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HAND CONTROL LEVER KITS
J041702009-10-06
GENERAL
Kit Numbers
34648-07, 42275-07A
Models
These kits fit 2006 and later VRSC model motorcycles.
Tools and Supplies Required
GM-40M grease (2 gram bag, H-D Part No. 42820-04) will be needed, and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 3 and Table 1.
INSTALLATION
WARNING
Rider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
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)
NOTE
Do not remove handlebar clamp or switch housing assembly to remove brake lever.
1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A).
WARNING
Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a)
2. Place a 4 mm (5/32 in) thick insert between the brake lever and the lever bracket.
NOTE
A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1.
3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar.
4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly.
5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to the area where the master cylinder pushrod seats against the brake lever. DO NOT apply grease to the stop-light switch contact surface of the lever. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever.
15/32-inch (4 mm) thick insert
2Brake lever
3Brake lever bracket
Figure 1. Protect Stop Light Switch
1Pushrod
2Tab
Figure 2. Master Cylinder Pushrod and Lever Tab
6. See Figure 3. Install the pivot pin (A) removed in Step 4, and the retaining ring (4) from the kit. Replace the insert shown in Figure 1.
7. Slide the brake master cylinder assembly back into place. Tighten the clamp screws to 7.9–9 N·m (70–80 in-lbs).
8. Remove the insert from between the brake lever and bracket, and check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is permissible.
WARNING
Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a)
9. Remove the master cylinder reservoir cover to verify proper operation of the master cylinder relief port. Actuate the brake hand lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
10. Install the master cylinder cover.
11. Turn the ignition key switch to IGNITION, but do not start the motorcycle. Actuate the front brake hand lever to verify operation of the brake lamp.
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)
Clutch 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)
  1. Remove the retaining ring from the pivot pin groove.
  2. See Figure 3. Remove the pivot pin (B) through the top of the housing. Save the pivot pin for installing the new clutch lever.
  3. Slide the bushing cups (D) onto the pins of the roller (C) with the cup flanges against the roller.
  4. With the connector bow portion of the bushing cups (D) parallel with the groove in the clutch handle, snap the roller pin with the bushing cups installed into the clutch lever roller groove. If the bushing is positioned correctly, the roller and bushing assembly will securely install with a snap.
  5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to grease the pivot bushing (3). Install the bushing into the clutch lever pivot hole. Position so the bushing is flush on both sides of the lever.
  6. Orient the clutch lever (2) in the lever mounting bracket. Insert the pivot pin (B) from the top and tap into place.
  7. Install the retaining ring (5) on the pivot pin (B).
  8. Check the clutch lever for proper operation. There should be no free play in the hand lever. A slight preload is permissible.
  9. Remove the master cylinder reservoir cover to 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.
  10. Install the master cylinder cover.
SERVICE PARTS
Figure 3. Service Parts for Hand Control Lever Kits
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 34648-07
Slotted Chrome
Hand Levers
1
Brake hand lever (slotted chrome)
42916-06
2
Clutch hand lever (slotted chrome)
Not sold separately
Kit 42275-07
Black Hand Levers
1
Brake hand lever (black)
42276-06
2
Clutch hand lever (black)
Not sold separately
Parts common
to ALL kits
3
Bushing, clutch lever
Not sold separately
4
Retaining ring, brake lever
11605
5
Retaining ring, clutch lever
11605
Items mentioned in text, but not included in kit:
A
Pivot pin, brake
B
Pivot pin, clutch
C
Roller
D
Bushing cups