CHROME REAR MASTER CYLINDER KIT - Harley
Contents
1. 4of42. MTOR HARLEY DAVIDSON AUA J03457 INSTRUCTIONS REV 06 01 04 Kit Number 41777 05 CHROME REAR MASTER CYLINDER KIT General The Chrome Rear Master Cylinder Kit fits 2005 and later Touring model motorcycles See the Service Parts illustration for a list of the items con tained in this kit Installation of this kit will require the following additional parts Steel rubber washers 2 Part No 41371 01 Wheel bearing grease Part No 99855 89 Brake pedal O rings 2 Part No 11364 These parts are available separately from any Harley Davidson dealer In addition to the additional parts Loctite Threadlocker 243 blue is also required for installation 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 informa tion A Service Manual for your model motorcycle is required for this installation and is available from any Harley Davidson Dealer Installation Removal WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the Owners Ma
3. nd nuts so that the nuts are on the inboard side Tighten nuts to 84 108 in lbs 9 5 12 2 Nm J03457 Bleeding Rear Brake Be sure that no lubricant gets on rear tire wheel or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047b NOTES Hydraulic brake fluid bladder type pressure equipment can be used to fill brake master cylinder through the bleeder valve Remove master cylinder reservoir cover so that sys tem cannot pressurize Do not use pressure bleeding equip ment when the hydraulic system is sealed with master cylin der reservoir cover and gasket in place 1 Close the bleeder valve on the rear caliper 2 If removed return a length of plastic tubing over caliper bleeder valve Place free end of tube in a clean container 3 Stand motorcycle upright clean and remove cover to master cylinder reservoir 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 attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a WARNING Use only fresh uncontaminated D O T 4 brake fluid Fluid containers that have been opened may have been contaminated by dirt or moi
4. nual and follow the instructions given to remove the seat and disconnect the negative battery cable 2 For Touring models w fairing lowers Remove right side lower fairing and right side saddlebag See Service Manual for procedure 3 Access the rear brake bleeder valve See Owners Manual or Service Manual for procedure Figure 1 Footboard Pivot Bolts and Locknuts 4 Install end of clear plastic tubing over rear caliper bleed er valve Place the free end in a suitable container WARNING Be sure that no lubricant gets on rear tire wheel or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047b 5 Open bleeder valve 1 2 turn and pump brake pedal to drain brake fluid Close bleeder valve 6 See Figure 1 Remove the 2 right side footboard pivot bolts and locknuts to remove the footboard 7 Place a suitable container under the rear brake master cylinder reservoir 1of4 CAUTION io6212 Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a AAA RLEY BAVID CM 8 See Figure 2 Remove banjo bolt 1 and 2 steel rubber 7 washers 3 to disconnect brake line banjo fitting 2 N 9 Drain brake line in container and secure brake line as required Discard steel rubber washers Banjo bolt Banjo line fitting Figure 3 Brake Pedal Master Cylinder Assembly Steel rubbe
5. r washer Hex nut Figure 2 Banjo Fitting NOTE If necessary to access hex nut 4 release rear brake line from frame clips to move banjo fitting forward See Service Manual for brake line routing and frame clip locations 10 Using 1 1 8 in wrench remove hex nut to free master cylinder assembly from mounting bracket 11 See Figure 3 Remove brake pedal master cylinder assembly Remove locknut with flat washer to free brake pedal master cylinder assembly from brake pedal spindle welded to frame 12 Remove and discard o rings on each side of brake pedal shaft bore Retain 2 brake lever bushings Disassembly 1 See Figure 4 Remove cotter pin 1 and flat washer 2 1 Cotter pin from clevis pin 2 Flat washer 3 Clevis pin 2 Supporting rear brake pedal master cylinder assembly in vise tap out clevis pin 3 using a brass drift and remove master cylinder assembly from brake pedal flange Figure 4 Master Cylinder Push Rod to Brake Pedal J03457 20f 4 Assembly NOTE Do not disassemble the master cylinder the pedal return spring boot and retainer The master cylinder assembly is completely assembled and installed in the reservoir cylinder assembly Awarninea Use denatured alcohol to clean brake system components Do not use mineral base solvents such as gasoline or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause brake failure which co
6. rious injury 00070a NOTE The sight glass enables the rider to visually check the brake 3 Refer to the Owner s Manual and follow the instructions fluid level without removing the master cylinder cover When given to re attach the negative battery cable and install the reservoir is full the sight glass is dark As the fluid level the seat drops the glass lightens up to indicate this condition to the rider 4 With the ignition light key switch turned to IGNITION actuate the rear brake pedal to verify operation of the Final Assembly and Test Ride brake lamp 1 Re install all brackets and saddlebag removed to access WARNING the rear brake calipers and the bleeder valve See Service Manual for procedure After servicing the brake system test brakes at low speed If brakes are not operating properly testing at 2 For Touring models w fairing lowers Install lower fair high speeds can cause loss of control which could ings See Service Manual for procedure result in death or serious injury 00289a 5 Test ride the motorcycle If the brake feels spongy repeat the rear brake bleeding procedure Part No 41777 05 Date 06 04 CN e Service Parts Chrome Rear Master Cylinder Kit i06424 Description Quantity Part No Item Description Quantity Part No Stainless steel screw 2 2573 4 Sight glass 45042 05 Reservoir cover 46421 05 5 Rear master cylinder reservoir assembly Cover gasket 42455 99 41776 04 J03457
7. sture Use of contaminated brake fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury A WARNING Never mix D O T 4 with other brake fluids such as D O T 5 Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury 4 Repeat the following until all air bubbles are purged and pure brake fluid flows from the brake line a Add fresh D O T 4 to master cylinder reservoir until the fluid level is 1 8 in 3 2 mm from the top b Press and hold brake pedal to build up hydraulic pressure c Open bleeder valve slowly about 1 2 turn counterclockwise Brake fluid and air bubbles will flow from bleeder valve and through tubing d When pedal has moved 1 2 to 3 4 of its full range of travel close bleeder valve clockwise Allow brake lever to return slowly to its released position 5 When all air bubbles have been purged verify fluid level in reservoir at 1 8 in 3 2 mm from the top 3of4 6 Remove clear plastic tubing and tighten bleeder valve to 9 0 11 3 NM 80 100 in Ibs Install bleeder valve cap AWARNING After installing seat pull upward on front of seat to be 7 Attach cover to master cylinder reservoir Tighten sure it is in locked position While riding a loose seat screws to 0 7 0 9 Nm 6 8 in Ibs can shift causing loss of control which could result in death or se
8. uld result in death or serious injury 00291a 1 Obtain new master cylinder reservoir assembly from kit 2 Clean new master cylinder reservoir assembly cover and cover gasket with denatured alcohol or D O T 4 SILICONE BRAKE FLUID Wipe dry with a clean lint free cloth 3 Install two screws from the kit to fasten the cover to the reservoir Finger tighten the screws 4 Install master cylinder reservoir to brake pedal flange 5 Supporting the assembly with out damaging the chrome finish tap in clevis pin using a brass drift Install flat washer and cotter pin on clevis pin 6 Apply a light coat of Wheel Bearing Grease Part No 99855 89 to the brake pedal shaft and bore 7 Install a new O ring on each side of bushings in brake pedal shaft bore Installation 1 Install brake pedal master cylinder assembly on the pedal spindle while fitting collar on cartridge body into square shaped hole in mounting bracket 2 See Figure 3 Install brake pedal to brake pedal spindle Install flat washer and new locknut Tighten to 15 20 ft Ibs 20 27 Nm 3 Thread on hex nut capturing cartridge to mounting flange Tighten the hex nut to 30 40 ft lbs 41 54 Nm 4 Obtain banjo bolt and two new steel rubber washers 5 Install hydraulic line to master cylinder reservoir using banjo bolt with washer oriented on each side of banjo fitting Tighten banjo bolt to 17 22 ft lbs 23 31 Nm 6 Install footboard with pivot bolts a
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