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chrome master cylinder kit - HARLEY

1. death or serious injury 00291a 8 Carefully inspect all parts for wear or damage and replace as necessary J04324 MASTER CYLINDER INSTALLATION 1 Align hole in brake hand lever with hole in master cylinder bracket From the top of the assembly slide pivot pin through bracket and hand lever 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 Install retaining ring in pivot pin groove Verify that retaining ring is completely seated in groove 3 See Figure 3 Position the brake lever master cylinder assembly inboard of the switch housing 4 assembly engaging the tab 1 on the lower switch housing in the groove 3 at the top of the brake lever bracket 2 h T A P hw Ea a Wak Brake lever bracket Groove Switch housing fae Figure 3 Brake Lever Bracket to Switch Housing 4 Align the holes in the handlebar clamp with those in the master cylinder housing and start the two screws with flat washers Position for rider comfort Beginning with the top screw tighten the screws to 70 80 in lbs 7 9 9 0 Nm using a T 27 TORX drive head CAUTION Avoid leakage Be sure gaskets banjo bolt s brake line and master cylinder bore are clean and undamaged before assembly 00322a 5 Positio
2. anchor pin it will be necessary to remove the retaining ring C and pivot pin A 4 Remove clevis E and clutch lever 5 Using a T 27 TORX drive head remove the two screws with flat washers securing the handlebar clamp to the clutch lever bracket CLUTCH LEVER BRACKET INSTALLATION 1 See Figure 6 Install the clutch cable F and anchor pin D in the clutch hand lever H The flat in the pin must face in towards the hand lever 3 of 5 2 Putcable clevis in position in clutch lever and slide anchor NOTE pin into place If clutch adjustment is necessary refer to the applicable Service 3 Place clutch lever in new bracket and install pivot pin and MARUBI retaining ring 6 Check clutch lever for proper operation 4 Align the holes in the handlebar clamp with those in the clutch lever bracket and start the two screws with flat iso1012 washers Position for rider comfort Beginning with the top screw tighten the screws to 70 80 in lbs 7 9 9 0 Nm 5 Adjust clutch lever free play by performing the following a See Figure 4 Turn cable adjuster 2 away from jam nut 3 until slack is eliminated at hand lever b See Figure 5 Pull clutch cable ferrule 2 away from clutch lever bracket 3 to check free play Turn cable adjuster as necessary to obtain 1 16 1 8 inch 1 6 3 2 mm free play between end of cable ferrule and clutch lever bracket c Hold adjuster with 1 2 inch wrench Using 9 16 inch wrench ti
3. cMOTOR HARLEY DAVIDSON NU J04324 INSTRUCTIONS REV 2007 04 12 CHROME MASTER CYLINDER KIT GENERAL Kit Number 45355 08 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required AWARNING 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 A Service Manual for your motorcycle is available from any Harley Davidson Dealer Kit Contents See Figure 6 and Table 1 MASTER CYLINDER REMOVAL See Figure 1 Master cylinders designed for dual disc two caliper operation have an 11 16 inch 17 5 mm bore while those that are designed for single disc one caliper operation have a 9 16 inch 14 3 mm bore The bore size is stamped 1 on the master cylinder assembly inboard of the handlebar clamp bracket NOTE Do not use an 9 16 inch bore master cylinder assembly on dual disc two caliper models or dual disc 11 16 inch bore master cylinder assembly on single disc one caliper models These master cylinder assemblies are not interchangeable Using the wrong assembly can adversely affect braking efficien
4. cy or result in brake failure which could result in death or serious injury CAUTION D O T 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 per formed Failure to comply can result in cosmetic damage 00239b J04324 is05025 1 Bore stamp size location Figure 1 Verify Correct Master Cylinder Bore Size t Open bleeder nipple caps on front brake caliper Install end of a length of clear plastic tubing over caliper bleeder valves while placing free end in a suitable container Open bleeder valves about 1 2 turn Pump brake hand lever to drain brake fluid Close bleeder valve CAUTION Avoid leakage Be sure gaskets banjo bolt s brake line and master cylinder bore are clean and undamaged before assembly 00322a 2 Remove bolt and two metal rubber gaskets to disconnect fitting of hydraulic brake line from master cylinder Discard gaskets CAUTION 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 3 See Figure 2 Place the cardboard insert between the brake lever and lever bracket 1of5 is01010 Fi
5. ghten jam nut against cable adjuster Clutch cable Cable ferrule Clutch lever bracket Freeplay 1 16 1 8 in 1 6 3 2 mm d Cover cable adjuster with rubber boot ron Figure 5 Clutch Hand Lever J04324 4of5 SERVICE PARTS is05024 Figure 6 Service Parts Chrome Master Cylinder Kit Table 1 Service Parts Chrome Master Cylinder Kit Item Description Quantity Part Number Item 1 Cover assembly chrome DOT4 Not Sold Separately Items mentioned in text but not in kit 2 Screw stainless steel 2 2573 A Pivot pin 3 Master cylinder assembly brake chrome 45297 08 B Bushing 9 16 inch bore 4 Bracket clutch lever chrome 38403 99 C Retaining ring 5 Clamp handlebar chrome 2 45282 99A D Anchor pin 6 Washer zinc 4 6099 E Clevis end 7 Screw zinc 4 4293 F Clutch cable 8 Gasket brakeline 7 16 inch 2 not shown 41733 88 G Brake hand lever H Clutch hand lever J04324 5of5
6. gure 2 5 32 in 4 mm Cardboard Insert P See Figure 6 Using T 27 TORX drive head remove the two screws with flat washers securing the handlebar clamp to the master cylinder housing Remove the brake lever master cylinder assembly and clamp from the han dlebar AWARNING 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 5 Remove retaining ring from pivot pin groove at bottom of master cylinder bracket D Remove pivot pin and brake hand lever from master cylinder assembly CAUTION 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 00205b NOTE New master cylinder comes with all internal components pre assembled It is not necessary to remove the components from the bore of the old master cylinder See Service Parts page 7 Clean all previously used parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a clean lint free cloth WARNING Use denatured alcohol to clean brake system components Do not use mineral based solvents such as gasoline or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in
7. n new metal rubber gaskets included in kit on each side of hydraulic brake line fitting Insert bolt through gaskets and fitting Thread bolt into master cylinder housing and tighten to 17 22 ft lbs 25 30 Nm 6 Install length of clear plastic tubing over caliper bleeder valve if removed Place free end of tube in a clean con tainer 7 Remove the master cylinder cover Stand the motorcycle upright so that the master cylinder is in a level position 2of5 CAUTION Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a NOTE The cover is labeled for D O T 4 BRAKE FLUID Install this cover on reservoirs filled only with D O T 4 BRAKE FLUID Do not mix grades of brake fluid as they are not compatible and could cause equipment damage NOTE Never mix D O T 4 with other brake fluids such as D O T 5 Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury 8 Add D O T 4 SILICONE HYDRAULIC BRAKE FLUID to the master cylinder reservoir until the fluid level is 1 8 inch 3 2 mm from the top Do not reuse old brake fluid Use only D O T 4 fl
8. uid from a sealed container WARNIN G Be sure the master cylinder relief port is not plugged A plugged relief port can cause brake drag or lockup and loss of vehicle control which could result in death or serious injury 0031 7a 9 Verify proper operation of the master cylinder relief port Actuate the brake hand lever A slight spurt of fluid will brake the fluid surface in the reservoir compartment if all internal components are working properly 10 Add brake fluid to the master cylinder reservoir until the fluid level is 1 8 inch 3 2 mm from the top 11 Depress and hold the brake hand lever to build up hydraulic pressure 12 Open bleeder valve about 1 2 turn Brake fluid will flow from bleeder valve through tubing Close bleeder valve when brake hand lever has moved 1 2 to 3 4 of its full range of travel Allow brake hand lever to return slowly to its released position 13 Repeat Steps 10 through 12 until all air bubbles are purged 14 Final tighten the bleeder valve to 80 100 in Ibs 9 0 11 3 Nm Install the bleeder cap 15 Add brake fluid to the master cylinder reservoir until the fluid level is about 1 8 inch 3 2 mm from the top 16 Note that the angular shape of the master cylinder cover makes one side thicker than the other Install the cover with gasket on the master cylinder reservoir so that the thicker side is positioned above the brake line fitting Install two Phillips screws to fasten the co
9. ver to the reservoir Tighten the screws to 6 8 in Ibs 0 7 0 9 Nm 17 With the Ignition Light Key Switch turned to IGNITION actuate the front brake hand lever to verify operation of the brake lamp J04324 IWIN NIN 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 18 Test ride the motorcycle If the brake feels spongy repeat the bleeding procedure NOTE The sight glass enables the rider to visually check the brake fluid level without removing the master cylinder cover When the reservoir is full the sight glass is dark As the fluid level drops the glass lightens up to indicate this condition to the rider CLUTCH LEVER BRACKET REMOVAL 1 Stand motorcycle upright and level 2 See Figure 4 Loosen clutch adjuster so clutch cable is fully slack by performing the following a Slide rubber boot 1 off cable adjuster b Holding cable adjuster 2 with 1 2 inch wrench loosen jam nut 3 using a 9 16 inch wrench c Back jam nut 3 away and turn cable adjuster 2 toward jam nut to introduce a large amount of free play at the clutch hand lever isO1266 Rubber boot Cable adjuster Jam nut 1 2 3 4 Cable end Figure 4 Loosen Clutch Adjuster 3 See Figure 6 Remove the clutch cable anchor pin D from the hand lever H To remove

chrome master cylinder kit - HARLEY

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