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Hydraulic Clutch Kit
J034102008-08-07
GENERAL
Kit Number
45380-02C (chrome), 45992-03B (black)
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 11 and Table 1.
Additional Parts Required
Separate purchase and installation of additional parts or accessories is required for proper installation of this kit on your model motorcycle. Please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
WARNING
Rider and passenger safety depend 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. (00333b)
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.
INSTALLATION
Removing the Existing Components
Support the motorcycle securely on the jiffy stand on a firm, level surface.
WARNING
Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311b)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. Refer to the SEAT and BATTERY sections of the service manual. Remove the seat and disconnect the battery cables, negative cable first.
2. Remove the left side mirror and mounting hardware. Remove the left side turn signal if mounted on the hand lever bracket. Save all parts for later installation.
3. Remove the right side saddlebag, if so equipped. Refer to SADDLEBAG REMOVAL in the Service Manual.
4. To access the transmission side cover assembly, see EXHAUST SYSTEM REMOVAL in the Service Manual. For some models, the right side exhaust system will need to be removed. In most cases, you will need to perform at least the following:
a. Loosen, but do not remove the front and rear header pipes at the cylinder heads.
b. Loosen the exhaust support bracket at the starter.
c. Loosen the exhaust system heat shields as needed to access the transmission side cover screws.
d. Remove the clamp holding the rear exhaust pipe to the transmission bracket. Discard clamp.
e. Remove and retain the two bolts and lockwashers attaching the right side muffler to the rear bracket.
5. Remove the magnetic drain plug at the bottom right side of the oil pan, and drain the transmission lubricant into a suitable container.
6. See Figure 1. Remove and retain the filler plug/dipstick (5) for later installation. Remove the six socket head screws with washers (6) to free the transmission side cover (1) from the transmission case. Retain two screws and discard the remaining four.
NOTE
If the hollow locating pins stay in the cover when removed, install pins back into the bearing housing.
1Transmission side cover
2Cover gasket
3Locating pin (2)
4Oil Slinger
5Filler plug/ dipstick
6Screw (6)
7Ramp
8Retaining ring
Figure 1. Riginal Transmission Side Cover
7. Actuate the clutch lever to break the cover seal. Remove the cover. Remove and discard the cover gasket (2).
8. Remove the clutch ramp retaining ring (8). Rotate the inner ramp (7) to a position that will allow the clutch coupling to be disconnected. Disconnect the clutch coupling and disconnect the cable end from the coupling.
9. Unscrew the cable fitting from the transmission side cover. Remove the clutch cable and fitting, and discard the cover. Leave the clutch cable in place at this point.
10. Remove the oil slinger (4) as an assembly from the transmission mainshaft. Discard the oil slinger.
NOTE
After the clutch cable has been disconnected at both ends, but before pulling the cable out, note the entire cable routing and the location of all cable straps and "P" clamps (if used). In many cases, you will be installing the new hydraulic fluid line the same way.
NOTE
Make sure you are using the correct retaining ring pliers. Verify that tips of pliers are not excessively worn or damaged.
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)
11. See Figure 2. Remove the retaining ring (9) from the clutch hand lever pivot pin (4). Remove the pivot pin and clutch hand lever (7) from the clutch lever bracket (3).
12. Remove the anchor pin (8) and the clutch cable eyelet (2) from the clutch hand lever. Remove any clamps retaining the clutch cable to the motorcycle, and remove the cable. Discard all components and hardware removed in this step.
1Clutch cable
2Cable eyelet
3Clutch lever bracket
4Pivot pin
5Handlebar clamp
6Screw
7Hand lever
8Anchor pin
9Retaining ring
Figure 2. Original Clutch Hand Lever Assembly
13. Using a T27 TORX® drive head, remove the two screws (6) with flat washers securing the handlebar clamp (5) to the clutch lever bracket. If installing Kit 45380-02C (Chrome), discard the handlebar clamp, but save the hardware for later installation. If installing Kit 45992-03B (Black), save the handlebar clamp and hardware for later installation.
NOTE
Standing the motorcycle upright is required so fluid does not spill. Verify that the vehicle is supported securely.
14. If necessary, remove the left side passenger footpeg or footboard. See Figure 3. Using a T27 TORX drive head, remove the clutch inspection (derby) cover (8) from the primary chaincase (1).
15. Remove the clutch release plate retaining ring (4) and discard. Remove the release plate (3), adjuster rod (5) and nut (6) as an assembly, and discard.
16. Extract the pushrod (2) by pushing it through from the right (transmission side cover) side until it can be grasped through the clutch pressure plate (10). Pull the pushrod out of the chaincase opening and discard it.
Installing the Clutch Release Plate
1. Refer to Figure 4. Obtain the new release plate (3) and bearing (4) from the kit. Pressing only on the outer race, install the bearing into the plate to form the clutch release plate assembly (2).
2. Assemble the new clutch release plate assembly to the new pushrod (1) as shown, with the large diameter first. Install a small retaining ring (5) from the kit onto the pushrod.
1Primary chaincase
2Pushrod
3Clutch release plate
4Retaining ring
5Adjuster rod
6Locknut
7Clutch cover seal
8Derby cover
9Cover screw (5)
10Clutch pressure plate (ref.)
Figure 3. Clutch Pushrod Removal
1Pushrod
2Release plate assembly
3Release plate
4Bearing (pressed into release plate)
5Retaining ring (small)
6Release plate ears (2)
7Retaining ring (large)
Figure 4. New Clutch Release Plate Assembly
3. Install the assembly into the clutch pressure plate. Fit the two ears (6) into the notches in the pressure release plate. Push in until the clutch release plate (3) bottoms out against the shoulder in the pressure plate. Install the new large retaining ring (7) in groove of pressure plate, and verify that the ring is fully seated.
Installing the Clutch Master Cylinder
NOTE
For Kit 46448-05, the clutch lever and master cylinder are not pre-assembled. Assemble the clutch lever to the master cylinder per the instructions packaged with the lever.
1. See Figure 5. Obtain the clutch lever/master cylinder assembly (4) from the kit, and the two screws (1) and two flat washers (2) saved earlier. If installing Kit 45380-02C (Chrome), obtain the handlebar clamp (3) from the kit. If installing Kit 45992-03B (Black), use the existing clamp saved during removal of the original clutch lever.
1Original equipment clamp screw (2)
2Original equipment washer (2)
3Handlebar clamp
4Clutch lever/ master cylinder
5Gasket (2)
6Banjo bolt
7Bango fitting
8Clutch fluid line
Figure 5. Clutch Master Cylinder/Reservoir
2. Slightly loosen the two screws holding the left-hand switch housing to the handlebar.
3. Position the clutch lever/master cylinder assembly to the handlebar, inboard of the left-hand switch housing assembly. Align the holes in the handlebar clamp with those in the master cylinder housing and start the two screws (with flat washers).
4. Adjust the clutch lever for rider posture and comfort. Use a T27 TORX drive head to tighten first the upper, then the lower clutch lever clamp screws to 60-80 in-lbs (7-9 Nm).
NOTE
Tighten the lower switch housing screw before tightening the upper switch housing screw. This will leave any gap in the switch housing at the front of the switch housing assembly for best appearance.
5. Adjust the switch housing for rider posture and comfort. Using a T25 TORX drive head, tighten first the lower, then the upper handlebar switch housing screws to 35-45 in-lbs (4-5 Nm).
Installing the Transmission Side Cover
1. Refer to Figure 6. Place the new cover gasket from the kit over the hollow locating pins (5) in the transmission housing. Line up the new transmission side cover assembly (which includes the secondary actuator [slave] cylinder and bleeder screw) on the locating pins.
2. Loosely install the two 2-1/4 inch (57 mm) long screws (saved from the old cover) into the top two holes in the new cover. Loosely install four new 1-3/4 inch (44 mm) long screws from the kit into the remaining four holes.
3. See Figure 7. For 2005 Softail models, tighten the side cover screws, in the sequence shown, to 84-108 in-lbs (9.5-12.2 Nm). For all other models, tighten the side cover screws, in the sequence shown, to 120-144 in-lbs (14-16 Nm).
1Upper screw (2-1/4 inch long) (saved) (2)
2New screw (1-3/4 inch long) (from kit) (4)
3Transmission side cover
4Side cover gasket
5Locating pins (2)
Figure 6. New Transmission Side Cover Installation
Figure 7. Torque Sequence, Transmission Side Cover
Installing the Clutch Fluid Line
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch line are clean and undamaged before assembly. (00329a)
  1. See Figure 5. Obtain the clutch fluid line assembly (8), banjo bolt (6) and new gaskets (steel/rubber washers, item 5) from the kit. Position the washers on each side of the hydraulic clutch line banjo fitting.
  2. Remove the cap plugs from the handlebar end of the clutch fluid line, if present.
    3. NOTE
    If a windshield is present, adjust the position of the clutch fluid line banjo fitting and/or the handlebar to verify that there is at least one inch (25.4 mm) clearance between the clutch fluid line and the windshield.
  3. Insert the banjo bolt through one brake line gasket, the clutch fluid line banjo fitting, and the second brake line gasket. Thread the bolt into the master cylinder housing but do not fully tighten at this time. Proceed to Step 4 for your model motorcycle.
For FLHR and FLHRC models:
4. See Figure 8. Carefully pry off the fork lock label plate (3) from the handlebar cover (2). Remove the entire plastic plate; do not remove the adhesive label from the plate.
5. Remove and retain the Phillips head screws holding the handlebar cover for later installation.
1Headlamp
2Handlebar cover
3Fork-lock plate
4Nacelle
Figure 8. Nacelle, Headlamp, and Handlebar Cover (FLHR/FLHRC Models)
6. Remove the headlamp assembly from the headlamp nacelle. See HEADLAMP in the Service Manual.
7. Route the clutch fluid line as follows:
a. Into the left top opening of the headlamp nacelle.
b. Down between the steering head and the harness mounting plate.
c. Around the front of the steering head to the right side.
d. Out of the nacelle, over the lower triple clamp, and over the right side engine guard.
e. Down along the front of the right side frame downtube.
f. Behind the rear brake master cylinder.
g. Over the footboard brackets to the transmission housing.
1Headlamp
2Handlebar cover
3Fork-lock plate
4Nacelle (left half)
5Nacelle trim strip
6Wind deflector
7Flange nut
8Flat head screw (2)
9Pan head screw
10Flat washer
11Nut with washer
Figure 9. Nacelle, Headlamp, and Handlebar Cover (FLHRS Model)
8. Remove the cap plugs from the clutch fluid line and transmission side cover, if present. Install the fitting to the cover and tighten to 80-115 in-lbs (9-13 Nm).
NOTE
The "P" clamps should position the clutch fluid line to be at least one inch (25.4 mm) from the re-installed muffler or exhaust pipe and 1/2 inch (12.7 mm) away from any part of the exhaust heat shield.
9. Attach the clutch fluid line to the bottom right side frame tube using the two "P" clamps from the kit. Bring the clutch fluid line down in a reverse "S" curve to the bottom right side frame tube, then:
a. Attach the line to the frame tube just below and to the rear of the cam cover.
b. Just below and to the front of the cam cover.
NOTE
Attaching the "P" clamps in any other way will allow chafing of the clutch fluid line against the cam cover or crankcase.
NOTE
Position the clutch fluid line so any excess slack occurs between the frame and the steering head.
10. Attach the clutch fluid line to the motorcycle using the tie straps included in the kit:
a. At two points on the bottom frame tube.
b. Near the bottom of the right side frame down tube.
c. To the front of the down tube above the reflector.
d. To the switch wire harness near the handlebar cover.
11. Tighten the banjo fitting bolt into the master cylinder housing to 17-22 ft-lbs (23-31 Nm). Proceed to "Bleeding the Clutch Fluid Line".
For FLHRS models
  1. See Figure 9. Carefully pry off the fork lock label plate (3) from the handlebar cover (2). Remove the entire plastic plate; do not remove the adhesive label from the plate.
  2. Remove and retain the two flat head Pozidrive screws (8) underneath the fork lock label plate.
  3. Loosen, but do not remove the pan head Pozidrive screw (9), nut (11) and flat washer (10) holding the front of the handlebar cover (2) and wind deflector (6) assembly.
  4. Raise the handlebar clamp cover slightly, and while separating the halves of the headlamp nacelle, slide the cover and wind deflector assembly forward, running the shaft of the screw down the gap until the assembly is free of the nacelle.
  5. Remove the headlamp assembly from the headlamp nacelle. See HEADLAMP in the Service Manual.
  6. Route the clutch fluid line:
    1. Into the left top opening of the headlamp nacelle.
    2. Behind the handlebar risers, over to the right side.
    3. Downward, out of the nacelle, around the front of the right side engine guard.
    4. Down along the front of the right side frame down tube.
    5. Behind the rear brake master cylinder.
    6. Over the footboard brackets to the transmission housing.
  7. Remove the cap plugs from the clutch fluid line and transmission side cover, if present. Install the fitting to the cover and tighten to 80-115 in-lbs (9-13 Nm).
    8. NOTE
    The "P" clamps should position the clutch fluid line to be at least one inch (25.4 mm) from the re-installed muffler or exhaust pipe and 1/2 inch (12.7 mm) away from any part of the exhaust heat shield.
  8. Attach the clutch fluid line to the bottom right side frame tube using the two "P" clamps from the kit. Bring the clutch fluid line down in a reverse "S" curve to the bottom right side frame tube, then:
    1. Attach the line to the frame tube just below and to the rear of the cam cover.
    2. Just below and to the front of the cam cover.
    9. NOTE
    Attaching the "P" clamps in any other way will allow chafing of the clutch fluid line against the cam cover or crankcase.
    NOTE
    Position the clutch fluid line so any excess slack occurs between the frame and the steering head.
  9. Attach the clutch fluid line to the motorcycle using the tie straps included in the kit:
    1. At two points on the bottom frame tube.
    2. Near the bottom of the right side frame down tube.
    3. To the front of the down tube above the reflector.
    4. To the switch wire harness near the handlebar cover.
  10. Tighten the banjo fitting bolt into the master cylinder housing to 17-22 ft-lbs (23-31 Nm). Proceed to "Bleeding the Clutch Fluid Line".
For FLHT, FLHTC and FLHTCU models:
  1. Route the clutch fluid line:
    1. Through the grommeted opening in the fairing, under the fuel gauge.
    2. Down along the front of the left side frame down tube.
    3. Across and down the frame to the right side frame down tube.
    4. Over the engine mount, down to the bottom right side frame tube.
    5. Along the top inside of the frame tube.
  2. Remove the cap plugs from the clutch fluid line and transmission side cover, if present. Install the fitting to the cover and tighten to 80-115 in-lbs (9-13 Nm).
    3. NOTE
    The "P" clamps should position the clutch fluid line along the top inside of the right side frame tube, at least one inch (25.4 mm) from the re-installed muffler or exhaust pipe and 1/2 inch (12.7 mm) away from any part of the exhaust heat shield.
  3. Attach the clutch fluid line to the bottom right side frame tube using the two "P" clamps from the kit. Bring the clutch fluid line down in a reverse "S" curve to the bottom right side frame tube, then:
    1. Attach the line to the frame tube just below and to the rear of the cam cover.
    2. Just below and to the front of the cam cover.
    4. NOTE
    Attaching the "P" clamps in any other way will allow chafing of the clutch fluid line against the cam cover or crankcase.
    Position the clutch fluid line so any excess slack occurs between the frame and the steering head.
    Attaching the cable strap too low will allow chafing of the clutch fluid line against the voltage regulator.
  4. Attach the clutch fluid line to the motorcycle using the tie straps included in the kit:
    1. To the right side frame down tube, at a point above the voltage regulator.
    2. To the left side frame down tube just below the engine guard.
  5. Tighten the banjo fitting bolt into the master cylinder housing to 17-22 ft-lbs (23-31 Nm). Proceed to "Bleeding the Clutch Fluid Line".
For FLTR and Softail models:
  1. Route the clutch fluid line:
    1. Along the left side of the handlebar, down to the top of the left side frame down tube.
    2. Across and down the frame to the right side frame down tube.
    3. Over the engine mount, down to the bottom right side frame tube.
    4. Along the top inside of the frame tube.
  2. Remove the cap plugs from the clutch fluid line and transmission side cover, if present. Install the fitting to the cover and tighten to 80-115 in-lbs (9-13 Nm).
    3. NOTE
    The "P" clamps should position the clutch fluid line along the top of the right side frame tube, inboard of the rear brake line or electrical wires, at least one inch (25.4 mm) from the re-installed muffler or exhaust pipe and 1/2 inch (12.7 mm) away from any part of the exhaust heat shield.
  3. Attach the clutch fluid line to the bottom right side frame tube using the two "P" clamps from the kit. Bring the clutch fluid line down in a reverse "S" curve to the bottom right side frame tube, then:
    1. Attach the line to the frame tube just below the front exhaust mount.
    2. At the bottom of the right side frame down tube, near the engine mount.
    4. NOTE
    Attaching the "P" clamps in any other way will allow chafing of the clutch fluid line against the engine mount or exhaust mount.
    Position the clutch fluid line so any excess slack occurs between the frame and the steering head.
    Attaching the cable strap too low will allow chafing of the clutch fluid line against the voltage regulator.
  4. Attach the clutch fluid line to the motorcycle using the tie straps included in the kit:
    1. To the right side frame down tube, at a point above the voltage regulator.
    2. To the existing clutch cable retainer, if so equipped, or to the upper portion of the left side frame down tube.
  5. Tighten the banjo fitting bolt into the master cylinder housing to 17-22 ft-lbs (23-31 Nm). Proceed to "Bleeding the Clutch Fluid Line".
Bleeding the Clutch Fluid Line
NOTE
D.O.T. 5 Silicone Hydraulic Brake Fluid is used for the hydraulic clutch. It is referred to as clutch fluid in these instructions and in the service manuals. Do not use other types of fluid as they are not compatible.
CAUTION
Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
1. Remove the bleeder cap from the transmission side cover bleeder valve. Install one end of a length of plastic tubing over the valve. Place the free end of the tube in a clean container.
NOTICE
Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c)
2. Stand the motorcycle upright so that the master cylinder is in a level position. Remove the master cylinder cover and gasket.
NOTE
Do not overfill master cylinder reservoir.
3. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the fluid level is at or just below the fill line. Do not reuse old fluid. Use only D.O.T. 5 fluid from a sealed container.
4. Activate the clutch lever 5-10 times.
5. Open the bleeder valve. Clutch fluid will flow from the bleeder valve through the tubing. It may take several minutes for fluid to exit the bleeder.
6. Once fluid exits the bleeder, close the bleeder valve.
NOTE
Do not overfill master cylinder reservoir.
7. If necessary, add additional clutch fluid to the master cylinder reservoir until the fluid level is at or just below the fill line.
8. Depress and hold the clutch hand lever to build up hydraulic pressure.
9. Open the bleeder valve about 1/2 turn. Clutch fluid will flow from the bleeder valve through the tubing. Close the bleeder valve when the clutch hand lever has moved 50% to 75% of its full range of travel. Allow the clutch hand lever to return slowly to its released position.
10. Repeat Steps 7 through 9 until all air bubbles are purged.
11. Tighten the bleeder valve to 80-100 in-lbs (9.0-11.3 Nm) and install the bleeder cap.
12. Again, if necessary, add clutch fluid to the master cylinder reservoir until the fluid level is at or just below the fill line.
13. Verify proper operation of the master cylinder relief port. Actuate the clutch hand lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
NOTE
The angular shape of the clutch master cylinder cover makes one side thicker than the other.
14. Install the clutch master cylinder cover (with gasket) on the master cylinder reservoir so that the thicker side is over the clutch line fitting. Fasten the cover with the two Phillips screws removed earlier. Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).
NOTE
The sight glass enables the rider to visually check clutch 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.
Measuring Clutch Plate Lift
  1. Attach the standoff of a dial indicator to one of the 1/4-20 clutch inspection (derby) cover mounting holes. Position the anvil to the end of the push rod.
    2. NOTE
    Insufficient clutch release plate movement can lead to difficulty or inability to shift.
  2. Actuate the clutch lever to measure the axial movement of the push rod and the clutch release plate assembly. The axial movement needs to be at least 0.065 inch (1.65 mm).
    3. NOTE
    Proper bleeding of the system will typically yield plate movement of greater than .065 inch (1.65 mm). If clutch release plate movement is less than .065 inch, the system MUST BE RE-BLED.
Installing the Clutch Inspection Cover
  1. See Figure 3. Remove the quad-ring clutch inspection cover seal (7) from the groove in the primary chaincase cover. Wipe all lubricant from the seal and inspect it for cuts, tears or signs of deterioration. Replace if necessary. If the motorcycle is using a gasket instead of the quad-ring seal, replace gasket.
  2. Swab all lubricant from the quad-ring groove. Install the seal into the groove with the nubs contacting the groove walls. Refer to your service manual for proper installation of derby cover gasket, if so equipped.
  3. Using a T27 TORX drive head, install the derby cover to the primary chaincase cover with the five screws (with captive washers) removed earlier.
  4. See Figure 10. Tighten the derby cover screws, in the sequence shown, to 84-108 in-lbs (10-12 Nm).
Final Assembly
1. Check the O-ring on the transmission drain plug removed earlier for tears, cuts or general deterioration, and replace if necessary.
2. Install the drain plug and torque to 14-21 ft-lbs (19-28 Nm).
NOTICE
Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak. (00200b)
3. Fill the transmission with the proper transmission lubricant. See the MAINTENANCE section of the applicable service manual.
4. Check the O-ring on the filler plug/dipstick removed from the old transmission side cover for tears, cuts or general deterioration, and replace if necessary. Install the filler plug/ dipstick into the new transmission side cover assembly.
NOTICE
Be sure exhaust pipes do not contact frame or components. Contact will transmit vibration to the rider. (00348a)
5. See EXHAUST SYSTEM INSTALLATION in the service manual. Install and tighten all exhaust system components loosened or removed at the beginning of the installation. Any gaskets or clamps that were removed should be replaced with new parts.
6. For 2004 and later FXSTS/I models: Replace the left side turn signal mounting bracket with a new bracket (Part Number 67355-04, purchased separately). For ALL models: Install the left side rear view mirror. Adjust for proper field of vision and tighten the acorn nut to 12 ft-lbs (16 Nm). Check mirror adjustment and reposition if necessary.
Figure 10. Torque Sequence, Primary Chaincase Cover
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
7. Refer to the service manual, and follow instructions to connect the battery cables, positive cable first.
8. Follow the instructions in the service manual to install the seat.
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)
9. If necessary, install the right side saddlebag.
10. Test ride the motorcycle. If the clutch does not work properly, it may be necessary to re-bleed the clutch fluid line and re-measure the clutch plate lift.
SERVICE PARTS
Figure 11. Service Parts: Hydraulic Clutch Kits
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Clutch master cylinder
Clutch lever/master cylinder assembly, chrome (for kit 45380-02C)
Not Sold Separately
Clutch lever/master cylinder assembly, black (for kit 45992-03B)
Not Sold Separately
1a
Clutch reservoir assembly, black (for kit 46448-05)
1b
Lever assembly, polished (for kit 46448-05) Includes lever, pivot pin bushing, retaining ring, bushing, and roller kit.
46243-01
2
Clamp, handlebar control, chrome (for kit 45380-02C only)
45282-99
3
Bolt, banjo
41747-82A
4
Gasket, brake line (2)
41731-01
5
Gasket, transmission side cover
36801-87C
6
Screw, 1/4-20 x 1-3/4 inch (4)
3480A
7
Side cover assembly (includes items 8 through 10)
Chrome (for kits 45380-02C and 46448-05)
37121-03A
Black, (for kit 45992-03B)
38689-03A
8
Cover, side
Not sold separately
9
Bleeder screw
44613-02
10
Cap, bleeder screw
44613-02
11
Clutch line assembly (braided stainless steel w/chrome fittings)
(Not in kit 46448-05)
38669-03
12
P-clamp (2)
69336-03
13
Screw, 1/4-20 x 3/8 inch (2)
3652
14
Locknut, 1/4-20 (2)
7686
15
Cable strap (6)
10006
16
Release plate
36731-91
17
Bearing
8885
18
Pushrod service kit (includes items 19, 20 and 21)
36818-03
19
Pushrod, clutch release
Not Sold Separately
20
Retaining ring, internal, 2 inch
37909-90
21
Retaining ring, internal, 3/8 inch
11143
Items mentioned in text, but not included in kit:
A
Original equipment screws
B
Original equipment washers
C
Handlebar clamp is not included in Black kit 45992-03B, use the original equipment black clamp.
D
Clutch release plate components
Also available:
E
Master cylinder repair kit 46244-01
F
Piston repair kit 37963-02A