1. | Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface, and turn handlebar so the top of the clutch master cylinder is level. | |
2. | See Figure 1. View reservoir sight glass and verify fluid level is at or above the Min line. If fluid level is low, proceed to 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 and remove the cover. | |
4. | Verify the fluid level 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 which is approved for clutch system use and 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 will force 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) ![]() 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.
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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 and secure with the two cover screws. Tighten the screws to 0.9–1.1 N·m (8–10 in-lbs). NOTE If the fluid level in the clutch master cylinder reservoir is correct but the clutch does not operate properly, refer to the service manual or see a Harley-Davidson dealer for service. |