Harley Davidson Softail 2000-2005. Service manual - page 41
8. Remove the banjo bolt and washers securing the clutch
hose to the master cylinder. Plug the clutch hose to pre-
vent brake fluid from dripping out.
9. Plug the bolt opening in the master cylinder to prevent
leakage and entry of debris.
10. On the left side frame down tube, remove the bracket
securing the clutch hose to the frame.
11. Remove the clutch hose from the frame and out from
behind the voltage regulator/rectifier and from the eyelet
on the right side of the crankcase behind the rear brake
master cylinder.
12. Install the
new
clutch hose through the frame follow-
ing the same path noted during removal.
13. Secure the clutch hose to the master cylinder with the
banjo bolt and two
new
washers on each side of the clutch
hose. Tighten the banjo bolt to 17-22 ft.-lb. (23-31 N•m).
14. Install a
new
O-ring (Figure 44) onto the end of the
clutch hose.
15. Connect the clutch hose (B, Figure 43) onto the
cover. Thread the flare nut all the way into the cover by
hand until it bottoms. Do not cross-thread it and tighten to
80-115 in.-lb. (9-13 N•m). Do not scratch the cover.
16. Bleed the clutch as described under
Clutch System
Bleeding
in this Supplement.
17. Test ride the motorcycle to ensure the clutch is oper-
ating correctly.
CLUTCH SYSTEM FLUSHING
(FXSTDSE2 AND FLSTFSE MODELS)
When flushing the clutch system, use DOT 5 brake
fluid as a flushing fluid. Flushing consists of pulling new
brake fluid through the clutch system until the new fluid
appears at the release cover bleed valve without the pres-
ence of any air bubbles. To flush the clutch system, follow
one of the bleeding procedures described under
Clutch
System Bleeding
in this Supplement.
CLUTCH SYSTEM BLEEDING
(FXSTDSE2 AND FLSTFSE MODELS)
Brake Bleeder Process
This procedure uses the Mityvac hydraulic brake bleed-
ing kit (Figure 47) that is available from automotive or
motorcycle supply stores.
1. Remove the dust cap from the bleed valve (C, Figure
43) on the release cover.
2. Place a clean shop cloth over the exhaust pipe and
frame to protect it from accidental brake fluid spills.
3. Assemble the Mityvac tool according to its manufac-
turer’s instructions. Secure it to the bleed valve.
4. Open the bleed screw approximately a half turn.
5. Clean the top of the master cylinder of all debris.
6. Turn the handlebars to level the clutch master cylinder
and remove the screws, reservoir cover and diaphragm.
7. Fill the reservoir almost to the top with DOT 5 brake
fluid and reinstall the diaphragm and cover. Leave the
cover in place during this procedure to prevent entry of
debris.
8. Operate the pump several times to create a vacuum in
the line. Brake fluid will quickly draw from the release
cylinder into the pump’s reservoir. Tighten the release cyl-
inder bleed valve before the fluid stops flowing through
the hose. To prevent air from being drawn through the
master cylinder, add fluid to maintain its level at the top of
the reservoir.
NOTE
Do not allow the master cylinder reservoir
to empty during the bleeding operation or
more air will enter the system. If this occurs,
the procedure must be repeated.
9. Continue the bleeding process until the fluid drawn
from the release cylinder is bubble free. If bubbles are
withdrawn with the brake fluid, more air is trapped in the
line. Repeat Step 8, making sure to refill the master cylin-
der to prevent air from being drawn into the system.
10. When the brake fluid is free of bubbles, tighten the
bleed valve and remove the brake bleeder assembly. Rein-
stall the bleed valve dust cap.
11. If necessary, add fluid to correct the level in the mas-
ter cylinder reservoir. When topping off the clutch master
cylinder, turn the handlebar until the reservoir is level;
add fluid until it is level with the reservoir gasket surface.
The fluid level in the rear master cylinder must be slightly
below the upper gasket surface.
12. Reinstall the reservoir diaphragm and cover. Install
the screws and tighten securely.
2004-2005 MODEL SERVICE INFORMATION
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