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FL SOFTAIL EXTENDED REACH REAR BRAKE LEVER
J054322011-05-20
GENERAL
Kit Number
41600008
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit also requires installing a brake pedal pad, sold separately. Refer to the appropriate Parts and Accessories Catalog for a stock replacement rubber pad.
Loctite® 243 Threadlocker and Sealant (blue) P/N 99642-97
WARNING
Rider 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.
Kit Contents
See Figure 1 and Table 1.
REMOVAL
  1. See Figure 1. Remove the cotter pin (5) and washer (E) from the master cylinder clevis pin (B). Discard the cotter pin.
    2. NOTE
    The clevis pin has a slight interference fit. It may be necessary to use pliers to pull the clevis pin from the push rod. Be careful not to damage mating parts.
  2. Remove the clevis pin (B) from the brake rod. Thoroughly clean and examine parts for wear. Replace if necessary.
  3. Remove the brake lever mounting screw (A) and flat washer (D), and save for installation, if necessary. Remove and discard the outer O-ring (2).
  4. Remove the brake lever by rotating counter-clockwise and lifting the master-cylinder clevis if necessary. Pull the lever from the shaft. Remove and discard the inner O-ring.
  5. Thoroughly clean the lever mounting shaft of grease and dirt.
INSTALLATION
NOTE
These levers are equipped with self-lubricating bushings. It is not necessary to lubricate the mounting shaft or bushings inside the lever prior to installation.
1. See Figure 1. Insert the new O-rings (4) on either side of the lever bushings (2). Install the new brake lever (1) onto the mounting shaft.
NOTE
There is insufficient clearance to install the clevis pin from the outside, so it must be installed from the inboard side of the brake lever.
2. Align the holes in the lever and brake rod and insert the stock clevis pin (B) from the inboard side.
3. Install the small flat washer (E) onto the clevis pin and insert the new cotter pin (5).
4. Place the large flat washer (D) onto the brake lever mounting screw (A). Apply Loctite 243 (blue) to the threads of the screw, and install into the brake lever mounting shaft. Tighten the screw to 16.3–21.7 N·m (12–16 ft-lbs).
5. Install the brake pedal pad (C) to the brake lever.
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)
6. Check the brake lever for proper operation and clearance through its full travel.
SERVICE PARTS
Figure 1. Service Parts: FL Softail Extended Reach Rear Brake Lever
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Kit 41600008
1
Brake lever assembly, includes items 2 and 3
Not Sold Separately
2
  • Bushing, (2) 0.719 O.D.
57217-02
3
  • Bushing, split, 0.25 I.D.
42644-00
4
O-ring (2)
11364
5
Cotter pin
515
Items mentioned in text, but not included in kit:
A
Screw
B
Clevis pin
C
Brake pedal pad, must be installed. Purchased separately (not shown)
D
Plain washer, type A
E
Washer
Some kits may require the use of original equipment hardware.