Harley-Davidson Sportster XL1200X Forty-Eight - Owner's Manual > Brakes

Brake Fluid

Clean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury.

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.

D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with.

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.

Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage.

NOTES:

• If the brake system is not leaking, there should never be a need to add fluid. If the fluid level is low, the pads are probably worn and need to be replaced. By replacing the pads, the fluid level rises.
• Replace the brake fluid every two years. Use only DOT 4 BRAKE FLUID. See a Harley-Davidson dealer.

Front brakes: Position motorcycle and handlebar so the master cylinder reservoir is level.

See Brake Fluid Low Level Marks. View sight glass (1) to verify that fluid level is at or above the center of sight glass.

Rear brakes: Position motorcycle so the master cylinder reservoir is level. Verify that fluid level is visible within the window (2).

If the fluid level is below the minimum mark or not present in either the front or rear brake reservoir, see a Harley-Davidson dealer.

Verify front brake hand lever and rear brake foot pedal have a firm feel when applied. If brakes are not firm, the brake system must be bled. See a Harley-Davidson dealer.

Brake Fluid Low Level Marks

1. Front
2. Rear

Brake Pads

Inspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury.

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury.

Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury.

Perform routine scheduled brake maintenance. Lack of maintenance at recommended intervals can adversely affect brake performance, which could result in death or serious injury.

Harley-Davidson has equipped your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry or wet conditions and at high operating temperatures. It exceeds all regulatory requirements currently in effect. However, during some braking you can experience noise. This noise is normal for this friction material.

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury.

1. Check the rear brake disc as it spins. The disc should run true in the brake caliper.

2. See Brake Pad Thickness. Measure the thickness of the brake pad friction material. For rear brakes, place the ruler against the brake disc through the space alongside the caliper.

Brake Pad Thickness

1. Front, from below
2. Rear, from above
3. Pad thickness

NOTE: Always replace brake pads in pairs.

3. Replace brake pads before friction material reaches minimum thickness. See a Harley-Davidson dealer. Refer to Minimum Brake Pad Friction Material Thickness.

Minimum Brake Pad Friction Material Thickness

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