We have installed a 23 inch front wheel with 2 inch longer frok tubes with LEGEND fork cartridges on Road Glide to make wheelie easier.
This setup requires longer brake lines.
It's impossible to relocate OEM brake lines due to rigid metal sections, so we are going to make new ones.
First, drain brake fluid from the calipers using a vacuum tool.
The brake fluid reservoir cap must be opened.
To reach the brake lines, it needs to remove the seat and the gas tank.
ABS system compressor is under the right side cover.
Banjo bolts are better to loosen when the compressor is fixed.
To completely unscrew the banjo bolts, you need to unscrew the battery box.
This allows to move down the ABS unit .
Brake lines are fixed with ties and clips. There is a guide on the steering column, which must be unfastened
It is easier to remove the brake lines towards the calipers due to the rigid sections under the lower triple clamp.
I will assemble new brake lines from HEL components on the motorcycle
Hel is one of the world leading manufacturers of steel braided brake lines.
The brake lines are very flexible, resistant to extremely low temperatures and aggressive environment
The unique patented design of the fitting allows it to be rotated in the sleeve after crimping
We got a dealership with number 129, which is on all sleeves, and which provides a lifetime warranty.
Stainless steel fittings can be bent to any angle
The most accurate and reliable way to make custom brake lines is to assemble it on the motorcycle
First, set the directions of all fittings, so that the brake lines from the calipers and ABS unit do not touch the fender and frame.
I'll put on the sleeves now, because they fix the line close to fitting
Next, new lines are laid along the original route, while the front wheel must be hung out to determine the maximum length
To fix the brake lines at the lower yoke, I use clamps that can be turned to set the proper direction
It is important to make sure that the brake lines do not rub against the frame
After the lines are laid and fixed, you can cut the right length
To prevent the tension of lines after crimping, it is desirable to mark the position of the fitting relative to the sleeve
The fitting can be rotated after crimping, but it is better to fix the proper positions now, not to do it during assembly.
The sleeves are crimped in a radial press to the required diameter
It is important to use new washers when installing banjo bolts.
First, it is better to lay and fix the brake lines, and after tighten the banjo bolts
Banjo bolts are tightened until the washers are deformed
The easiest way to fill the system is to use a vacuum pump.
It is important to control brake fluid level in the reservoir not to drain it and sack in air.
The calipers are filled first
Since the liquid is foamed inside the system, it must be left under pressure to collect the foam into a bubble.
Remaining air is removed from each cylinder under pressure
On Road Glide 2015 the ABS unit must be bleeded programmatically
Brake lines assembly on the motorcycle is the most accurate, but the most time consuming method, because you have to install the lines twice - first to determine the length, and the second time after crimping
It is unrealistic to make such a complex scheme by eye, or using the original lines,
even a small error in the length or direction will lead to the lines being rubbed, kinked or in tension
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