CHROME REAR MASTER CYLINDER KIT

J035192013-11-01

GENERAL

Kit Number

41777-05A

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 5 and Table 1.

Additional Parts Required

Installation of this kit will require the following additional parts:

Steel/rubber washers (2) (Part Number 41731-01)

Wheel bearing grease (Part Number 99855-89)

Brake pedal O-rings (2) (Part Number 11364)

Cotter pin (Part Number 515)

Loctite^® Threadlocker 243 (blue) (Part Number 99642-97)

These parts are available separately from any Harley-Davidson dealer.

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

Removal

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

See the Service Manual. Remove the seat and disconnect the negative battery cable.

For Touring models with fairing lowers: See the Service Manual. Remove right side lower fairing and right side saddlebag.

See the Service Manual. Access the rear brake bleeder valve.

Install end of clear plastic tubing over rear caliper bleeder valve. Place the free end in a suitable container.

WARNING

Be sure that no lubricants or fluids get on tires, wheels 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. (00047d)

Open bleeder valve 1/2 turn and pump brake pedal to drain brake fluid. Close bleeder valve.

1	Footboard
2	Pivot bolts
3	Locknuts

Figure 1. Footboard Pivot Bolts and Locknuts

See Figure 1. For Touring and FL Softail models, remove the 2 right side footboard pivot bolts (2) and locknuts (3) to remove the footboard (1).

Place a suitable container under the rear brake master cylinder/reservoir.

1	Banjo bolt
2	Banjo line fitting
3	Steel/rubber washer
4	Hex nut

Figure 2. Banjo Fitting

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

See Figure 2. Remove banjo bolt (1) and 2 steel/rubber washers (3) to disconnect brake line banjo fitting (2).

Drain brake line in container and secure brake line as required. Discard steel/rubber washers.

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 inch wrench, remove hex nut to free master cylinder assembly from mounting bracket.

Figure 3. Brake Pedal/Master Cylinder Assembly

11.

See Figure 3. Remove brake pedal/master cylinder assembly. Remove locknut with flat washer (screw with washer on Softail models) 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.

1	Cotter pin
2	Flat washer
3	Clevis pin

Figure 4. Master Cylinder Push Rod to Brake Pedal

Disassembly

See Figure 4. Remove cotter pin (1) and flat washer (2) from clevis pin (3). Discard cotter pin.
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.

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.

WARNING

Use denatured alcohol to clean brake 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 brake failure, which could result in death or serious injury. (00291a)

Obtain new master cylinder/reservoir assembly from kit.
Clean new master cylinder/reservoir assembly, cover and cover gasket with denatured alcohol or D.O.T. 4 BRAKE FLUID. Wipe dry with a clean, lint free cloth.
Install two screws from the kit to fasten the cover to the reservoir. Finger tighten the screws.
Install master cylinder/reservoir to brake pedal flange.
Supporting the assembly with out damaging the chrome finish, tap in clevis pin using a brass drift. Install flat washer and new cotter pin on clevis pin.
Apply a light coat of Wheel Bearing Grease (Part Number 99855-89) to the brake pedal shaft and bore.
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. a. For FLT (Touring models), install flat washer and new locknut. Tighten to 20–27 N·m (15–20 ft-lbs). b. For Softail models, install screw and washer. Tighten to 16–22 N·m (12–16 ft-lbs).
3.	Apply Loctite 243 (blue) (Harley-Davidson Part Number 99642-97) to hex nut and thread on hex nut capturing cartridge to mounting flange. Tighten the hex nut to 68 N·m (50 ft-lbs).
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 23–31 N·m (17–22 ft-lbs).
6.	If equipped and removed earlier, install footboard with pivot bolts and nuts so that the nuts are on the inboard side. Tighten nuts to 9.5–12.2 N·m (84–108 in-lbs).

Bleeding Rear Brake

WARNING

NOTE

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 system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder 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. 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.
	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)
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 inch (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 inch (3.2 mm) from the top.
6.	Remove clear plastic tubing and tighten bleeder valve to 9–11.3 N·m (80–100 in-lbs). Install bleeder valve cap.
7.	Attach cover to master cylinder reservoir. Tighten screws to 0.7–0.9 N·m (6–8 in-lbs).

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.

Final Assembly and Test Ride

1.	See the Service Manual. Install all brackets and saddlebag removed to access the rear brake calipers and the bleeder valve.
2.	For Touring models with fairing lowers: See the Service Manual. Install lower fairings.
	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.	See the Service Manual. Attach the negative battery cable and install the seat.
4.	With the ignition/light key switch turned to IGNITION, actuate the rear brake pedal 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)
5.	Test ride the motorcycle. If the brake feels spongy, repeat the rear brake bleeding procedure.

SERVICE PARTS

Figure 5. Service Parts

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	Stainless steel screw (2)	2573
2	Reservoir cover assembly	Not sold separately
3	Cover gasket	42568-05
4	Rear master cylinder reservoir assembly	41776-04
Note: Item 2, Chrome Rear Reservoir Cover Assembly includes the master cylinder cover, gasket and sight glass. The gasket, part number 42568-05 can be purchased separately from any Harley-Davidson dealer.