Safety First: Essential Tips on How to Measure Harley Brake Line for Optimal Performance

Knowing how to measure Harley brake lines accurately is crucial for ensuring optimal braking performance and safety on the road. Whether you’re replacing worn-out lines, customizing your ride, or simply need to know the right length for a new set, this comprehensive guide will walk you through the process, step-by-step.

Why Measure Harley Brake Lines?

Precisely measuring your Harley brake lines is paramount for several reasons:

• Safety: Incorrectly sized brake lines can lead to excessive slack, causing delayed braking response and compromising your safety.
• Performance: Properly fitted lines ensure optimal hydraulic pressure transfer, resulting in a firmer brake feel and improved stopping power.
• Aesthetics: Customizing your Harley often involves replacing brake lines with braided stainless steel or other performance-enhancing options. Accurate measurement ensures a seamless fit and a polished look.

Essential Tools for the Job

Before diving into the measuring process, gather the necessary tools to ensure a smooth and accurate experience:

• Tape Measure: A flexible, retractable tape measure is essential for obtaining precise length measurements.
• Marker: A permanent marker will help you mark the exact points on your existing brake lines.
• Ruler: A ruler is helpful for verifying smaller measurements and ensuring accuracy.
• Calculator: A basic calculator will come in handy for calculating the total length of your brake lines.

Step-by-Step Guide to Measuring Harley Brake Lines

Follow these steps to accurately measure your Harley brake lines:

1. Identify the Brake Lines: Locate the brake lines you need to measure. These are typically routed from the master cylinder to the calipers on both the front and rear wheels.
2. Locate the Points of Measurement: Determine where you need to measure the brake lines. This typically includes:

• Master Cylinder to Caliper: Measure the distance from the master cylinder outlet to the caliper inlet.
• Caliper to Caliper: If you’re measuring a dual-disc setup, measure the distance between the two calipers.

3. Remove Existing Brake Lines: It’s recommended to remove the existing brake lines for accurate measurement. This allows for a clear view of the routing and prevents any interference.
4. Measure the Length: Using your tape measure, carefully measure the length of the existing brake lines, following the exact routing. Mark the starting and ending points with a permanent marker.
5. Account for Routing: Consider any bends, curves, or angles in the brake lines and factor them into your measurements.
6. Additional Length: Add a small amount of extra length (typically 1-2 inches) to account for potential routing adjustments or future maintenance.
7. Double-Check Measurements: Review your measurements and ensure accuracy before purchasing new brake lines.

Choosing the Right Brake Lines

Once you’ve accurately measured your Harley brake lines, it’s time to choose the right replacements. Consider these factors:

• Material: Stainless steel braided brake lines are known for their durability, resistance to corrosion, and improved braking performance.
• Length: Select brake lines that match your precise measurements, ensuring a snug fit and optimal hydraulic pressure transfer.
• Routing: Choose brake lines that are designed for your specific Harley model and routing configuration.
• Fittings: Ensure the brake lines have the correct fittings for your master cylinder and calipers.

Installing New Brake Lines

Once you’ve chosen the right brake lines, follow these steps for a safe and successful installation:

1. Prepare the Installation: Clean the master cylinder and caliper fittings to ensure a clean connection.
2. Install New Brake Lines: Carefully connect the new brake lines to the master cylinder and calipers, ensuring a tight and secure fit.
3. Bleed the Brakes: After installing the new lines, bleed the brake system to remove any air bubbles and restore optimal braking performance.

Beyond the Basics: Tips for Accurate Measurement

Here are a few additional tips to ensure the most accurate brake line measurements:

• Use a Helper: Having someone assist you with holding the tape measure and marking points can improve accuracy.
• Consider Suspension Travel: If your Harley has adjustable suspension, factor in the maximum travel when measuring brake lines to ensure sufficient length under all conditions.
• Consult a Professional: If you’re unsure about any aspect of measuring or installing brake lines, consult a qualified motorcycle mechanic for assistance.

Final Thoughts: Ride with Confidence

By following these steps and taking the time to measure your Harley brake lines accurately, you’ll ensure a safe and enjoyable ride. Remember, properly sized brake lines are essential for optimal braking performance, and a little extra effort in the measurement process can save you from potential headaches and safety risks down the road.

Answers to Your Questions

Q: Can I reuse my old brake lines?

A: While it’s possible to reuse old brake lines, it’s not recommended. Over time, brake lines can become brittle, corroded, or develop internal leaks. Replacing them with new lines ensures optimal braking performance and safety.

Q: What’s the difference between braided stainless steel brake lines and rubber lines?

A: Braided stainless steel lines offer superior performance and durability compared to rubber lines. They are less prone to expansion under pressure, resulting in a firmer brake feel and improved stopping power. They are also more resistant to corrosion and wear.

Q: What should I do if I can’t find brake lines that match my measurements?

A: If you can’t find pre-made brake lines that match your measurements, you can consider having custom-made lines fabricated by a specialist. Alternatively, you can adjust the routing of your brake lines slightly to accommodate the available options.

Q: How often should I replace my brake lines?

A: While there’s no specific time frame for replacing brake lines, it’s generally recommended to inspect them regularly for signs of wear, corrosion, or damage. If you notice any issues, replace the lines immediately.