CUSTOM HAND LEVER KITS - Harley
Contents
1. MOTOR HARLEY DAVIDSON WY J04278 INSTRUCTIONS REV 2014 07 15 CUSTOM HAND LEVER KITS GENERAL Kit Numbers 38843 08 38845 08 38853 08 36700004 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only These kits do not fit police models or models equipped with a hydraulic clutch Installation Requirements Separate purchase of G40M Brake Grease Part No 42820 04 is required for proper installation of this kit See a Harley Davidson dealer WARNING The rider s safety depends 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 00333a NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is required for this installation One is available from a Harley Davidson dealer IWAN IN Brakes are a critical safety component Contact a Harley Davidson dealer for brake repair or replacement Improp erly serviced brakes can adversely affect brake perform ance which could result in death or serious injury 00054a Kit Contents See Figure 1 and Table 1 BRAKE LEVER INSTALLATION IWIN NIN Wear safe2. lever chrome includes Items 7 through 12 38844 08 Kit 38845 08 1 Brake hand lever black includes Items 3 through 6 Not sold separately Black Levers 2 Clutch hand lever black includes Items 7 through 12 Not sold separately Kit 38853 08 1 Brake hand lever slotted includes Items 3 through 6 42916 06 Slotted Levers 5 Clutch hand lever slotted includes Items 7 through 12 38855 08 Kit 36700004 1 Brake hand lever slotted includes Items 3 through 6 Not sold separately Te 2 Clutch hand lever slotted includes Items 7 through 12 Not sold separately Parts common Brake hand lever Not sold separately to ALL Kits Pivot pin kit polished For all Kits EXCEPT 38845 08 includes Items 5 and 6 42105 06A Pivot pin kit black For Kit 38845 08 includes Items 5 and 6 42860 06B 5 Pivot pin brake lever Not sold separately 6 e Retaining ring brake pivot pin 11615 7 Clutch hand lever Not sold separately 8 Bushing clutch lever pivot 45423 92 9 Clip anti rattle 45021 86 10 Screw 90770 79 11 Pivot pin clutch lever polished 45032 82 Pivot pin clutch lever black 38738 08 12 Retaining ring clutch pivot pin 11143 Reference items not included in kit A Front brake master cylinder B Clutch hand lever bracket C Original equipment OE clutch cable anchor pin D OE clutch control cable J04278 30f3
3. ng motorcycle Low visibility of rider can result in death or serious injury 00316a CLUTCH LEVER INSTALLATION 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 _ See Figure 1 and the service manual Remove the retaining ring 12 from the groove in the pivot pin 11 N Remove the pivot pin from the clutch lever 7 and bracket B Discard the original equipment OE clutch lever 7 pivot pin 11 and retaining ring 12 w Align the hole in the clutch hand lever with the hole in the lever bracket From the top of the assembly slide the new pivot pin 11 down through the bracket and hand lever gt Install the new retaining ring 12 from the kit in the pivot pin groove Verify that the retaining ring is seated in the groove a See the service manual for clutch lever 7 adjustment procedures 1 of 3 Please dispose of materials responsibly SERVICE PARTS is04452a os 8 J04278 Figure 1 Service Parts Hand Control Lever Kits 20f3 SERVICE PARTS Table 1 Service Parts Hand Control Lever Kits Kit Item Description Quantity Part Number Kit 38843 08 1 Brake hand lever chrome includes Items 3 through 6 42271 06A Chrome Levers 5 Clutch hand
4. ty 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 1 See Figure 1 and the service manual Remove the retaining ring 6 from the groove in the pivot pin 5 J04278 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled N Remove the pivot pin from the brake lever and master cylinder housing A Discard the original equipment OE brake lever 3 pivot pin 5 and retaining ring 6 w Apply a small amount of GM 40M grease Part No 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 gt Align the hole in the brake hand lever with the hole in the master cylinder bracket From the top of the assembly slide the new pivot pin 5 down through the bracket and hand lever Check that the pushrod is properly seated on the lever a Install the new retaining ring 6 from the kit in the pivot pin groove Verify that the retaining ring is seated in the groove D Check the front brake for proper operation There must be no free play in the hand lever A slight preload is normal Check that the stop light illuminates when the brake lever is actuated WARNING Be sure that all lights and switches operate properly before operati
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