CHROME FRONT BRAKE MASTER CYLINDER KIT - Harley
Contents
1. Use denatured alcohol to clean clutch system components Do not use mineral based solvents such as gasoline or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause clutch failure which could result in death or serious injury 00296a 7 With denatured alcohol clean and inspect all parts that will be reused Replace as necessary and wipe dry with a clean lint free cloth 20f6 Install Chrome Master Cylinder Reservoir is01013 Q Fa 10 gt JS mo Master cylinder housing Handlebar clamp Brake lever Master cylinder cover Cover gasket Reservoir Pivot pin Retaining ring Cover screw 10 Flat washer 11 Screw OONO ES D Figure 4 Brake Master Cylinder Reservoir 1 See Figure 4 Align hole in brake hand lever 3 with hole in master cylinder housing 1 From the top of the assembly slide pivot pin 7 through bracket and hand lever 2 Install retaining ring 8 in pivot pin groove Verify that retaining ring is completely seated in groove NOTICE Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4 mm thick insert between the brake lever and lever bracket Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch 00324a J03735 Brake lever bracket Groove Switch2. WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 3 With the ignition light key switch turned to IGNITION actuate the front brake hand lever to verify operation of the brake lamp WARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 4 Test ride the motorcycle a If the brake feels spongy repeat the front brake bleeding procedure b If the clutch drags or if the transmission shifts hard repeat the clutch bleeding procedure 5 of 6 SERVICE PARTS is01286 Figure 9 Service Parts Chrome Front Brake Master Cylinder Kit Table 1 Service Parts Table Item Description Quantity Part Number Item Description Quantity Part Number 1 Bracket clutch lever 38403 99 6 Chrome clamp 2 45282 99 2 Oval head screw 2 2573 7 Master cylinder reservoir bracket 45298 99 assembly dual disc 11 16 in bore 3 Gasket brakeline 2 dual disc 41731 01 Master cylinder reservoir bracket 45297 99 assembly single disc 9 16 in bore Gasket brakeline 2 single disc 41733 01 8 Washer 4 6099 4 Button head screw 4 4293 9 Master cylinde
3. LEVER BRACKET Remove the Existing Clutch Lever Bracket 1 Stand motorcycle upright and level is01014 1 Rubber boot 2 Cable adjuster 3 Jam nut 4 Cable end Figure 7 Clutch Cable Adjuster 2 See Figure 7 Loosen clutch cable adjuster so clutch cable is fully slack by performing the following a Slide rubber boot 1 off cable adjuster b Holding cable adjuster 2 with 1 2 inch wrench loosen jam nut 3 using a 9 16 inch wrench c Back jam nut 3 away and turn cable adjuster 2 toward jam nut to introduce a large amount of free play at the clutch hand lever WARNING Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 3 Remove the clutch cable anchor pin from the hand lever To remove anchor pin it will be necessary to remove the retaining ring and pivot pin 4 Remove clevis and clutch lever 4of6 5 Using a T27 TORX drive head remove the 2 screws with flat washers securing the handlebar clamp to the clutch lever bracket Install the Chrome Clutch Lever Bracket 1 See Figure 9 Install the clutch cable and anchor pin in the clutch hand lever The flat in the pin must face in towards the hand lever 2 Put cable clevis in position in clutch lever and slide anchor pin into place IWIN NIN Wear safety glasses or goggles when removing
4. Damage to seating surfaces can cause leakage 00320a 2 Remove bolt and 2 steel rubber washers to disconnect fitting of hydraulic brake line from master cylinder Discard washers NOTICE Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4 mm thick insert between the brake lever and lever bracket Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch 00324a J03735 is01010 Figure 3 5 32 in 4 mm Cardboard Insert 3 See Figure 3 Place the cardboard insert between the brake lever and lever bracket 4 Using T27 TORX drive head remove the 2 screws with flat washers securing the handlebar clamp to the master cylinder housing Remove the brake lever master cylinder assembly and clamp from the handlebar WARNING Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 5 Remove retaining ring from pivot pin groove at bottom of master cylinder bracket D Remove pivot pin and brake hand lever from master cyl inder assembly NOTE New master cylinder comes with all internal components pre assembled It is not necessary to remove the components from the bore of the old master cylinder See Figure 9 WARNING
5. In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 5 brake fluid can cause digestive discomfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00144a CAUTION Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a is01009 Figure 6 Reservoir Fill Level 1 8 in 3 2 mm Below Gasket Surface NOTE Check your owner s manual for the correct type of brake fluid for your year and model motorcycle 8 See Figure 6 Add the correct type of BRAKE FLUID to the master cylinder reservoir until the fluid level is 1 8 inch 3 2 mm from the top Do not reuse old brake fluid Use only D O T approved brake fluid from a sealed container IWIN NIN Be sure the master cylinder relief port is not plugged A plugged relief port can cause brake drag or lockup and loss of vehicle control which could result in death or serious injury 0031 7a 9 Verify operation of the master cylinder relief port Actuate the brake hand lever A slight spurt of fluid will brake the fluid surface in the reservoir compar
6. cMOTOR HARLEY DAVIDSON QU J03735 INSTRUCTIONS REV 2009 03 03 CHROME FRONT BRAKE MASTER CYLINDER KIT GENERAL Kit Number 45281 99D 45284 99D Models These Chrome Master Cylinder Kits are designed to replace the original equipment front brake master cylinder on the fol lowing Harley Davidson models e 1996 to 2004 Touring e 1996 to 2003 Sportster e 1996 2005 Softail and Dyna Additional Parts Required AWARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 9 and Table 1 See Figure 1 Master cylinders designed for dual disc 2 caliper operation have an 11 16 inch 17 5 mm bore Kit No 45281 99D while those that are designed for single disc 1 caliper operation have a 9 16 inch 14 3 mm bore Kit No 45284 99D The bore size is stamped on the master cylinder assembly inboard of the handlebar clamp bracket WARNING Do not use parts from single caliper repair kits 9 16 inch bore
7. housing Tab 1 2 3 4 Figure 5 Brake Lever Bracket to Switch Housing 3 See Figure 5 Position the brake lever master cylinder assembly inboard of the switch housing 3 engaging the tab 4 on the lower switch housing in the groove 2 at the top of the brake lever bracket 1 4 See Figure 4 Align the holes in the handlebar clamp 2 with those in the master cylinder housing and start the 2 screws 11 with flat washers 10 Position for rider com fort Beginning with the top screw tighten the screws to 70 80 in lbs 7 9 9 0 Nm using a T27 TORX drive head NOTICE Avoid leakage Be sure gaskets banjo bolt s and brake line are clean and undamaged before assembly 00323a WARNING Replace brake line gaskets Re using original gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a 5 Position new steel rubber washers included in kit on each side of hydraulic brake line fitting Insert bolt through washers and fitting Thread bolt into master cylinder housing and tighten to 17 22 ft lbs 25 30 Nm 6 If removed install length of clear plastic tubing over caliper bleeder valve Place free end of tube in a clean container 7 Stand the motorcycle upright so that the master cylinder is in a level position CAUTION Direct contact of D O T 5 brake fluid with eyes can cause eye irritation swelling and redness Avoid eye contact
8. on dual caliper models Likewise do not use parts from dual caliper repair kits 11 16 inch bore on single caliper models Using incorrect parts can cause brake failure which could result in death or serious injury 00278a J03735 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled is01006 1 Dual caliper bore stamp size 11 15 2 Single caliper bore stamp size 9 16 Figure 1 Master Cylinder Bore Identification INSTALLATION Prepare the Motorcycle 1 Follow the Service Manual instructions to remove the seat WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Follow the Service Manual instructions to disconnect the negative battery cable 1 of 6 Please dispose of materials responsibly CHROME MASTER CYLINDER RESERVOIR Remove the Existing Master Cylinder Reservoir is01008 Figure 2 Draining Brake Fluid e See Figure 2 Drain the brake fluid a Open bleeder nipple cap on front brake caliper b Install end of a length of clear plastic tubing over cal iper bleeder valve while placing free end in a suitable container Open bleeder valve about 1 2 turn ao Pump brake hand lever to drain brake fluid e Remove cover f Close bleeder valve NOTICE Remove brake line components carefully
9. or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 3 Place clutch lever in new bracket and install pivot pin and retaining ring 4 Align the holes in the handlebar clamp with those in the clutch lever bracket and start the 2 screws with flat washers Position for rider posture Beginning with the top screw tighten the screws to 70 80 in Ibs 7 9 9 0 Nm using a T27 TORX drive head is01012 Clutch cable Cable ferrule Clutch lever bracket Freeplay 1 16 1 8 in 1 6 32 mm Pena Figure 8 Clutch Hand Lever J03735 5 Adjust clutch lever free play a See Figure 7 Turn cable adjuster away from jam nut until slack is eliminated at hand lever b See Figure 8 Pull clutch cable ferrule 2 away from clutch lever bracket 3 to check free play Turn cable adjuster as necessary to obtain 1 16 1 8 inch 1 6 3 2 mm free play between end of cable ferrule and clutch lever bracket 4 c Hold adjuster with 1 2 inch wrench Using 9 16 inch wrench tighten jam nut against cable adjuster d Cover cable adjuster with rubber boot 6 Check clutch lever for proper operation NOTE If clutch adjustment is necessary refer to the Service Manual Return the Motorcycle to Service 1 Connect the negative battery cable to the battery 2 Follow the instructions in the Service Manual to replace the seat
10. r kit dual disc 11 16 45072 96C in bore 5 Chrome reservoir cover kit D O T 5 45078 96D Master cylinder kit single disc 9 16 45006 96C in bore J03735 6 of 6
11. tment if all internal components are working properly 10 Add brake fluid to the master cylinder reservoir until the fluid level is 1 8 inch 3 2 mm from the top 11 Press and hold the brake hand lever to build up hydraulic pressure 12 Open bleeder valve about 1 2 turn Brake fluid and air bubbles will flow from bleeder valve through tubing Close bleeder valve when brake hand lever has moved 1 2 to 3 4 of its full range of travel Allow brake hand lever to return slowly to its released position 13 Repeat until all air bubbles are purged and pure brake fluid flows from the brake line 14 Final tighten the bleeder valve to torque 80 100 in lbs 9 0 11 3 Nm Install the bleeder cap J03735 15 Add brake fluid to the master cylinder reservoir until the fluid level is about 1 8 inch 3 2 mm from the top 16 Note that the angular shape of the master cylinder cover makes one side thicker than the other Install the cover with gasket on the master cylinder reservoir so that the thicker side is positioned above the brake line fitting Install 2 Phillips screws to fasten the cover to the reservoir Tighten the screws to 12 15 in Ibs 1 4 1 7 Nm NOTE The sight glass enables the rider to visually check the brake fluid level without removing the master cylinder cover When the reservoir is full the sight glass is dark As the fluid level drops the glass lightens up to indicate this condition to the rider CHROME CLUTCH
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