Table of Contents

REF: Wheels, Brakes & Tires


Brake Fluid

HD Recommendations

Year ModelHydraulic brake fluid Type
1959 to prior to Sept. 1976 production modelsDOT 3 1)
Sept. 1976 to 2006DOT 5 (99902-77) 2) 3)
2007 and laterDOT 4 4)

When to Check or Change Brake Fluid

Copper content is the most destructive aspect of brake fluid breakdown.
So even without moisture being present in the fluid, it is still a good idea to change the fluid when it is suppose to be changed. 5)

Year ModelCheckChange
1959-1969
1970-19786)Every 2,000 milesEvery 5,000 miles
1979-19857)Initial 500, then every 2,500 milesEvery 2 years
1986-19908)Check at initial 500 then every 5,000 miles, prior to storage or annuallyChange/ Replace as needed
1991 to 20039)Every 300 til and including initial 1,000 miles, then every 5,000 milesReplace as needed

Testing Your Brake Fluid

Mixing Brake Fluids

Note the gooey mess from mixing Dot 5 and Dot 3 fluids. 16) 17)

Swapping Brake Fluid (Dot 3 to Dot 5)

The following is found in HD Technical Service Bulletin M-712 dated June 16,1977.

When changing from D.O.T. 3 to D.O.T. 5 fluid or when flushing the brake system, it is important that D.O.T. 3 fluid be removed completely.
Old fluid could be contaminated with water and if mixed with the new D.O.T.-5 fluid, it would detract from it's effectiveness.
The old fluid could also cause varnish deposits if the system is operated above the boiling point of D.O.T. 3.
Caution should be used when bleeding because any brake fluid on the pad will contaminate the pad material and reduce brake effectiveness.
The fluid absorbed by the pads cannot be removed satisfactorily with any solvent nor by operating the brakes.

Procedure:

  1. Disconnect the brake lines from the master cylinder and wheel calipers (wheel cylinders if drum brakes).
    Catch old fluid in container and discard.
  2. Remove master cylinder and brake calipers from motorcycle.
  3. Disconnect brake hoses from the metal brake lines (if applicable).
  4. Flush the metal brake lines several times with silicone brake fluid (D.O.T. 5) fluid to remove all the old fluid.
    Solvent flushing is not recommended.
  5. Replace the brake hoses with new ones.
  6. Disassemble the master cylinder and wheel calipers or cylinders.
  7. Drain and remove any residual D.O.T. 3 brake fluid with a dry, clean cloth that will not leave lint or grit on the master cylinder or caliper parts.
  8. Replace master cylinder and wheel caliper rubber seals, piston cups and 0-rings with new parts.
  9. Coat pistons, piston bores and rubber parts with silicone brake fluid and reassemble.
  10. Install master cylinder and calipers on motorcycle.
  11. Reassemble brake lines to master cylinder and calipers.
  12. Fill brake system with D.O.T.-5 silicone brake fluid and bleed air from system following procedure in Service Manual.
    Fluid leakage from the rear master cylinder boot after bleeding is often caused by excessive piston travel due to air in the system.
    The boot should be wiped clean of any brake fluid to avoid contaminating the cylinder with road dust.

DOT 3, DOT 4, DOT 5.1

DOT 5

Brake Fluid Boiling Points

SAE Testing Brake Fluid Lubricity


1) , 3)
Clymer Repair Manual for Sportsters 1959-1985 pg 83
2) , 8)
1986-1990 HD Sportster FSM
6) , 7)
1959-1969 Clymer Sportster Repair Manual
9)
1986-2003 Clymer Sportster Repair Manual
21)
HD Service Letter M-28
23) , 24)
HD Service Bulletin #M712 dated June 16, 1977 pg 1
28)
article by Matt Robertson
29)
Seine Systems
30)
article by Marc Randolph