HAND LEVER KITS
J043422014-04-15
GENERAL
Kit Numbers
44994-08, 45075-08, 45459-08, 46710-08, 46982-08, 42535-08, 41793-08, 55798-10, 36700104, 36700105
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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.
BRAKE LEVER INSTALLATION
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)
| 1. | See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. |  Figure 1. 5/32 in. (4 mm) Cardboard Insert |
| 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. | See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the service manual. Remove the retaining ring (4) from the groove in the pivot pin (B) and discard retaining ring. | |
| 3. | Remove and retain the pivot pin. Remove and discard the original equipment brake lever and pivot lever bushing. NOTE New brake levers come with the pivot lever bushing installed. Follow the instructions in Steps 3 and 4 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. | |
| 4. | Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. | |
| 5. | Install the pivot pin removed in Step 2 and new retaining ring (4) from kit. | |
| 6. | Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is permissible. | |
| WARNING A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) | ||
| 7. | To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. | |
| 8. | Install the master cylinder cover. | |
| WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 9. | Check that the stop light goes on when the brake lever is actuated. |
CLUTCH LEVER INSTALLATION
See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures.
SERVICE PARTS
Figure 2. Service Parts: Hand Lever Kits
Table 1. Service Parts Table
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 44994-08 | 1 | Brake lever, black | 44995-08 |
2 | Clutch lever, black | 44996-07 | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 45075-08 | 1 | Brake lever, chrome | 45076-08 |
2 | Clutch lever, chrome | 45077-07 | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 46710-08 | 1 | Brake lever, flame | Not Sold Separately |
2 | Clutch lever, flame | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 46982-08 | 1 | Brake lever, skull | Not Sold Separately |
2 | Clutch lever, skull | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 45459-08 | 1 | Brake lever, slotted, emblem mount | Not Sold Separately |
2 | Clutch lever, slotted, emblem mount | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
5 | Clutch emblem | 44419-02 | |
6 | Brake emblem | 44418-02 | |
Kit 41793-08 | 1 | Brake lever, black skull | Not Sold Separately |
2 | Clutch lever, black skull | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 42535-08 | 1 | Brake lever, black flame | Not Sold Separately |
2 | Clutch lever, black flame | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 55798-10 | 1 | Brake lever, edge cut | Not Sold Separately |
2 | Clutch lever, edge cut | Not Sold Separately | |
3 | Bushing, pressed into brake lever | 45423-96 | |
4 | Retaining ring (2) | 11143 | |
Kit 36700104 | 1 | Brake lever, chrome | Not Sold Separately |
2 | Clutch lever, chrome | Not Sold Separately | |
3 | Brake retaining ring | 11379 | |
4 | Clutch retaining ring | 11143 | |
Kit 36700105 | 1 | Brake lever, black | Not Sold Separately |
2 | Clutch lever, black | Not Sold Separately | |
3 | Brake retaining ring | 11379 | |
4 | Clutch retaining ring | 11143 | |
Items mentioned in text, but not included in kit: | |||
A | Press piston cap forward | ||
B | Brake lever pivot pin | ||
C | Clutch control cable (reference only) | ||
D | Clutch cable anchor pin (reference only) | ||
E | Clutch lever pivot pin bushing | ||
F | Clutch lever pivot pin | ||