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. |
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. | |||||||||||||||||||||||||||||||||||||||||||||||||||||
![]() 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). |
Figure 2. Original Clutch Hand Lever Assembly
Figure 3. Clutch Pushrod Removal
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). |
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. |
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. |
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. |
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
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). |
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. |
Figure 9. Nacelle, Headlamp, and Handlebar Cover (FLHRS Models) |
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. | |
![]() 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. |
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 |