Handlebar Reservoir Cover Set
J012712004-11-22
GENERAL
Kit Number
46098-98 and 46099-98
Models
Kit 46098-98 fits the following models with single-disc front brake.
- 1996 through 2003 XL (Sportster®) models
- 1996 and later Dyna models
- 1996 and later Softail® models
Kit 46099-98 fits the following models with dual-disc front brake.
- 1996 through 2003 XL (Sportster) models
- 1996 and later Dyna models
- 1996 and later Softail models
- 1996 and later FL Touring models
NOTE
These kits DO NOT fit VRSC (V-rod®) models, or models equipped with a hydraulic clutch.
Kit Contents
See Table 1 for kit contents.
Figure 1. Kit Components
Table 1. Figure 1. Kit Contents
Description (Quantity) | Part Number | |
|---|---|---|
1 | Chrome clutch bracket | 46523-00 |
2 | Handlebar clamp half (2) | Not Sold Separately |
3 | Flat washer (4) | Not Sold Separately |
4 | Screw, 1-1/4 inch long (4) | 3601 |
5 | Chrome brake reservoir cover | Not Sold Separately |
6 | Standoff stud (2) | 5218 |
7 | Wave washer (2) | Not Sold Separately |
8 | Screw, 3/16 inch long (2) | Not Sold Separately |
9 | Hole plug (2) | Not Sold Separately |
10 | Anti-seize | Not Sold Separately |
INSTALLATION
WARNINGWear 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
Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged.
| 1. | Adjust the clutch cable for maximum free play. With snap ring pliers, remove and retain the external snap ring from the bottom of the clutch lever pivot pin. Remove the pivot pin, clutch lever, clutch cable and rear-view mirror from the clutch bracket. NOTE Apply anti-seize (10) (Harley-Davidson part number 98960-97) from the kit to all screw threads prior to installation. | |||
| 2. | See Figure 1. Install the new chrome clutch bracket (1) using a clamp half (2), washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). |  Figure 2. Clutch Cable Adjustment | ||
| 3. | Re-install the clutch cable and clutch lever, mirror and pivot pin and snap ring. See Figure 2. Re-adjust the clutch cable so there is a 1/16-1/8 inch (1.6-3.1 mm) gap between the clutch cable ferrule and the end of the clutch bracket (1). | |||
| 4. | Remove the original clamp half from the front brake master cylinder assembly. | |||
| 5. | See Figure 1. Install the new chrome clamp half (2) on the front brake master cylinder assembly using washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). | |||
| 6. | Remove the two screws retaining the brake master cylinder reservoir cover. See Figure 3. Replace with the two standoff studs (1) in the kit. Tighten to 6-8 in-lbs (0.7-0.9 Nm). | 
Figure 3. Installing Standoff Studs | ||
| 7. | Remove the rear-view mirror from the front brake master cylinder assembly. Place the new chrome brake reservoir cover from the kit in position. The holes in the top of the cover should line up with the holes in the standoff studs. Fasten the cover to the studs with the wave washers (7) and screws (8) from the kit. | |||
| 8. | Reinstall the rear-view mirror. |
WARNINGBe sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
- Be sure clutch cable and brake line do not pull tight when handlebars are turned fully to left or right fork stops.
- Check both the brake and clutch controls for free, unrestricted movement and travel.
- Insert the hole plugs into the handlebar clamp bolt heads.