I tried to bleed the brakes with the bleeder pump from Harbor Freight with no Luck, so I gave up and brought it to Harley. They called me today and it turned out it was the ABS module. That's the bad news, the good news was it was covered under warranty. I thought the extended warranty was up July last year.

 

The brake system on an ABS Harley is just like the non ABS unit. It is totally stand alone. The ABS is of course plumbed into it and has the readers and special sensor in the wheel bearing and such, control the ABS pump to keep both wheels from locking up with up to 7 on and off applications per second. When you went into the master and caliper, did you grease the piston with caliper piston grease? Also with all you have done, there is a very good chance you have air in the ABS unit (However that is not the problem). Only Harley dealer can get that out and I do not think a little air will throw a light in the check. However it will affect how the ABS reacts in an emergency stop. As critical as this is, you really should get an expert to check it out. PS, after you added the fluid back to the master cylinder and attempted to pump it back thru the caliper, did you have the cap off or loose on the master cylinder? Remember, Harley masters are non vented. Once filled and air is bleed out, the rubber gasket has a bellows in it which has a slit in it at the top that lets air to the top side of the bellows. As the fluid presses the caliper pistons out, this bellow goes down and of course up when you let off and will get totally extended as shoes wear and pistons stay out. However when you tighten cap when all is down, only screw the cap down till you see or fill a slight bulge on the gasket. Be sure you do not tighten so far as to close off this slit. It's easy to do. Harley calls for an inch lb torque but do to outside temperature and how old gasket is, do it by bludge. That bulge keeps screws tight and you have no leaks. Over Tighten and you have stiff brakes and leaks...You do not need any special tools to bleed a Harley. Any one should be able to reach lever and bleeder by them self. If you do use a vac, go easy. The seals on the master are cup. The exert tremendous pressure one way. However when you pull fluid with over a few lbs of vacuum, its real easy to pull air into the master..then all you are is a dog chasing its tail..

 

No fluid would go through the ABS brake module. I finally took it in and that's what they said it was. They were fixing an oil leak and found the compensator was bad and had to replace that and the rotor. When they called to give me the bad news, they also said it was under warranty. So I screwed up I thought my extended warranty was up last July it's up this coming July. I wouldn't have tried to find the problem if I'd know that. The warranty company wouldn't pay for the rotor, so it cost $150, otherwise it would have been just over $1000.