1. | Block the motorcycle under the frame so that it is upright and level, with the weight off of the jiffy stand. | |
2. | Remove footpeg. | |
3. | Remove jiffy stand, shifter linkage and bracket per applicable Service Manual instructions, retaining hardware. | |
4. | See Figure 5. Obtain the new left side shifter bracket (2), and three TORX® screws (3) from the kit. | |
5. | Place washers previously removed on the screws. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 54.2 N·m (40 ft-lbs). | |
6. | See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9). | |
WARNING If leg stop is incorrectly installed, excessive wear can allow vehicle to fall when rested on jiffy stand, which could result in death or serious injury. (00479b) | ||
7. | Install jiffy stand and attach the spring. When properly installed, the hook on the spring side connected to the bracket will face upward. | |
8. | Verify that rubber bumper is in place on prong of jiffy stand. Without the bumper, the stand will make hard contact with the primary drive cover when retracted, which may result in damage to the cover. | |
9. | Extend and retract the jiffy stand leg several times to verify proper operation. The stand should swing freely to the fully extended and fully retracted positions. | |
10. | Refer to applicable Service Manual and re-attach the shifter linkage. |
1 | Bracket* |
2 | Washer |
3 | Screw (3)* |
4 | Master cylinder |
5 | Clevis pin |
6 | Washer |
7 | Cotter pin |
8 | Nut |
9 | Steel/rubber gaskets (2) |
10 | Banjo bolt |
11 | Brake lever |
12 | O-rings |
13 | Washer |
14 | Screw |
15 | Clip* (2011 and later) |
1. | See Figure 1. Remove FL brake lever (11) and footpeg (not shown). | |||||||||||||||
2. | Remove master cylinder (4) per applicable Service Manual instructions. | |||||||||||||||
3. | Remove FL bracket from frame. | |||||||||||||||
4. | Obtain the new right side chrome bracket (1), and three chrome screws (3) from the kit. NOTE See Figure 2. 2011 and later models must use mounting clip either from kit or re-use from stock vehicle. Install as shown. | |||||||||||||||
5. | See Figure 1. Place the washers (2) previously removed over the screw threads. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 54.2 N·m (40 ft-lbs). | |||||||||||||||
6. | Obtain the new brake lever (11) and make sure the O-rings (12) remain in position. Slide the new brake lever onto the mounting bracket shaft. Install the screw (14) and washer (13). Tighten to 16–22 N·m (12–16 ft-lbs). |
Figure 2. Clip Location
Figure 3. Rear Brake Reservoir Mount | ||||||||||||||
7. | See Figure 3. Fit the collar of the master cylinder cartridge body into the hole of the new right-side footboard mounting bracket (5). Apply LOCTITE® 243 (Blue) to the threads of the nut (4). Install the nut on the cartridge body until finger tight. Tighten to 40.7–54.2 N·m (30–40 ft-lbs). | |||||||||||||||
WARNING Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) | ||||||||||||||||
8. | Lubricate new steel/rubber gaskets (2) with the appropriate brake fluid for your year and model of motorcycle. See your Owner's Manual for the proper brake fluid specification. Position a gasket on each side of the brake line banjo fitting (3). Insert the banjo bolt (1) through the gaskets and fitting. Tighten to 23–30 N·m (17–22 ft-lbs). |
Figure 4. Rear Brake Control: Rear Mount | ||||||||||||||
9. | See Figure 4. Install master cylinder assembly on brake lever. Install washer (2) and new cotter pin (1) on clevis pin (3). | |||||||||||||||
10. | Lubricate the brake lever fitting with Wheel Bearing Grease (Part Number 99856-92) until a small amount of grease is visible around the edges of the brake lever. NOTE The rear brake is nonadjustable. When brake system components are properly assembled, brake lever is correctly adjusted. | |||||||||||||||
11. | See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9). | |||||||||||||||
WARNING Contact 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.
| ||||||||||||||||
12. | Make sure that the rear brake master cylinder is in a level position. Remove the master cylinder cover. | |||||||||||||||
13. | Bleed the brakes. See BLEEDING HYDRAULIC BRAKES in the Service Manual. | |||||||||||||||
WARNING After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) | ||||||||||||||||
14. | Install the gasket and cover to the master cylinder. Tighten the cover screws to 0.7–0.9 N·m (6–8 in-lbs). | |||||||||||||||
WARNING The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result in death or serious injury. (00006a) | ||||||||||||||||
15. | Move the jiffy stand to the full forward (down) position. Carefully remove the support from beneath the motorcycle frame and rest the motorcycle on the jiffy stand. | |||||||||||||||
16. | Make sure the jiffy stand operates correctly prior to riding the motorcycle. | |||||||||||||||
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) | ||||||||||||||||
17. | Turn the Ignition/Light Key Switch to IGNITION. Pump the rear brake foot lever to verify proper operation of the brake lamp. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Brake pedal mounting assembly, gloss black | 42508-11BHP |
2 | Gear shifter bracket assembly | 33683-07A |
3 | Button head TORX screw, 0.375-16 x 1 in. (6) | 4512A |
4 | Foot shifter lever assembly | 34564-90B |
5 | Shifter peg/stud assembly | 34611-65A |
6 | Foot brake lever assembly | 42515-07 |
7 | Foot gear shifter assembly | 33660-07 |
8 | Spring washer (2) | 50912-72 |
9 | Retaining ring (2) | 11304 |
10 | Clevis pin (2) | 45041-01A |
11 | Clip (2011 and later) | 10866 |