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CUSTOM HAND LEVER KITS
J042782014-07-15
GENERAL
Kit Numbers
38843-08, 38845-08, 38853-08, 36700004
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
These kits do not fit police models, or models equipped with a hydraulic clutch.
Installation Requirements
Separate purchase of G40M Brake Grease (Part No. 42820-04) is required for proper installation of this kit. See a 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
WARNING
Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)
Kit Contents
See Figure 1 and Table 1.
BRAKE LEVER INSTALLATION
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. See Figure 1 and the service manual. Remove the retaining ring (6) from the groove in the pivot pin (5).
  2. Remove the pivot pin from the brake lever and master cylinder housing (A). Discard the original equipment (OE) brake lever (3), pivot pin (5) and retaining ring (6).
  3. Apply a small amount of GM-40M grease (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.
  4. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the new pivot pin (5) down through the bracket and hand lever. Check that the pushrod is properly seated on the lever.
  5. Install the new retaining ring (6) from the kit in the pivot pin groove. Verify that the retaining ring is seated in the groove.
  6. Check the front brake for proper operation. There must be no free play in the hand lever. A slight preload is normal. Check that the stop light illuminates when the brake lever is actuated.
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 INSTALLATION
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. See Figure 1 and the service manual. Remove the retaining ring (12) from the groove in the pivot pin (11).
  2. Remove the pivot pin from the clutch lever (7) and bracket (B). Discard the original equipment (OE) clutch lever (7), pivot pin (11) and retaining ring (12).
  3. Align the hole in the clutch hand lever with the hole in the lever bracket. From the top of the assembly, slide the new pivot pin (11) down through the bracket and hand lever.
  4. Install the new retaining ring (12) from the kit in the pivot pin groove. Verify that the retaining ring is seated in the groove.
  5. See the service manual for clutch lever (7) adjustment procedures.
SERVICE PARTS
Figure 1. Service Parts: Hand Control Lever Kits
SERVICE PARTS
Table 1. Service Parts: Hand Control Lever Kits
Kit
Item
Description (Quantity)
Part Number
Kit 38843-08
Chrome Levers
1
Brake hand lever, chrome (includes Items 3 through 6)
42271-06A
2
Clutch hand lever, chrome (includes Items 7 through 12)
38844-08
Kit 38845-08
Black Levers
1
Brake hand lever, black (includes Items 3 through 6)
Not sold separately
2
Clutch hand lever, black (includes Items 7 through 12)
Not sold separately
Kit 38853-08
Slotted Levers
1
Brake hand lever, slotted (includes Items 3 through 6)
42916-06
2
Clutch hand lever, slotted (includes Items 7 through 12)
38855-08
Kit 36700004
Edge Cut Levers
1
Brake hand lever, slotted (includes Items 3 through 6)
Not sold separately
2
Clutch hand lever, slotted (includes Items 7 through 12)
Not sold separately
Parts common
to ALL Kits
3
Brake hand lever
Not sold separately
4
Pivot pin kit (polished). For all Kits EXCEPT 38845-08 (includes Items 5 and 6)
Pivot pin kit (black). For Kit 38845-08 (includes Items 5 and 6)
42105-06A
42860-06B
5
  • Pivot pin, brake lever
Not sold separately
6
  • Retaining ring, brake pivot pin
11615
7
Clutch hand lever
Not sold separately
8
Bushing, clutch lever pivot
45423-92
9
Clip, anti-rattle
45021-86
10
Screw
90770-79
11
Pivot pin, clutch lever (polished)
Pivot pin, clutch lever (black)
45032-82
38738-08
12
Retaining ring, clutch pivot pin
11143
Reference items not included in kit:
A
Front brake master cylinder
B
Clutch hand lever bracket
C
Original equipment (OE) clutch cable anchor pin
D
OE clutch control cable