Transcript
-J05517
REV. 2012-04-20
VRSC MID-CONTROL KIT GENERAL
The rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)
Kit Number
2.
Remove muffler pipes. If necessary, remove auxiliary volume and the front and rear header pipes.
3.
Remove right rear engine mount and discard. Save hardware for later installation.
4.
Remove foot brake lever and discard.
5.
Remove master cylinder assembly. Discard master cylinder. Save hardware for later installation.
6.
Remove brake line and discard.
7.
Remove shifter rod and linkage and discard.
8.
Remove foot pegs and mounting hardware. Save hardware for later installation.
50700013
Models
INSTALLATION
For model fitment information, See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Right Side Footrest and Brake Control Installation 1.
See Figure 1. From the kit, install right rear engine mount (1) using screw (B) and washer (A) at top of engine mount. Tighten screw to 34-41 Nm (25-30 ft-lbs).
For Models without ABS Brakes: Rear Brake Line assembly (Part Number P/N 41968-07A), Rear master cylinder hose with conduit (Part Number 41669-06) and Loctite® 243 Threadlocker and Sealant-Blue (Part Number 99642-97).
2.
Insert footpeg (L) into clevis (5) and insert pivot pin (8) through spring (7) into clevis and install retaining ring (K).
3.
Install wear peg (M) to end of footpeg.
For Models with ABS Brake System: Rear Master Cylinderto-HCU Brake Line (Part Number 42268-08), HCU-to-Rear Caliper Brake Line (Part Number 42285-08A) and Loctite® 243 Threadlocker and Sealant-Blue (Part Number 99642-97).
4.
Install the master cylinder (2) to the right rear engine mount with two screws (F). Tighten screws to 58-66 Nm (42.748.6 ft-lbs).
5.
Install footrest and brake pedal as a unit. Position brake pedal (4) to motorcycle and insert master cylinder rod into brake pedal. Install master cylinder brake pedal washer and clip. Apply Loctite 243 (blue to screw (6) and tighten screw to 34-41 Nm (25-30 ft-lbs).
6.
Remove right side trim panel from radiator for access to reservoir assembly.
7.
Install front hose (E) with clamp (H) to reservoir assembly (I).
8.
Fasten the opposite end of hose (E) to the reservoir port and fasten with clamp (H).
REMOVE
9.
Install port to master cylinder.
Refer to the service manual for detailed information on the following generalized steps:
10. Run the hose from the reservoir through the two large clips on the bottom frame rail. Tie a cable strap in front of the first clip and another between the two clips. The hose should be rolled toward the inside of the frame rail.
Additional Parts Required
The rider's safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a)
Kit Contents See Figure 1, Figure 2, Figure 3 and the Service Parts tables.
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1.
11. Install the brake line assembly to the master cylinder with a gasket (9) on each side of the hose end. Install brake switch banjo bolt (3) through hose end into the master cylinder. Tighten bolt to 23.1-25.8 Nm (16.9-21.3 ft-lbs).
Remove main fuse.
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Many Harley-Davidson® Parts & Accessories are made of plastics and metals which can be recycled. Please dispose of materials responsibly.
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12. Position the rest of the rear brake line to clamp locations underneath the swing arm. Use the three small clips to route the electrical wire with the brake line. NOTE Older models have a post stem that use a special cable strap. Later models have a hole drilled into the downtube and use a push in christmas tree type fastener with cable strap. 13. Use clip (18) to fasten hydraulic clutch hose to post on rear engine mount. 14. Install the end of the brake line to the rear brake caliper. Be sure the brake lever does NOT contact the hydraulic clutch hose. Use a gasket (9) on each side of brake line bolt (G). Tighten bolt to 23.1-25.8 Nm (16.9-21.3 ft-lbs) NOTE It may be necessary to remove the cable straps and clamps securing the hydraulic clutch hose to the right side mid-frame down tube in order to allow the clutch hose to be routed through the clip (18). 15. Refer to the brake sections in your model year service manual for necessary brake maintenance.
FINAL ASSEMBLY
When any hydraulic brake component, line or connection is loosened or replaced on an ABS motorcycle, Digital Technician II must be used during the brake bleeding procedure to verify all air is removed from the system. Failure to properly bleed the brake system could adversely affect braking, which could result in death or serious injury. (00585c) 1.
Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a) 2.
16. Install the trim panel to the radiator. 17. See Figure 3. Install the exhaust system. Thread the screw clamps (S) into the slots of the rear heat shield (T). Thread the two clamps (S) into the lower heat shield (17). The lower heat shield will fit to the underside of the rear exhaust pipe near the bend. Tighten the clamps to the exhaust pipe.
Left Side Footrest and Control Installation 1.
2.
3.
See Figure 2. Install the left side rider foot mount (11). Apply Loctite® 243 (blue) to capscrews (14) and (16). Install screws and tighten to 30-35 Nm (22-26 ft-lbs). Align shifter (10) with rider foot mount (11). Apply Loctite® 243 to cap screw (15). Insert cap screw to foot mount/shifter linkage assembly. Tighten to 30-35 Nm (2226 ft-lbs). Insert footrest (L) into clevis (13). Insert spring (7) to clevis. Slide pin (8) into clevis assembly and secure with retaining ring (K).
4.
Install wear peg (M) to footrest (L).
5.
Install shift linkage (12) to shift lever (10) with buttonhead screws (N) and tighten to 11-16 Nm (8.1-11.8 ft-lbs).
6.
Apply Loctite® 243 to peg stud (O). Install toe peg (R) and screw to shift lever (10). Tighten screw to 9-15 Nm (7-11 ft-lbs).
7.
Install cap screw (Q) to transmission arm (P) and tighten to 14-16 Nm (10.3-11.8 ft-lbs).
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Fill and bleed the brake fluid in the rear brake reservoir and lines per the instructions in the service manual.
Verify proper operation of the master cylinder relief port. Slowly apply and release the rear brake foot pedal. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly.
RETURN TO SERVICE 1.
Verify that the shifter linkage is operating properly.
NOTE Verify that the ignition key switch is in the OFF position before installing the main fuse. 2.
Refer to the service manual and follow the instructions to install the main fuse.
Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b) 3.
Turn the ignition key switch to IGNITION, but do not start the motorcycle. Actuate the rear brake foot pedal to verify operation of the brake lamp.
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) 4.
Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure.
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SERVICE PARTS is07235b
A
1
B
18 4
9
G 2
C D
H
F
E H
9 6
3
I
5 8
K L 7
M
Figure 1. Service Parts: VRSC Mid-Control Kit (Right Side) Table 1. Service Parts Item
Description (Quantity)
Part Number
1
Bracket assembly, right rear engine mount
16300-06
2
Master cylinder assembly
44571-06B
3
Banjo bolt, rear brake switch
72025-06
4
Brake pedal, right rear assembly
42704-06
5
Clevis, right side rider footpeg
51089-06BK
6
Screw, hex socket cap
4470M
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Table 1. Service Parts Item
Description (Quantity)
Part Number
7
Spring, footpeg return (2)
45065-06
8
Pin, footpeg pivot (2)
45067-06
9
Gasket, brake line (4)
41751-06A
18
Clip, T-Stud
10116
Items mentioned in text, but not included in kit: A
Washer
B
Screw
C
Screw
D
Clip
E
Hose
F
Screw (2)
G
Bolt
H
Clamp
I
Reservoir port, master cylinder
K
Retaining ring
L
Foot rest
M
Wear peg
is07239
8
15 10
7 11 13
Q 16
K
L
P M 14
N 12
R N
O
Figure 2. Service Parts: VRSC Mid-Control Kit (Left Side)
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Table 2. Service Parts Item
Description (Quantity)
Part Number
10
Shifter lever assembly
34686-06
11
Bracket, left hand rider footpeg mount
51091-06BK
12
Shifter link
33785-06
13
Clevis, left hand rider footpeg
51097-06
14
Screw, socket head cap
4250M
15
Screw, socket head cap
4471M
16
Screw, socket head cap, M6 X 20 (2)
1009M
Items mentioned in text, but not included in kit: K
Retaining ring
L
Foot rest
M
Wear peg
N
Button head screw (2)
O
Peg stud
P
Transmission arm
Q
Screw
R
Toe peg
Table 3. Service Parts
is07237
Item
U
17
Description (Quantity) Heat shield, lower rear exhaust/stainless
Part Number 66820-06
Items mentioned in text, but not included in kit.
S
S
17
S
Clamps (4)
T
Rear heat shield
U
Rear exhaust pipe
T
Figure 3. Service Parts: VRSC Mid-Control Kit Heat Shield
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