I'm gonna save you some steps Bookie.

https://www.hdforums.com/forum/frame...at-dealer.html

Start at post #10

Here's the short version. I'm the original owner, I performed all my brake service and documented it. I had absolutely nothing wrong with my bike when I took it in for the recall and part of the ABS system failed (during the recall procedure). What you have there is just shy of a $1000.00 repair. No dealer will sell you the part(s). I stand upon my first reply.

"Bend over Bookie."

Sometimes, HD means Hard D*ck.

 

Just had an idle thought .If sensors and bearings are the same as the newer system,would it be possible to retrofit the newer HCU and ECM from Bosch in place of the failure prone chinese units? you are in it for 1000 plus anyway, what more would be needed?

 

Bookie, please file a report with the NHTSA at safecar.com. If they understand the magnitude of the problem we may get a real recall instead of a free fluid flush.

 

I agree wibiker.

However a follow up to my issue noted last week and am not sure if is the ABS module or not now.

I totally bleed my brakes with new DOT 4 stuff. Now I can push through the hard pedal and it works fine. This now makes me believe it is a sticking caliper or a master cylinder issue. If the bike sits for a long period the hard pedal returns however I am able to muscle through it and then it is normal. Comments??

It could still be the ABS sticking, however some opinions are appreciated.

 

Ok, a few thoughts...

Brakes are a critical component.
Brakes are not working properly.
One day you may not be able to "push through" it. Possibly at a critical moment.
What's your life worth to you?

 

I agree with you and wish that Harley Davidson felt the same for the other riders that were not so fortunate because of their poorly designed braking system.

 

When you get the Hard brake pedal you should be able to narrow it down to what component is bad. Next time you have a hard brake, before you push thru it, try loosening the banjo bolt at the rear master. If the pedal goes down right away then the problem is not with the master. You could even do the same thing at the ABS module. Loosen the line from the master to the ABS module. If the pedal sinks it's not the master or that brake line. If nothing changes, tighten that line & loosen the line at the module that goes to the rear caliper. If you still have a hard pedal then the problem is in the abs module. If the pedal sinks, tighten that line and crack open the bleeder on the caliper. If it sinks it might be a frozen rear caliper. Jack the bike up and see if the wheel spins freely and if it stops with a little pressure on the pedal.
Let us know what you find. As you loosen any of the lines, keep some pressure on the pedal (as if you were bleeding the brakes) to keep air from getting in the system. Tighten the line before releasing the pedal.

 

The next time you get a hard lever or pedal; loosen the line at the ABS module (of the brake that's frozen), you'll save yourself some time. When a master cylinder fails, it fails to create or hold pressure, not freeze the control.

 

While I agree with you, I wasn't trying to save Bookie time. I was trying to show a step by step way to find which brake system component was causing the hard pedal.

 

Agreed, your way is thorough.