Harley-Davidson Sportster Evolution Front Brake Fluid Change

Bleeding and refilling the front brake lines

  • Author: Brett Hartt
  • Time required: 45 minutes
  • Difficulty: Moderate

This guide will show you how to bleed and refill the front brake lines on the Harley-Davidson Sportster Evolution.

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Add Note Edit Step 1 — Preparing the Motorcycle  ¶ 

  • When working with the brake lines, we strongly recommend using a bike stand or similar apparatus to stand the bike upright and lock the front tire in place.

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Add Note Edit Step 2 — Opening the brake line  ¶ 

  • Using a Phillips #2 screwdriver, remove the two screws securing the lid on the master brake fluid cylinder.

  • Remove the lid from the master cylinder, and set it aside.

    • Brake fluid is very caustic, and will easily strip paint and discolor chrome. Do your best to not spill any, and be ready with a damp rag in the event of a spill.

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Add Note Edit Step 3  ¶ 

  • Locate the brake fluid bleed valve on the top of the front brake assembly, and flip up the rubber cap covering it.

  • Slide a 3/8" brake bleeder hose over the bleed valve.

    • If you are using a stop valve for bleeding the brake lines, make sure that the arrow on the valve is pointing away from the brake assembly (along the direction of flow).

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Add Note Edit Step 4  ¶ 

  • Make sure that the free end of the bleed tube is safely pointed at some kind of reservoir. A glass bottle works great.

  • Bleeding the brake lines is a whole-body effort. You will need to use one hand to pump the brake handle and one hand to maneuver a wrench on the brake bleed valve.

    • You may need to raise or lower your bike stand to be able to reach all the way across the bike.

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Add Note Edit Step 5 — Flushing the brake line  ¶ 

  • Before proceeding, read all the way through steps five and six to make sure that you completely understand the actions for bleeding the brake lines.

  • Carefully pump the brake lever a few times to build up pressure in the brake lines.

  • In the next step, you will release the fluid from the brake lines by opening the bleed valve at the bottom of the lines and simultaneously squeezing the brake lever.

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Add Note Edit Step 6  ¶ 

  • Using a 3/8" wrench with your left hand, open the bleed valve on the front brake cylinder.

    • The built-up pressure in the lines will force some of the brake fluid out of the lines.

  • Continue to force more brake fluid out of the brake lines by depressing the front brake lever with your right hand.

    • While bleeding the brakes, focus on the bleeder hose. If you see an air bubble traveling up the bleed hose, close the bleed valve immediately, and begin the process again.

  • Once the brake lever is completely depressed, quickly close the bleed valve, making sure that no air bubbles enter into the brake lines.

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Add Note Edit Step 7  ¶ 

  • Repeat the process outlined in step five and six until the amount of brake fluid in the master cylinder is getting low.

    • Make sure to not remove so much brake fluid that air gets into the brake lines.

  • Refill the master cylinder with fresh brake fluid until the level of fluid is even with the metal protrusion in the rear right corner of the master cylinder.

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Add Note Edit Step 8  ¶ 

  • Continue flushing the brake lines as described above until you see the new brake fluid coming through the bleed tube.

    • The new brake fluid will be a lighter color than the old, discolored brake fluid.

  • Keep an eye on the master cylinder. If the fluid level gets too low again, be sure to add more fluid.

  • When you are seeing new brake fluid coming through the bleed hose, stop the flushing process and firmly close the bleed valve.

  • Gently pull the bleed tube off of the bleed valve and re-cover the valve with the little rubber cap.

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