BILLET-STYLE REAR BRAKE LEVER KITS
J017182015-03-23
GENERAL
Kit Number
42666-03, 46873-09, 41600003
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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)
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 2 and Table 1.
REMOVAL
  1. See Figure 1. Remove cotter pin (12) and washer (11) from clevis pin (2). If necessary, use a pliers to remove cotter pin. Discard cotter pin.
  2. Remove and save footrest bolt, spring washer and footrest.
  3. Remove clevis pin (2) from the push rod (1). Thoroughly clean and examine clevis pin assembly for wear. Replace if necessary.
  4. Remove brake lever mounting fastener (3) and footrest mounting clevis (4) from bracket mount (8). Save all hardware for assembly.
  5. Remove and save the brake pedal pad (9) and nut (10), if equipped. Discard brake lever (5). For 2006 and later models, also discard the OE brake pedal pad.
  6. Thoroughly clean the lever mounting shaft (6) of grease and dirt.
  7. NOTE
    It is not necessary to remove fasteners (7) and mounting bracket (8).
INSTALLATION
NOTE
Bushing(s) are press-fit into the brake lever and under normal circumstances should remain in the lever.
1. See Figure 2. Install billet-style brake lever (2) onto shaft.
2. See Figure 1. Align the brake lever shaft and footrest mounting clevis (4) and secure to bracket mount (8) with fastener (3). Tighten fastener to 43–47 N·m (32–35 ft-lbs).
3. Align clevis holes and insert clevis pin (2) (removed earlier). If clevis pin is a press-fit, tap it in gently while supporting the mating clevis of the master cylinder.
4. Install washer (11) as shown and insert new cotter pin (item 1, Figure 2 ) to secure clevis pin (2).
5. For 2003-2005 Models: Install brake pad (9) to brake lever with nut (10). Tighten securely. For 2006 and Later Models: Install new brake pad (9) of your choice.
6. Install footrest with spring washer and secure to mount using fastener.
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)
7. Check brake for proper operation and clearance through full travel.
1Push rod
2Clevis pin
3Fastener
4Clevis, footrest mounting
5Brake lever
6Shaft
7Fastener (2)
8Bracket mount (brake pedal and footrest)
9Brake pedal pad
10Nut
11Washer
12Cotter pin
Figure 1. Stock Brake Lever (2003-2005 Models Shown)
SERVICE PARTS
Figure 2. Service Parts: Billet-Style Rear Brake Lever
Table 1. Service Parts: Billet-Style Rear Brake Lever
Item
Description (Quantity)
Part Number
1
Cotter pin
515
2
Billet-style brake lever
Not Sold Separately