Special Tools

Description	Part Number	Qty.
DOT 4 BRAKE FLUID MOISTURE TESTER	HD-48497-A	1

Squeezing the left hand lever causes the clutch master cylinder to actuate and apply pressure to the clutch actuation cylinder mounted in the engine right side cover. The actuation cylinder piston extends and contacts the clutch release bearing to release the clutch.

Check clutch fluid level periodically. Refer to Maintenance Scheduling → Service Records → Regular Service Intervals: 2017 V-Rod Models .

NOTE

At every service, check moisture content of fluid using DOT 4 BRAKE FLUID MOISTURE TESTER (Part Number:HD-48497-A). Follow the instructions included with tool.
Flush clutch system and replace DOT 4 fluid every two years or sooner if brake fluid test shows moisture content is 3% or greater.
Fluid should never need to be added or removed from the system during normal wear, except for fluid replacement as specified in the maintenance schedule.
Fluid level in reservoir will rise with clutch wear. Reservoir volume is adequate to provide fluid to the wear limits of the clutch.

1.	Position motorcycle and handlebar so the master cylinder reservoir is level.
2.	See Figure 1. View reservoir sight glass. Sight glass appears dark if fluid is present. If the entire sight glass is not dark, then proceed to the next step.
	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.	Clean all dirt and debris from the clutch master cylinder cover. Remove the two clutch master cylinder cover screws. Remove the cover.
4.	Verify that the fluid in the clutch master cylinder reservoir is at the FILL level mark at the top of the ledge on the rear inside wall of the reservoir. If the fluid level is low, add DOT 4 BRAKE FLUID (Part No. 99953-99A) available from a Harley-Davidson dealer. NOTE Do not overfill the clutch master cylinder reservoir. As the clutch friction discs wear, the piston in the clutch cylinder forces fluid back into the reservoir which could cause fluid overflow. If clutch fluid level is over full, the clutch can be damaged.
	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) 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) 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. 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 (00240e)
5.	Inspect the clutch master cylinder cover gasket for rips, cuts, cracks or other signs of damage. Replace the gasket if necessary. Carefully place the cover and cover gasket on the master cylinder reservoir. Secure with the two cover screws. Tighten the screws to: Torque: 0.7–0.9 N·m (6–8 in-lbs) Clutch master cylinder cover screws NOTE If the fluid level in the clutch master cylinder reservoir is correct but the clutch does not operate properly, See the service manual or a Harley-Davidson dealer for service.

Figure 1. Clutch Reservoir Sight Glass