Frequently Asked Harley

Commonly Asked Harley-Davidson Questions

What is the difference between Street Legal™ brakelines and Cycleflex™ brakelines?

In order to pass the Department of Transportation standard MVSS-106 requirements, brake lines are subjected to what is called a "whip test", where the brakeline is literally whipped back and forth for a specified period of time. When subjected to this abnormal abuse, our Cycleflex lines may begin to fray where the braided stainless steel jacket meets the crimp-on fitting. In order to pass this test, Russell engineers have incorporated a TeflonÆ sleeve along with the crimp-on fitting that distributes the loads of this test over a broader section of hose, thereby preventing the stainless steel braid from fraying. Other than this TeflonÆ sleeve and DOT markings on the hose itself, the pressure ratings, burst strengths and flow capacities are identical between the two styles of brakelines.

What is the difference between DOT3, DOT4, DOT 5 and DOT 5.1 brake fluids?

DOT 3, DOT 4 and DOT 5.1 brake fluids are glycol based compounds that are compatible with one another. DOT 5 brake fluid is silicone based and should never be mixed with DOT 3, DOT 4 or DOT5.1. DOT 3, DOT 4 and DOT 5.1 fluids may damage painted surfaces and DOT 3 and DOT 4 have lower boiling temperatures than DOT 5 (DOT 5.1 has the same boiling point as DOT 5). Furthermore, DOT 3, DOT 4 and DOT 5.1 fluids are "hygroscopic", which means they absorb moisture from the air. This causes the fluid to turn dark, indicating that it is time for the brake fluid to be replaced. DOT 5 fluid will not damage paint, has a boiling temperature in excess of 500ƒ F, and is not hygroscopic.

What different designs of brake rotors does Russell offer?

Russell offers three styles of brake rotors, all of which are compatible with most brake pad materials, including KevlarÆ and sintered pads. The first is the standard (non-floating) rotor in a satin machined finish. This is a high quality, economical OEM replacement rotor made of SVS420JZ stainless steel, which is highly rust resistant. Mounting holes and heat dissipation holes are computer machined, guaranteeing consistent precision for easy installation. Available in 10" and 11 1/2" diameters to fit most Harley-DavisonsÆ with hydraulic disc brakes from 1974-98. Our next style of rotor is our exclusive Pro Polish Rotor. Made with the same materials and manufacturing methods as the satin finish rotor, the Pro Polish rotor utilizes our E.F.S.™ process, producing the first "mirror surface" rotor for Harley-DavidsonÆ motorcycles. Pro Polish rotors are held to exacting specifications, with flatness within one lightband (.0000116") and a surface finish to within one micro inch or less. The end result is a precision rotor with the flattest braking surface in the industry. Available to fit most Harley-Davidsons with hydraulic disc brakes from 1974-98. The third style of rotor is the Russell True Floating Rotor. This rotor features our integral spring-loaded retention system that maintains maximum floatation for precise alignment, guaranteeing full contact with the brake pads. This ensures greater braking power and longer pad life. Floating rotors are made from SVS420JZ stainless steel with chromed center. Available in 11 1/2" diameters only for most Harley-Davidsons from 1984-98.

What are Speed BleedersÆ and how do they work?

Russell's patented new Speed Bleeders are the one-man bleeder valves with a stainless steel one-way check ball in them. Install them in place of the original bleeder valves, and when it is time to bleed your brakes, simply crack them open 1/4 to 1/2 turn and continuously pump the brakes. The spring-loaded check ball opens to let out the old brake fluid and air, then closes between pumps to prevent the old fluid or air from re-entering the brake system. A patented thread compound keeps air from leading past the threads. When you see clean new fluid coming out, you know all the old fluid has been purged and you simply tighten down the Speed Bleeder. Packaged two per pack, they are available in sizes to fit almost any vehicle on the road.

How do I get Russell stainless steel braided brakelines to fit a modified or custom motorcycle?

Russell has several solutions to the common problem of needing custom brakelines. First, we offer overstock lengths for a wide variety of Harely-Davidsons to accommodate either extended forks or high-rise handlebars. Generally speaking, these lines are available in 2" , 4" and 6" overstock lengths. Next, we have our "Universal Brake Hose Assemblies", which are brakelines anywhere from 9" to 66" long. These universal brakelines come with female -3 AN fittings crimped on both ends which will then accept any of our universal brake adapters. In order to install our universal lines, you must first measure the length of the lines needed and determine the type and dimensions of the hose ends. A knowledgeable parts man is a valuable source for this information if you can not find these specifications. Yet another way to fit up a custom bike is to use our new Pro System I Series of brakelines and adapters. These chromeplated adapters can be installed on our brake hose without the use of expensive crimping equipment, using ferrule technology that results in a secure hose attachment. Pro System I Hose is available in bulk, simply cut the hose to length, determine what type of hose ends you require, and assemble your own custom brake line. Pro System I Hose comes with an exclusive extruded clear coat for protection against abrading painted or polished surfaces. As you can see, Russell provides the versatility to satisfy all of your stainless steel braided brakeline needs.

I own a motorcycle shop. How can I carry Russell brakelines to satisfy my customers without stocking a huge inventory?

Russell has two Plan-O-Grams that allow a dealer to affordably stock stainless steel braided brakelines to fit most applications. Part #87001 is our Performance Brake Line Center, designed to allow you to create a brakeline kit for custom bikes with dual disc front brakes. A selection of universal brakelines is included along with all of the brake tees, banjos and banjo bolts required to accommodate bikes with extended or lowered forks and raised or lowered handlebars. Part #87002 is our Street Legal Brake Line Center, which contains DOT approved brakelines for most popular late-model Harley-Davidsons, including Sportsters, Dynas and Softails. Both Plan-O-Grams come with an attractive three-color pegboard and the necessary hooks for free.