Filed Under (Harley Davidson) by admin on 02-02-2011

INSTALLATION The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Dav- idson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) Brake Lever 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) NOTE Do not remove handlebar clamp or switch housing assembly to remove brake lever. 1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A). Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a) 2. Place a 4 mm (5/32-inch) thick insert between the brake lever and the lever bracket. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1. 3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar. 4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly. 5. Apply a small amount of GM-40M grease (H-D 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. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever

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