CHROME CLUTCH AND MASTER CYLINDER/RESERVOIR KIT
J042922018-03-23
GENERAL
Kit Number
42100-06B, 42100-06E
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
NOTE
Installation of this kit requires the installation of brake and clutch hand control levers. If replacement of the original equipment (O.E.) levers is needed, refer to the Parts Catalog for your year and model vehicle.
See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a selection of Genuine Motor Accessory hand control levers that are available. These can be easily installed at the same time as this kit.
Additional Parts Required
A Brake Lever Pivot Pin Kit (42105-06A) and a retaining ring (Part Number 11143) for the clutch lever pivot pin are required for the proper installation of this kit.
Tools and Supplies Required
Fresh, uncontaminated D.O.T. 4 brake fluid from a sealed container will be needed. GM-40M grease (2 gram bag, H-D part number 42820-04) will also be needed. These items are available from a Harley-Davidson Dealer.
WARNINGRider 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 references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
WARNINGBrakes 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)
INSTALLATION
Prepare Motorcycle for Service
- Remove the right side cover and remove the Maxi® Fuse. Remove the left side cover and disconnect the negative (-) battery cable.
- Rest the motorcycle on the jiffy stand, with the front wheel turned toward the right fork stop so that the master cylinder is in a level position.
Remove Existing Clutch Master Cylinder/Reservoir
| 1. | While holding turn signal locknut underneath clutch lever/master cylinder assembly, unthread mirror (counterclockwise). Remove mirror and turn signal assembly. Save mirror and washers for installation. Secure turn signal assembly so it is out of the way. | |||||||||||||||||||||||||||
| 2. | Loosen the clutch master cylinder cover screws to relieve pressure. NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of D.O.T. 4 brake fluid. | |||||||||||||||||||||||||||
| 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.
NOTICE DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c) | ||||||||||||||||||||||||||||
| 3. | While holding a cup under the banjo bolt connection, remove the banjo bolt and allow brake fluid from clutch master cylinder to drain into cup. When reservoir appears to be drained, remove banjo bolt and clutch line. NOTE Immediately orient clutch line end upward to prevent further drainage from line. Use cable strap, rubber band or similar device to secure the line to handlebar with open end up. Save banjo bolt. Discard gaskets. | |||||||||||||||||||||||||||
| 4. | Use a clean cloth and wipe remaining areas clean of brake fluid. | |||||||||||||||||||||||||||
| 5. | See Figure 1. Remove two screws (3) securing the handlebar clamp (1) to master cylinder assembly (11). Plug the banjo bolt hole with index finger and take master cylinder (with clutch lever assembly) to a clean work area. | 
Figure 1. Clutch Master Cylinder/Reservoir Assembly | ||||||||||||||||||||||||||
NOTICE Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c) | ||||||||||||||||||||||||||||
| 6. | Remove screws securing cover to master cylinder/reservoir and remove cover and gasket. Turn reservoir upside down over a shop rag to remove remaining brake fluid from the clutch master cylinder. NOTE Use the correct retaining ring pliers and inspect the tips of the pliers for wear or damage. | |||||||||||||||||||||||||||
| 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) | ||||||||||||||||||||||||||||
| 7. | See Figure 1. Remove the retaining ring (10) from the groove in the clutch pivot pin (7). Discard retaining ring. NOTE To remove the pivot pin, gently force the clutch lever toward the piston (as if operating the clutch). This will take the piston spring load off of the pivot pin. | |||||||||||||||||||||||||||
| 8. | See Figure 1. Remove the clutch hand lever (9) from the master cylinder assembly by sliding the pivot pin (7) out from the top. Gently pry the pivot pin up and out to remove. Discard pivot pin. NOTE It is not necessary to remove components from the bore of the old master cylinder. The new clutch master cylinder comes with all internal components preassembled. If reusing the stock clutch lever, then also save lever and lever components for reuse. | |||||||||||||||||||||||||||
| 9. | Save the clutch lever with clutch lever components installed. Discard clutch master cylinder assembly. |
NOTE
Be careful not to lose any of the clutch lever components. If you are replacing the clutch lever with a chrome lever or original master cylinder cover with a chrome cover, at this time, refer to the Instruction Sheet packaged with the kit(s). If you are not replacing the lever, leave the clutch roller components in place on the clutch hand lever.
Install Chrome Clutch Master Cylinder/Reservoir
WARNINGUse denatured alcohol to clean clutch system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause clutch failure, which could result in death or serious injury. (00296a)
| 1. | See Figure 1. Clean new master cylinder reservoir (11), cover (5) and cover gasket (6) with denatured alcohol or D.O.T. 4 brake fluid. Wipe dry with a clean, lint free cloth. NOTE See Figure 2. When installing clutch lever to master cylinder assembly, position the bushing cup bow facing away from mounting bracket. To align lever and allow the pivot pin to fit, gently compress the piston. | 
Figure 2. Clutch Lever Components | ||||||
| 2. | If necessary, install the roller with plastic bushing cups. Orient clutch lever in bracket portion of master cylinder assembly and align pivot pin hole with lever bracket holes. Install pivot pin from top and tap into place. | |||||||
| 3. | Install new pivot pin retaining ring into new pivot pin groove. Verify that retaining ring is completely seated in groove. | |||||||
| 4. | See Figure 7. Obtain master cylinder clamp (2) and two screws (1). Align master cylinder clutch lever assembly and install screws to hold assembly in place. Do not tighten clamp screws at this time. | |||||||
| 5. | Use banjo bolt (15) and two new gaskets from kit. Install clutch line to master cylinder with gaskets oriented on each side of line. Do not tighten banjo bolt at this time. | |||||||
| 6. | Align entire clutch master cylinder assembly for rider posture. Beginning with the top handlebar clamp mounting screw, tighten the clamp
screws. Torque: 7.9–9 N·m (70–80 in-lbs) clamp screw | 
Figure 3. Turn Signal Assembly and Mirror | ||||||
| 7. | See Figure 3. Install mirror (1) and left turn signal assembly. Tighten turn signal locknut (2) securely. |
Bleed the Hydraulic Clutch
| 1. | See Figure 4. To access the clutch bleeder valve (2), remove the three bolts and the clutch actuator cover. | |||||||||
NOTICE Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c) | ||||||||||
| 2. | Stand motorcycle upright and square handlebars to level clutch reservoir. NOTE Clutch fluid volume actually increases with clutch wear. Do not overfill reservoir. | 
Figure 4. Clutch Actuator with Cover Removed | ||||||||
| 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.
NOTICE DOT 4 hydraulic brake fluid is used in the hydraulic clutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00353b) | ||||||||||
| 3. | Add the D.O.T. 4 brake fluid to the clutch master cylinder reservoir. Do not reuse old brake fluid. Use only brake fluid from a sealed container. Initial fill level should not exceed FILL LEVEL indicator. | |||||||||
| 4. | To bleed master cylinder of air bubbles: a. Pump clutch hand lever 5 times. b. Hold clutch hand lever against handlebar. c. Hold shop towel under fitting and loosen banjo bolt. d. Watch banjo fitting for air bubbles. e. Retighten banjo fitting. f. Release hand lever. | |||||||||
| 5. | Fill reservoir to FILL LEVEL and repeat the previous step three times or more until only a steady flow of brake fluid escapes the banjo fitting and fluid level in reservoir is at FILL LEVEL with motorcycle upright. | |||||||||
| 6. | Cover exhaust with towel and place a pan under the right side case to catch the excess brake fluid. | |||||||||
| 7. | To bleed the clutch line and the secondary actuator: a. Pump clutch hand lever 5 times. b. Hold clutch hand lever against handlebar. c. Loosen secondary clutch actuator bleeder screw. d. Watch bleeder screw for air bubbles. e. Tighten bleeder screw. f. Release hand lever. | |||||||||
| 8. | Fill reservoir to FILL LEVEL and repeat the previous step 3 times or more until only a steady flow of brake fluid escapes the bleeder screw and fluid level in the reservoir is at FILL LEVEL with the motorcycle upright. | |||||||||
| 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. | Verify proper operation of the clutch master cylinder relief port. Actuate the clutch lever. A slight spurt of fluid will break the fluid surface in reservoir if all internal components are working properly. | |||||||||
| 10. | Tighten reservoir banjo bolt. Torque: 23–31 N·m (17–23 ft-lbs) banjo bolt | |||||||||
| 11. | Install the cover with gasket on the master cylinder reservoir so that the thicker side is positioned above the clutch line fitting. Install the two cover screws and
tighten. Torque: 0.7–0.9 N·m (6–8 in-lbs) cover screws NOTE A sight glass enables the rider to visually check the brake fluid level without removing the clutch master cylinder cover. Do not allow the level of brake fluid to fall below the minimum level indicated by the sight glass. | |||||||||
| 12. | Tighten the secondary clutch actuator fasteners: a. Bleeder screw to 9–11 N·m (80–100 in-lbs). b. Secondary clutch actuator cover fasteners to 6–10 N·m (53–88 in-lbs). |
Front Brake Master Cylinder Removal
WARNINGContact 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.
- If inhaled: Keep calm, remove to fresh air, seek medical attention.
- If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
- If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
- If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
- See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
NOTE
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splash of D.O.T. 4 brake fluid.
| 1. | Drain the front brake master cylinder. a. Open the bleeder nipple caps on each of the front brake calipers. b. Install one end of a length of clear plastic tubing over each caliper bleeder valve, while placing the free ends in a suitable container. c. Open the bleeder valves about 3/4-turn. Pump the hand lever to drain the fluid from the reservoir. d. Close the bleeder valves. | 
Figure 5. Protect Stop Light Switch | ||||||
| 2. | Remove the mirror and front turn signal from the brake hand lever bracket. | |||||||
| 3. | Clean the area surrounding the banjo bolt at the front brake master cylinder. Remove the banjo bolt and the two copper gaskets to disconnect the brake line fitting from the master cylinder. Discard the gaskets, but save the banjo bolt. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 5. | |||||||
NOTICE Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) | ||||||||
| 4. | Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. | |||||||
| 5. | See Figure 7. Using a T-27 TORX® drive head, remove and discard the two screws (1) and flat washers (1A) securing the handlebar clamp (2A) to the master cylinder housing (3). Remove the brake lever/master cylinder assembly and clamp from the handlebar. |
If the current brake lever WILL NOT be re-used with the new
master cylinder: Continue after Step 6.
If the current brake lever IS being re-used with the new master
cylinder:
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)
- Remove and discard the retaining ring (11) from the groove in the pivot pin (12). Remove and discard the pivot pin.
- Remove the brake hand lever (A) from the master cylinder.
NOTE
The new master cylinder comes with all internal components pre-assembled. It is not necessary to remove the components from the bore of the old master cylinder.
New Front Brake Master Cylinder Installation
| 1. | Obtain the O.E. brake hand lever removed earlier, or a new lever (purchased separately). Apply a small amount of GM-40M grease (H-D part number 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. Align the hole in the brake hand lever with the hole in the new master cylinder bracket. From the top of the assembly, slide the new pivot pin (purchased separately) down through the bracket and hand lever. Check that the pushrod is properly seated on the lever. | |||||||||
| 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) | ||||||||||
| 2. | Install the new retaining ring (purchased separately) in the pivot pin groove. Verify that the retaining ring is completely seated in the groove. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 5 | |||||||||
NOTICE Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) | ||||||||||
| 3. | Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. | 
Figure 6. Brake Lever Bracket to Switch Housing | ||||||||
| 4. | See Figure 6. Position the brake lever/master cylinder assembly inboard of the switch housing (4) assembly, engaging the tab (1) on the lower switch housing in the groove (3) at the top of the brake lever bracket (2). | |||||||||
| 5. | See Figure 7. Obtain the new screws (1) and flat washers (1A) from the kit. Place a washer onto the threads of each screw. Align the holes in the new handlebar clamp with those in the master cylinder housing, and start the two screws into the threaded holes. | |||||||||
| 6. | Adjust the position of the brake lever assembly on the handlebar for rider comfort and posture. Beginning with the top screw, use a T27 TORX drive head to
tighten the screws. Torque: 7.9–9 N·m (70–80 in-lbs) TORX head screw | |||||||||
NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) | ||||||||||
| 7. | See Figure 1. Position new copper gaskets (12) on each side of
the brake line fitting. Insert the new banjo bolt (13) through the gaskets and fitting. Thread the bolt into the master
cylinder housing and tighten. Torque: 17–20 N·m (13–15 ft-lbs) hex head bolt | |||||||||
| 8. | Remove the insert from the brake lever. See Figure 5. |
Final Assembly
NOTE
For ABS-equipped vehicles: Refer to the Service Manual for brake bleeding procedures.
For Non-ABS vehicles: Refer to Steps 1 through 11 that follow.
- If removed earlier, install one end of a length of clear plastic tubing over the right-side caliper bleeder valve, and place the free end in a suitable container. Verify that both caliper bleeder valves are closed tightly.
- Remove the master cylinder cover. Rest the motorcycle on the jiffy stand, with the front wheel turned toward the right fork stop so that the master cylinder is level.
WARNINGContact 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.
- If inhaled: Keep calm, remove to fresh air, seek medical attention.
- If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
- If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
- If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
- See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
NOTE
The brake system on this vehicle uses D.O.T. 4 BRAKE FLUID. Do not mix grades of brake fluid as they are not compatible. Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury.
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
Verify that the fuel tank, front fender, chrome, and footboards are properly covered with a polyethylene protective sheet.
| 9. | Add D.O.T. 4 HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the fluid level reaches the MAX marking inside the reservoir. Do not reuse old brake fluid. Use only D.O.T. 4 fluid from a sealed container. | |
| 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) | ||
| 10. | Verify proper operation of the master cylinder relief port. Actuate the brake hand lever. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly. | |
| 11. | Pump the front brake hand lever to build up hydraulic pressure. | |
| 12. | While holding the lever, open the right-side caliper bleeder valve about 3/4-turn. Brake fluid will flow from the bleeder valve through the tubing. Close the bleeder valve as soon as a loss of pressure is detected . Allow the brake hand lever to return slowly to its released position. NOTE Pay careful attention to the fluid level in the master cylinder reservoir during the bleeding procedure. To avoid drawing air into the brake lines, always add fluid as needed to the reservoir before it becomes completely empty. | |
| 13. | Repeat Steps 5 and 6 until all air bubbles are purged, and a solid column of fluid is observed in the bleeder tube. | |
| 14. | Final tighten the right-side bleeder valve. Torque: 9–11.3 N·m (80–100 in-lbs) hex nut | |
| 15. | Install the bleeder cap. | |
| 16. | If removed earlier, install one end of a length of clear plastic tubing over the left-side caliper bleeder valve, and place the free end in a suitable container. Add brake fluid to the master cylinder reservoir until the fluid level reaches the MAX marking inside the reservoir. Repeat Steps 5 through 8 for the left-side brake line. | |
| 17. | Add brake fluid as needed to the master cylinder reservoir per the instructions in the Service Manual. NOTE Before installing the master cylinder cover, verify that the cover gasket bellows is not expanded. If bellows is expanded, brake fluid will be ejected from the reservoir during cover installation, which could damage the vehicle finish. | |
| 18. | Note that the shape of the master cylinder cover has one end thinner than the other. Install the cover (with gasket compressed) on the master cylinder
reservoir so the thinner end is positioned above the brake line fitting. Install two Phillips-head screws to fasten the cover to the reservoir. Tighten the screws. Torque: 0.8–1.2 N·m (7–11 in-lbs) Phillips-head screw NOTE The sight glass enables the rider to visually check the brake fluid level without removing the master cylinder cover. When the master cylinder is level and the reservoir is full, the sight glass is dark. As the fluid level drops, a bubble of air will start to appear in the glass to indicate this condition to the rider. | |
| 19. | Turn the Ignition/Light Key Switch to IGNITION, but do not start the motorcycle. Actuate the front brake hand lever to verify operation of the brake lamp. | |
| 20. | Check the clutch lever for proper operation. If necessary, refer to CLUTCH ADJUSTMENT in the Service Manual. | |
| 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) | ||
| 21. | Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure. |
Return the Motorcycle to Service
| 1. | Replace the left side cover and install the MAXI Fuse and the right side cover. | |
| 2. | Close and lock the seat. | |
NOTICE When closing the seat, make sure the ignition switch is in the FUEL position. If the ignition switch is in any other position when the seat is closed, the seat latch mechanism could be damaged. (00196a) | ||
| 3. | With the ignition/light key switch turned to IGNITION, actuate the front brake hand lever to verify operation of the brake lamp. | |
| WARNING Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d) WARNINGAfter 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) | ||
| 4. | Test ride the motorcycle. a. If the brake feels spongy, repeat the front brake bleeding procedure. b. If the clutch drags or if the transmission shifts hard, repeat the clutch bleeding procedure. |
SERVICE PARTS
Figure 7. Service Parts: Chrome Master Cylinder Reservoir Kit
Table 1. Service Parts: Chrome Master Cylinder Reservoir Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 1A | Screw, handlebar clamp Washer (4) | 4293 6099 | 13 | Pivot pin, clutch | 45032-82 | |
2 2A | Clamp, handlebar, clutch and brake | 42119-08 | 14 | Screw kit, clutch cover | 3089 | |
3 | Master cylinder housing, brake (chrome) | Not Sold Separately | 15 | Banjo bolt (2) | 42010-06A | |
4 | Gasket, brake | Not Sold Separately | 16 | Cover assembly, brake | 42116-06A | |
5 | Cover, brake | Not Sold Separately | 17 | Cover assembly, clutch | 36700094 | |
6 | Screw kit, brake cover | 42882-06 | 18 | Retaining ring | 11143 | |
7 | Label | 42856-06 | Items mentioned in text, but not included in kit: | |||
8 | Master cylinder housing, clutch (chrome) | Not Sold Separately | A | Lever, brake | ||
9 | Gasket, clutch cover | Not Sold Separately | B | Roller | ||
10 | Cover, clutch | Not Sold Separately | C | Lever, clutch | ||
11 | Retaining ring | 11615 | D | Bushing cup | ||
12 | Pivot pin kit, brake (includes item 11) | 42105-06A | E | Bushing | ||