-J02326 REV. 2005-09-09
46114-02, 46157-03, 46161-04
These kits are designed for installation on 2002 and later VRSC
(V-Rod ® ) model motorcycles and other models equipped with a Hydraulic Clutch Kit.
See Figure 5 and Table 1.
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) made of hard, brittle plastic, and the bowed area connecting the bushing cups can easily break.
3.
Note the orientation of the bowed portion of the bushing cups. Using a small screwdriver (such as a jewelers screwdriver), remove the roller and roller bushings by gently prying them out of the lever. Save the roller and roller bushing cups for reinstallation.
4.
Obtain the new clutch lever from the kit.
NOTE
When performing the following step, the bowed portion connecting the bushing cups must be positioned away from the
mounting bracket as shown in Figure 2. Each of the bushing
cups have 2 tabs that cleanly snap into place when the assembly is pushed into the lever groove, but only if the bowed portion is positioned correctly.
5.
Carefully install the bushing cups to the pins on the ends of the roller.
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1
1
2
2
3
1.
Clutch lever
2.
Retaining ring
3.
Pivot pin
Figure 1. Clutch Lever Retaining Ring and Pivot Pin
1.
See Figure 1. Remove the retaining ring from the groove
in the clutch pivot pin, and set it aside for later installation.
2.
Remove the pivot pin by sliding it out from the top. It may be necessary to gently pry the pivot pin up and out to remove. Save the pivot pin for re-installation.
NOTE
When performing the following steps, be extremely careful when handling the roller bushing cups. The bushings cups are
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3
1.
Roller
2.
Bushing Cup Bow Orientation
3.
Clutch lever
Figure 2. Clutch Lever Roller and Bushings
6.
See Figure 2. With the bowed portion of the bushing cups
facing away from the mounting bracket, snap the roller
(with cups installed) into the clutch lever mounting groove.
If positioned correctly, the roller and bushing cup assembly will install with a definitive snap and will be held securely.
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1
2
1.
Clutch Lever Aligned with Lever Bracket
2.
Groove in Pivot Pin
Figure 3. Install Chrome Clutch Lever
NOTE
When performing the following step, it may be necessary to apply a little force to the hydraulic piston (in the lever mount) in order to align the lever and allow the pivot pin to be inserted.
7.
See Figure 3. Orient the clutch lever in the lever mounting
bracket, and align the pivot pin hole with the lever bracket holes. Install the pivot pin from the top and tap into place.
8.
Obtain the retaining ring removed in Step 1 and install to the groove in the pivot pin.
9.
Operate the clutch lever and check for proper operation.
Figure 4. 5/32 in. (4 mm) Cardboard Insert
1.
See Figure 4. Squeeze the brake lever and place the
cardboard insert between the brake lever and lever bracket.
NOTE
Use the eyelet of an ordinary cable strap if the cardboard insert is not available.
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)
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
When performing the following steps, note that the procedures for removing and installing the retaining ring and pivot pin are identical to those for the clutch lever.
2.
See Figure 1. Remove the retaining ring from the groove
in the brake lever pivot pin, and set it aside for later installation.
3.
Remove the pivot pin by sliding out from the top. It may be necessary to gently pry the pivot pin up and out to remove. Save the pivot pin for re-installation. Remove and discard the brake lever.
NOTE
When performing the following step, it may be necessary to apply a little force to the hydraulic piston (in the lever mount) in order to align the lever and allow the pivot pin to be inserted.
4.
Refer to Figure 3. Obtain the new brake lever from the kit.
Orient the new brake lever in the lever mounting bracket and align the pivot pin hole with the lever bracket holes.
Install the pivot pin from the top and tap into place.
5.
Obtain the retaining ring removed in Step 2 and install to the groove in the pivot pin.
6.
Operate the brake lever and check for proper operation.
7.
With the ignition/light key switch turned to IGNITION, actuate the front brake hand lever to verify operation of the brake lamp.
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A
C
2
5
7
6
C
4
1
B
Figure 5. Service Parts: Hand Control Lever Kits
Table 1. Service Parts Table
Item
1
2
3
Description (Quantity)
Lever assembly, front brake control (includes item 2)
For Kit 46114-02 (Chrome)
For Kit 46157-03 (Black)
For Kit 46161-04 (Buckshot)
Bushing, brake lever pivot pin
Lever assembly, clutch control (includes items 4 through 7)
For Kit 46114-02 (Chrome)
For Kit 46157-03 (Black)
For Kit 46161-04 (Buckshot)
Bushing, clutch lever pivot pin 4
5
6
Bushing and roller kit
Roller
7 Bushing, roller
Items mentioned in text, but not included in kit:
A Press Piston Cap forward
B
C
Stock retaining ring
Stock pivot pin
B
3
Part Number
45076-96
45995-00
46217-03
45423-96
46115-02
45388-03
46158-04
45423-92
46246-01
Not Sold Separately
Not Sold Separately
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