Hydraulic Clutch Kit
J037552006-07-10
GENERAL
Kit Number
46414-05A, 46415-05A
Models
For the most up to date model fitment information, please see the product label or www.harley-davidson.com.
Additional Parts Required
2006 and later models require the separate purchase of diaphragm spring, Part Number 37871-04. See Service Manual for installation instructions.
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.
The kits are not compatible with:
  • Accessory handlebar kits that include clutch cables of non-standard length,
  • Larger-than-standard-diameter handlebars having no depression for clutch master-cylinder clearance,
  • Bullet Spoilers and Chin Spoilers,
  • Engine/ Transmission Interface Covers,
  • Chrome Clutch Ferrule and Banjo Bolt Cover Kit 32714-98,
  • Chrome Billet Clutch Cable Clamp 10260 or 91147-02,
  • Screamin' Eagle® Race Clutch Kit 37960-98A.
Kit Contents
These kits consist of a black or chrome clutch master-cylinder assembly and transmission side cover, a clutch-fluid line and all internal mechanical components necessary for a hydraulic clutch installation.
Kit Number 46414-05A contains Chrome components.
Kit Number 46415-05A contains Black components.
INSTALLATION
Removing 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. 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. On Touring models, 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.
e. Remove and retain the two bolts and lockwashers attaching the right-side muffler to the rear bracket.
5. On Touring models, remove the magnetic drain plug at the bottom-right side of the oil pan, and drain the transmission lubricant into a suitable container.
1Transmission side cover
2Cover gasket
3Locating pin (2)
4Oil slinger
5Filler plug/ dipstick
6Screw (6)
7Ramp
8Retaining ring
Figure 1. Original Transmission Side Cover
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.
7. Actuate the clutch lever to break the cover seal. Remove the cover. Remove and discard the cover gasket (2).
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)
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.
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).
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
1Primary chaincase
2Pushrod
3Clutch release plate
4Retaining ring
5Adjuster rod
6Locknut
7Clutch cover seal
8Derby cover
9Cover screw (5)
10Clutch pressure plate (reference only)
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
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 bike, and remove the cable. Discard all components and hardware removed in this step.
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 46414-05 (Chrome), discard the handlebar clamp, but save the hardware for later installation. If installing Kit 46415-05 (Black), save the handlebar clamp and hardware for later installation.
NOTE
Standing the motorcycle upright is required so fluid doesn't spill. Ensure 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).
1Original equipment clamp screw (2)
2Original equipment washer (2)
3Handlebar clamp
4Clutch lever/ master cylinder
5Gasket (2)
6Banjo bolt
7Banjo fitting
8Clutch fluid line
Figure 5. Clutch Master Cylinder/Reservoir
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 (2) to the new pushrod (1) as shown, with the large diameter first. Install the small retaining ring (5) from the kit onto the pushrod.
1Upper screw (2-1/7 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
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) to the clutch-release plate, and verify that the ring is fully seated.
Installing the Clutch Master Cylinder
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 46414-05 (Chrome), obtain the handlebar clamp (3) from the kit. If installing Kit 46415-05 (Black), use the existing clamp saved during removal of the original clutch lever.
Figure 7. Torque Sequence, Transmission Side Cover
1Headlamp
2Handlebar cover
3Fork-lock plate
4Nacelle
Figure 8. Nacelle, Headlamp, and Handlebar Cover (FLHR/FLHRC Models)
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 in. (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 in. (44 mm) long screws from the kit into the remaining four holes.
  3. See Figure 7. Tighten the side cover screws, in the sequence shown, to 84-108 in-lbs (9.4-12.2 Nm).
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.
NOTE
If a windshield is present, adjust the position of the clutch-fluid line banjo fitting and/or the handlebar to ensure 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.
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 Models)
For FLHR and FLHRC models:
  1. 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.
  2. Remove and retain the Phillips-head screws holding the handlebar cover for later installation.
  3. Remove the headlamp assembly from the headlamp nacelle. See HEADLAMP in the Service Manual.
  4. Route the clutch-fluid line:
    1. into the left top opening of the headlamp nacelle,
    2. down between the steering head and the harness mounting plate,
    3. around the front of the steering head to the right side,
    4. out of the nacelle, over the lower triple-clamp, and over the right-side engine guard,
    5. down along the front of the right-side frame downtube,
    6. behind the rear-brake master cylinder, and
    7. over the footboard brackets to the transmission housing.
  5. 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).
  6. 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.
  7. 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, and
    2. just below and to the front of the cam cover.
  8. 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, and
    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 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, and
    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.
  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:
    1. attach the line to the frame tube just below and to the rear of the cam cover, and
    2. just below and to the front of the cam cover.
  10. 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.
  11. 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, and
    4. to the switch-wire harness near the handlebar cover.
  12. 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 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, and
    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.
  4. 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, and
    2. just below and to the front of the cam cover.
  5. 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.
  6. 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.
  7. NOTE
    Attaching the cable strap too low will allow chafing of the clutch-fluid line against the voltage regulator.
  8. 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, and
    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.
  4. 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, and
    2. at the bottom of the right-side frame down tube, near the engine mount.
  5. NOTE
    Attaching the P-clamps in any other way will allow chafing of the clutch-fluid line against the engine mount or exhaust mount.
    NOTE
    Position the clutch-fluid line so any excess slack occurs between the frame and the steering head.
  6. 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.
  7. NOTE
    Attaching the cable strap too low will allow chafing of the clutch-fluid line against the voltage regulator.
  8. 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
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
NOTE
D.O.T. 4 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.
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
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
The cover is labeled for D.O.T. 4 brake fluid. Install this cover on reservoirs filled only with D.O.T. 4 brake fluid. Do not mix grades of brake fluid as they are not compatible and could cause equipment damage.
NOTE
DO NOT OVERFILL.
WARNING
Clean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury. (00504d)
3. Add D.O.T. 4 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. 4 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.
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 one-half-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.
SERVICE PARTS
Figure 10. Service Parts: Hydraulic Clutch Kits
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Clutch master cylinder assembly
Chrome
46413-05
Black
46416-05
2
Clamp, handlebar control (in chrome kit only)
45282-99
3
Bolt, banjo
41747-82A
4
Gasket, brakeline (2)
41731-01
5
Gasket, transmission side cover
36801-87C
6
Screw (4)
3480A
7
Side cover assembly (includes items 8 through 10)
Chrome
37121-03A
Black
38689-03A
8
Cover, side
38689-03A (black)
9
Bleeder screw
44613-02
10
Cap, bleeder screw
43817-02
11
Clutch line assembly (braided stainless steel w/chrome fittings)
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
Strap, cable (6)
10006
16*
Pushrod, clutch release
Not sold separately
17
Release plate assembly (includes items 18 and 19)
Not sold separately
18
Release plate
37918-91
19
Bearing
8885
20*
Retaining ring, external (3/8 inch)
11143
21*
Retaining ring, internal (2 inch)
37909-90
Items mentioned in text, but not included in kit:
A
Original equipment screws
B
Original equipment washers (6099 included in part number 46414-05)
C
Handlebar clamp is not included in Black kit 45992-03. Use the original equipment black clamp.
D
Clutch release plate components
Note: * items 16, 20, and 21 are available as a kit, Part Number 36818-03