Line Extension Kit: The kit you’ve chosen.
• Torque Wrench: Essential for tightening fittings to the correct specifications.
• Wrench Set: For loosening and tightening nuts and bolts.
• Adjustable Wrench: For working with various sizes of fittings.
• Pliers: For gripping and holding fittings.
• Brake Fluid: DOT 3 or DOT 4 brake fluid.
• Clean Rags: For cleaning brake components and spills.
• Safety Glasses: To protect your eyes from brake fluid and debris.
• Gloves: To protect your hands from brake fluid and grime.

Step-by-Step Guide to Extending Harley Brake Lines

Now that you have everything you need, let’s get started:

1. Prepare the Bike: Park your Harley on a level surface and engage the parking brake. If necessary, use a jack to lift the bike for easier access to the brake lines.
2. Locate the Brake Line: Identify the brake line you need to extend. It’s typically located between the master cylinder and the caliper.
3. Bleed the Brake System: Before disconnecting the brake line, bleed the system to remove air bubbles. This ensures proper brake function after reassembly.
4. Disconnect the Brake Line: Carefully loosen and remove the banjo bolts connecting the brake line to the master cylinder and caliper. Use a wrench to hold the fittings while loosening the bolts to prevent damage.
5. Install the Extension Kit: Connect the extension kit components according to the manufacturer’s instructions. Make sure the fittings are properly aligned and secured.
6. Tighten the Fittings: Using a torque wrench, tighten the banjo bolts to the manufacturer’s specifications. Overtightening can damage the fittings.
7. Re-Bleed the Brake System: After connecting the extended brake line, bleed the brake system again to remove any air introduced during the process.
8. Test the Brakes: With the system bled and the fittings tightened, test the brakes thoroughly to ensure proper function.
9. Finalize Installation: Once you’re satisfied with the brake performance, clean up any spills or debris.

Tips for a Successful Brake Line Extension

• Cleanliness: Maintain a clean working area to prevent contamination of the brake system.
• Proper Tools: Use the correct tools and torque settings to avoid damage.
• Bleeding: Thoroughly bleed the brake system after installation to ensure proper function.
• Safety First: Always wear safety glasses and gloves when working with brake fluid.
• Professional Assistance: If you’re not comfortable with the process, consult a qualified motorcycle mechanic.

Beyond the Basics: Advanced Considerations

For more complex modifications or custom builds, you might consider these advanced techniques:

• Custom-Bent Lines: For unique applications, you can have brake lines custom-bent to fit your specific needs.
• Stainless Steel Braided Lines: These lines offer superior durability, performance, and aesthetic appeal.
• Adjustable Brake Line Extensions: Some kits offer adjustable lengths for fine-tuning the brake line length.

Riding into the Sunset: A Final Word on Brake Line Extension

Extending your Harley’s brake lines is a relatively straightforward process, but it requires attention to detail and proper technique. By following the steps outlined above, you can confidently extend your brake lines and enjoy the benefits of a more comfortable and customized ride. Remember, safety should always be your top priority, and if you have any doubts, consult a professional.

Popular Questions

Q: Can I extend the brake line myself, or should I take it to a mechanic?

A: If you’re comfortable working on motorcycles and have the necessary tools, you can extend the brake line yourself. However, if you’re unsure or unfamiliar with the process, it’s best to consult a qualified mechanic.

Q: What type of brake fluid should I use?

A: Use DOT 3 or DOT 4 brake fluid, as recommended by your Harley’s owner’s manual.

Q: What if I extend the brake line too much?

A: If the brake line is too long, it can create slack and affect brake performance. You might need to adjust the brake lever or shorten the line.

Q: How often should I bleed my brake system?

A: It’s good practice to bleed your brake system annually or whenever you make significant changes to the system, such as extending the brake lines.

Q: What are the signs of a bad brake line?

A: Signs of a bad brake line include spongy brakes, a soft brake pedal, fluid leaks, or visible damage to the line. If you notice any of these issues, consult a mechanic immediately.