CUSTOM HAND LEVER KIT
J038182005-11-01
GENERAL
Kit Number
46710-06, 46982-06
Models
These kits are designed for installation on all 1996 - 2003 XL models and 1996 and later Dyna, Softail, and Touring model motorcycles.
This kit is not compatible with a Hydraulic Clutch.
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.
BRAKE LEVER INSTALLATION
NOTICE
Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a)
Figure 1. 5/32 in. (4 mm) Cardboard Insert
| 1. | See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. | |
| 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) | ||
| 2. | See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (B) from the groove in the pivot pin (C). Save the retaining ring for re-use. | |
| 3. | Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. | |
| 4. | Insert the pivot lever bushing (2) from the kit into the new brake lever (1). NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. | |
| 5. | Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. | |
| 6. | Install the pivot pin and retaining ring removed in Steps 1 and 2. | |
| 7. | Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is permissible. | |
| WARNING A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) | ||
| 8. | To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. | |
| 9. | Reinstall the master cylinder cover. | |
| WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 10. | Check that the stop light goes on when the brake lever is actuated. |
CLUTCH LEVER INSTALLATION
See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures.
SERVICE PARTS
Figure 2. Service Parts: Hand Control Lever Kits
Table 1. Service Parts: Custom Hand Control Kits
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Flame lever, front brake control (includes bushing) | 46712-06 | Items mentioned in text, but not included in kit: | |||
Skull lever, front brake control (includes bushing) | 46983-06 | A | Press piston cap forward | |||
2 | Bushing, brake lever pivot pin | 45423-96 | B | Stock retaining ring | ||
3 | Flame lever assembly, cable clutch control (includes bushing, clip and screw) | 46713-06 | C | Stock pivot pin | ||
Skull lever assembly, cable clutch control (includes bushing, clip and screw) | 46984-06 | D | Clutch control cable (ref.) | |||
4 | Bushing, clutch lever pivot pin | 54523-92 | E | Clutch cable anchor pin (ref.) | ||
5 | Clip, anti-rattle | 45021-86 | ||||
6 | Screw | 90770-79 | ||||