Removal
Inspect the clutch fluid line for wear, damage, and leaks. Replace if necessary.
1. Remove secondary clutch actuator cover from left side clutch cover.
Warning! Be sure NO clutch fluid gets on rear tire, wheel or brakes when draining clutch fluid. Traction will be adversely affected which could result in loss of control of the motorcycle and death or serious injury.
2. Place a suitable container under secondary clutch actuator. Loosen flare nut and allow clutch fluid to drain from clutch line.
Important note. Dispose of clutch fluid in accordance with local regulations.
3. Remove banjo bolt and two steel/rubber washers to disconnect fitting of hydraulic clutch fluid line from clutch reservoir and master cylinder. Discard washers.
4. See Figure 2-35. Remove clutch fluid line from clips on frame.
![](https://motoinstruction.ru/img/harley/2/111320.jpg)
Figure 2-35. Clutch fluid line clips
5. Carefully thread banjo fitting end of clutch line out through upper triple clamp. Thread flare nut end of clutch line out through bottom of motorcycle and remove clutch line through front down tubes.
Installation
1. Route clutch line banjo fitting up through upper triple clamp, then route line behind steering head over to right frame rail and along inside of rail under engine and back up between bottom frame rails to loop out and forward to secondary clutch actuator mounted on clutch cover.
2. Thread in and finger tighten flare nut fastening clutch fluid line to secondary clutch actuator.
3. Attach banjo fitting of the clutch fluid line to master cylinder with new steel/rubber washers.
4. Replace all clutch line clips in corresponding locations along frame.
Warning! Be sure NO clutch fluid gets on rear tire, wheel or brakes when adding clutch fluid. Traction will be adversely affected which could result in loss of control of the motorcycle and death or serious injury.
Warning! Do NOT allow foreign matter to enter the clutch master cylinder reservoir. Dirt or debris in the reservoir may cause improper operation of the clutch and equipment damage.
Warning! Direct contact of DOT 5 SILICONE BRAKE FLUID with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and seek medical attention immediately. Swallowing large amounts of DOT 5 SILICONE BRAKE Fluid may cause digestive discomfort. If swallowed, seek medical attention immediately. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
5. Remove secondary clutch actuator cover and loosen bleeder screw.
6. Fill reservoir with DOT 5 SILICONE BRAKE FLUID. Allow fluid to fill clutch line until a steady flow of clutch fluid flows from bleeder screw. Finger tighten bleed screw.
Note. A Snap-on BASIC VACUUM BRAKE BLEEDER with a fitting that mates to the bleed screw threads can be used to draw the fluid down the clutch line.
7. Bleed clutch line. See 1.13 Bleeding clutch fluid line.
8. Verify that fluid level in clutch fluid reservoir is at FILL LEVEL with motorcycle upright.
Note. Clutch fluid volume increases with clutch wear. Do not overfill clutch reservoir.
9. Test pressure by squeezing clutch hand lever.
10. Tighten fasteners as follows:
- a. Banjo bolt (6) to 23-31 Nm (17-23 ft-lbs).
- b. Clutch line flare nut to 9-13 Nm (80-115 in-lbs).
- c. Bleeder screw to 9-11 Nm (80-100 in-lbs).
- d. Reservoir cover screws to 0.7-0.9 Nm (6-8 in-lbs).
- e. Secondary clutch actuator cover mounting bolts to 6-10 Nm (53-89 in-lbs).
11. Test ride motorcycle.