HAND CONTROL LEVER KITS
J035332005-07-29
GENERAL
Kit Number
42270-06, 42275-06 and 34648-06
Models
These kits fit 2006 and later VRSCR model motorcycles.
INSTALLATION
WARNINGRider 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
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
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. | See Figure 1. Place a 4 mm (5/32 inch) cardboard insert between the brake lever and lever bracket. | |||||
| 3. | See Figure 3. Loosen brake master cylinder clamp screws. Rotate master cylinder assembly slightly forward and then slide toward the center of the handlebar. | |||||
| 4. | Remove pivot pin (A) and original equipment brake lever. Retain pivot pin for reuse. | |||||
| 5. | See Figure 2. Slip the new brake lever into position and align the pivot pin holes. Ensure the pushrod (1) in the master cylinder is seated in the bowl shaped tab (2) on the brake lever. |  Figure 1. Cardboard Insert - 4 mm (5/32 in.) 
Figure 2. Master Cylinder Pushrod and Lever Tab | ||||
| 6. | Install pivot pin (A) removed in Step 2, and retaining ring (4) from kit. Replace cardboard insert shown in Figure 1. | |||||
| 7. | Slide brake master cylinder assembly back into place. Tighten clamp screws to 7.9–9 N·m (70–80 in-lbs). | |||||
| 8. | Remove cardboard insert and check 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 master cylinder reservoir cover to check the operation of the relief port. | |||||
| 10. | Reinstall master cylinder cover. | |||||
| 11. | Check that stop light is on when brake lever is actuated. |
WARNINGBe 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
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)
| 1. | Remove retaining ring from pivot pin groove. | |
| 2. | See Figure 3. Remove pivot pin (B) through the top of the housing. Save pivot pin for installing the new clutch lever. | |
| 3. | Slide bushing cups (D) onto the pins of the roller (C) with 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 clutch lever roller groove. If the bushing is positioned correctly, roller and bushing assembly will securely install with a snap. | |
| 5. | Grease pivot bushing (3) and install into clutch lever pivot hole. Position so bushing is flush on both sides of lever. | |
| 6. | Orient clutch lever (2) in lever mounting bracket. Insert pivot pin (B) from top and tap into place. | |
| 7. | Install retaining ring (5) on pivot pin (B). | |
| 8. | Check clutch lever for proper operation. There should be no free play in 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 master cylinder reservoir cover to check the operation of the relief port. | |
| 10. | Reinstall master cylinder cover. |
SERVICE PARTS
Figure 3. Service Parts for Hand Control Lever Kits
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Brake Hand Lever (Chrome Hand Lever Kit 42270-06) | 42271-06 |
Brake Hand Lever (Black Hand Lever Kit 42275-06) | 42276-06 | |
Brake Hand Lever (Slotted Chrome Hand Lever Kit 34648-06) | 38760-06 | |
2 | Clutch Hand Lever (Chrome Hand Lever Kit 42270-06) | 42272-06 |
Clutch Hand Lever (Black Hand Lever Kit 42275-06) | 42277-06 | |
Clutch Hand Lever (Slotted Chrome Hand Lever Kit 34648-06) | 38762-06 | |
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 | |