VRSC CLUTCH MASTER CYLINDER REBUILD KIT
J022652008-07-09
GENERAL
Kit Number
46244-01
Models
This kit consists of the components and instructions for rebuilding the clutch master cylinder on 2002 and later VRSC model motorcycles.
WARNINGRider 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.
Additional Materials Required
2002 to 2005 VRSC models use D.O.T. 5 hydraulic brake fluid in the clutch system.
2006 and later VRSC models use D.O.T. 4 hydraulic brake fluid in the clutch system.
REFER TO YOUR OWNER'S MANUAL FOR THE CORRECT FLUID TO USE IN YOUR CLUTCH SYSTEM.
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)
NOTICE
DOT 4 hydraulic brake fluid is used in the hydraulic clutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00353b)
D.O.T. 4 is used in 2006 and later models.
WARNINGContact 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
CAUTIONDirect 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)
NOTICE
DOT 5 silicone hydraulic brake fluid is used in the hydraulic clutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00204b)
D.O.T. 5 is used in 2002 to 2005 models.
INSTALLATION
Remove Master Cylinder/Clutch Lever Assembly
| 1. | Cover painted parts with clean service covers or blankets. | |||||||||||||||||||||||
| 2. | Remove left mirror and turn signal assembly. Save mirror and washers for installation. Use cable strap or other device and secure turn signal assembly so it is out of the way. NOTE When performing the next step, place a large cup directly under the master cylinder housing at point where banjo bolt attaches the hydraulic line to the master cylinder reservoir. Hydraulic fluid will begin dripping from the line as the banjo bolt is removed. Immediately orient clutch line end upward to prevent further drainage from line. Use tie wrap, rubber band or similar device to secure the line to handlebar (with end up). Save banjo bolt. Discard steel/rubber washers. | |||||||||||||||||||||||
| 3. | See Figure 1. Loosen master cylinder cover screws to remove pressure. While holding a cup under the banjo bolt/hydraulic line assembly, slowly remove the banjo bolt and allow clutch fluid from reservoir to drain into cup. When reservoir appears to be well drained, completely remove banjo bolt and hydraulic line. | 
Figure 1. Remove Master Cylinder Assembly (2002-05 shown) 
Figure 2. Remove Clutch Lever | ||||||||||||||||||||||
| 4. | Use a clean cloth and wipe down any remaining areas of hydraulic fluid. | |||||||||||||||||||||||
| 5. | Remove two screws with flat washers securing the handlebar clamp to master cylinder housing and remove clamp. Cover the hole where the banjo bolt was removed and move the master cylinder from the handlebar to a clean working area. | |||||||||||||||||||||||
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) | ||||||||||||||||||||||||
| 6. | Remove screws, cover and gasket. Turn housing upside down over rag to remove remaining clutch fluid from reservoir. Save cover, gasket and screws for installation. |
WARNINGWear 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)
Remove Clutch Lever Assembly
- See Figure 2. Remove the retaining ring from the groove in the clutch pivot pin. Discard retaining ring.
- Remove the pivot pin by sliding out from the top. It may be necessary to gently pry the pivot pin up and out to remove. Save pivot pin for installation.
- Remove and save the clutch lever and clutch lever components.
NOTE
When performing the next Step, it will be easier to remove the pivot pin if you gently force the clutch lever toward the piston (as if operating the clutch). This will take the piston spring load off of the pivot pin.
NOTE
Remove and save the pivot pin, clutch lever and clutch components.
Disassemble Master Cylinder
| 7. | See Figure 3. Gently pry the outer edge rim of piston boot from groove in piston bore. NOTE Carefully pull the existing piston assembly with cups and spring out of the bore and discard. | |||||||||||||||||||
| WARNING Use denatured alcohol to clean clutch 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 clutch failure, which could result in death or serious injury. (00296a) | ||||||||||||||||||||
| 8. | Remove the existing piston components from the bore and discard. | |||||||||||||||||||
| WARNING Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) | ||||||||||||||||||||
| 9. | Clean master cylinder housing, reservoir cover and cover gasket with denatured alcohol. Do not contaminate with mineral oil or other solvents. Wipe dry with a clean, lint free cloth. Blow out drilled passages and bore in master cylinder housing with a clean air supply. Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir. | 
Figure 3. Remove Piston Boot 
Figure 4. New Piston Assembly 
Figure 5. Seating Piston Boot | ||||||||||||||||||
| 10. | Inspect cylinder housing bore for scoring, pitting or corrosion. Also check outlet port for damage. Replace housing if any of these exist. NOTE The new master cylinder piston comes with components (i.e. primary, secondary cups) pre-assembled. | |||||||||||||||||||
| 11. | Obtain new piston assembly and lubricant packet from kit. | |||||||||||||||||||
| 12. | See Figure 4. Using lubricant from kit, thoroughly coat the outside diameters of the primary and secondary cups. | |||||||||||||||||||
| 13. | Using remaining lubricant, thoroughly coat the piston bore of the master cylinder reservoir. | |||||||||||||||||||
| 14. | Install spring into opening on inboard side of piston assembly (with tapered end out). | |||||||||||||||||||
| 15. | Align and install the piston assembly into the bore. While holding cylinder housing, firmly press on flat end of piston (compressing the spring) until you feel the entire assembly slide completely into the cylinder bore. Slowly release the piston and examine the sealing edges of the piston boot; portions of the sealing boot may have already seated into groove in bore. NOTE When performing the next Step, be extremely careful not to tear, perforate or damage the piston sealing boot. | |||||||||||||||||||
| 16. | See Figure 5. Using one hand, hold the housing and using your thumb, compress the piston until it is approximately even with the end of the bore. Gently work around sealing edges of boot until the entire circumference of the boot is seated in the cylinder bore groove. Release pressure on piston and check seating around boot. If necessary, continue to work around the edges until the boot is completely seated. |
Reinstall Clutch Lever to Master Cylinder Housing
- Figure 6 illustrates assembled clutch lever ready to be installed to master cylinder housing.
- See Figure 2. Orient clutch lever in bracket portion of master cylinder assembly and align pivot pin hole with lever bracket holes. Install pivot pin from top and tap into place.
- See Figure 9 and refer to Figure 2. Install new pivot pin retainer (7) into pivot pin groove.
NOTE
When installing clutch lever to housing, the bowed portion of the bearing cups must oriented so bow pivots toward the outer end of the clutch lever.
When performing the following step, it may be necessary to apply a little force (compress the piston using the lever) in order to align the lever and allow the pivot pin to be inserted.
Reinstall Master Cylinder Housing/Clutch Lever
| 17. | Obtain master cylinder housing clamp and two screws removed in step 4. Align master cylinder housing/clutch lever on handlebar and install screws to hold assembly in place. Snug the mounting screws but do not tighten completely at this time. | |||||||||||||||||
| 18. | Refer to Figure 9 and Figure 1. Obtain banjo bolt removed in step 2 and two new steel/rubber washers (6) from kit. Install hydraulic line to master cylinder housing using banjo bolt with washer oriented on each side of line. Tighten banjo bolt to 23-31 Nm (18-23 ft-lbs). | |||||||||||||||||
| 19. | Align entire master cylinder housing/clutch lever assembly for rider comfort. Beginning with the top handlebar clamp mounting screw, tighten the clamp screws to 8-9 Nm (5.9-6.6 ft-lbs). | |||||||||||||||||
| 20. | Refer to Figure 7 and install mirror and left turn signal assembly. Tighten turn signal locknut securely. | |||||||||||||||||
| 21. | Add the appropriate brake fluid for your model to the clutch master cylinder reservoir until the fluid level is 32 mm (1/8 inch) from the top. Do not reuse old brake fluid. Use only brake fluid from a sealed container. | |||||||||||||||||
| WARNING A plugged or covered relief port can cause clutch drag, which could lead to loss of control, resulting in death or serious injury. (00583b) | ||||||||||||||||||
| 22. | Verify proper operation of the clutch master cylinder relief port. Actuate the clutch lever. A slight spurt of fluid will brake the fluid surface in reservoir compartment if all internal components are working properly. | |||||||||||||||||
| 23. | Obtain the clutch master cylinder reservoir cover, reservoir gasket and two screws removed in step 5. Install the cover (with gasket) on the master cylinder reservoir so that the thicker side is positioned above the clutch line fitting. Install the two Phillips screws and tighten to 0.7-0.9 Nm (6-8 in-lbs). | |||||||||||||||||
| 24. | See Figure 8. On the right side of the motorcycle, remove the three bolts securing the clutch actuator cover and remove cover. This will allow access to the clutch bleeder valve. | |||||||||||||||||
| 25. | Follow instructions in applicable service manual and bleed the clutch system. NOTE A sight glass enables the rider to visually check the 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. | 
Figure 6. Clutch Lever Installation 
Figure 7. Install Turn Signal Assembly and Mirror 
Figure 8. Remove Actuator Cover to Access Clutch Bleeder Valve |
SERVICE PARTS
Figure 9. Service Parts: Clutch Master Cylinder Rebuild Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Spring | 46249-01 |
2 | Primary cup | 46250 |
3 | Piston | 46251-01 |
4 | Secondary cup | 46252-01 |
5 | Boot | 46253-01 |
6 | Washer, steel/rubber (2) | 41731-01 |
7 | Retaining ring | 11279 |
8 | Lubricant | Not Sold Separately |