Filed Under (Harley Davidson) by admin on 24-03-2011

REMOVAL 1. See Figure 1. Remove the cotter pin (5) and washer (E) from the master cylinder clevis pin (B). Discard the cotter pin. NOTE The clevis pin has a slight interference fit. It may be necessary to use pliers to pull the clevis pin from the push rod. Be careful not to damage mating parts. 2. Remove the clevis pin (B) from the brake rod. Thoroughly clean and examine parts for wear. Replace if necessary. 3. Remove the brake lever mounting screw (A) and flat washer (D), and save for reinstallation, if necessary. Remove and discard the outer O-ring (2). 4. Remove the brake lever by rotating counter-clockwise and lifting the master-cylinder clevis if necessary. Pull the lever from the shaft. Remove and discard the inner O-ring. 5. Thoroughly clean the lever mounting shaft of grease and dirt. INSTALLATION NOTE These levers are equipped with self-lubricating bushings. It is not necessary to lubricate the mounting shaft or bushings inside the lever prior to installation. 1. See Figure 1. Insert the new O-rings (4) on either side of the lever bushings (2). Install the new brake lever (1) onto the mounting shaft. NOTE There is insufficient clearance to install the clevis pin from the outside, so it must be installed from the inboard side of the brake lever. 2. Align the holes in the lever and brake rod and insert the stock clevis pin (B) from the inboard side. 3. Install the small flat washer (E) onto the clevis pin and insert the new cotter pin (5). 4. Place the large flat washer (D) onto the brake lever mounting screw (A). Apply Loctite 243 (blue) to the threads of the screw, and reinstall into the brake lever mounting shaft. Tighten the screw to 12-16 ft-lbs (16.3-21.7 Nm) . 5. Install the brake pedal pad (C) to the brake lever. 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) 6. Check the brake lever for proper operation and clearance through its full travel