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. This could result in loss of control of the motorcycle and death or serious injury.
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.
Note. When filling an empty clutch fluid line, a Snap-on BASIC VACUUM BRAKE BLEEDER with a fitting that mates to the secondary clutch actuator bleeder screw threads can be used to initially draw the fluid down the clutch line.
1. Stand motorcycle upright and square handlebars to level clutch reservoir. Remove reservoir cover.
Caution! Clutch fluid volume actually increases with clutch wear. Do not overfill reservoir.
2. If necessary, add DOT 5 SILICONE BRAKE FLUID, (HD-99902-77) to master cylinder reservoir. Initial fluid level should not exceed FILL LEVEL.
Caution! Loosen banjo bolt only enough to allow air bubbles to escape. Clutch fluid under pressure can squirt a steady stream several feet.
3. While holding reservoir cover in place:
- a. Pump clutch hand lever 5 times.
- b. Hold clutch hand lever against handlebar.
- c. Hold shop towel under fitting and loosen banjo bolt.
- d. Watch banjo fitting for air bubbles.
- e. Retighten banjo fitting.
- f. Release hand lever.
4. Fill reservoir to FILL LEVEL and repeat the previous step three times or more until only a steady flow of clutch fluid escapes banjo fitting and fluid level in reservoir is at FILL LEVEL with motorcycle in an upright position.
5. Remove secondary clutch actuator cover.
Figure 1-35. Secondary clutch actuator bleed screw
6. Cover exhaust with towel and place a suitable pan under right side case to catch excess clutch fluid.
7. While holding reservoir cover in place:
- a. Pump clutch hand lever 5 times.
- b. Hold clutch hand lever against handlebar.
- c. Loosen secondary clutch actuator bleed screw.
- d. Watch bleed screw for air bubbles.
- e. Tighten bleeder screw.
- f. Release hand lever.
8. Fill reservoir to FILL LEVEL and repeat the previous step three times or more until only a steady flow of clutch fluid escapes bleeder screw and fluid level in reservoir is at FILL LEVEL with motorcycle in an upright position.
Caution! Clutch fluid volume actually increases with clutch wear. Do not overfill reservoir.
9. Test pressure by squeezing clutch hand lever.
Note. If continued repetition of procedure does not build pressure in line and maintain FILL LEVEL, there is a leak in the clutch system. If the leak is not visible, remove and check the secondary clutch actuator boot for leakage.
10. Tighten fasteners as follows:
- a. Reservoir banjo bolt to 23-31 Nm (17-23 ft-lbs).
- b. Reservoir cover screws to 0.7-0.9 Nm (6-8 in-lbs).
- c. Bleed screw to 9-11 Nm (80-100 in-lbs).
- d. Secondary clutch actuator cover fasteners to 6-10 Nm (53-89 in-lbs).
11. Test ride motorcycle. Incorrect pressure can cause:
- a. Dragging clutch.
- b. Hard shifting.