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Library Home Page > 2nd Generation (1999 to current) > Brakes
Build Your Own Integrated Brakes
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Integrated Brakes

You can buy the steel braided brake lines at any HD shop or any catalog. The price is about $160 for all the parts needed, plus the DOT4 brake fluid. Required fittings are:
  • 1 straight banjo
  • 3 45degree banjos
  • 2 90 degree banjos
  • 11 crush washers
  • 1 long fluid bolt for the rear master cylinder
  • 2 brake lines 36" long
  • 1 brake line 24" long
  • 1 brake line 12" long
  • 1 in-line connector

    Connect the rear caliper to the right front caliper and they will be operated by the foot brake pedal. The left caliper will be activated by the front brake lever. From the rear caliper, start with 45 degree to 36" hose to 90 degree to rear master cylinder. From there, opposed 90 degree to 24" hose to in-line connector to 36" hose through front end to 45 degree and connct to right front caliper. At center juction for the front calipers, use the straight banjo to the 18" hose to the 45 degree connector to the left caliper, using all 11 crush washers between each banjo fitting. 3 are required at the rear master cylinder. Use a known good vacuum pump with constant vacuum to bleed the systems. The intergrated side is the tricky one because you have to go higher than the rear fill cup. Once properly bled, pump the pedal a lot, with a slow yet firm action. You will see bubbles escape to the top of the fill cup. Your pedal will be lower than original, with a power brake feel. I assure you I have tested this system and it works great. Nothing like stopping a half ton machine firmly with no skidding.

  • Last update: 06:25 PM Sunday, September 26, 2004

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