V-Twin Mfg. Hydraulic Clutch Kit VT Part No. 18-0673/18-0562
V-Twin Mfg. Hydraulic Clutch Kit VT Part No. 18-0673/18-0562
V-Twin Mfg. Hydraulic Clutch Kit VT Part No. 18-0673/18-0562
These kits fit 1999 through 2004 FL Touring models, 2000 through 2004 ST model motorcycles except FXSTB/I and FXSTD/I, and 2005 ST model motorcycles
except FXSTB/I, FXSTD/I, FLSTFSE, FLSTN/I and FLSTSC/I.
Installation Instructions:
1. Remove the left-side mirror and mounting hardware. Remove the left-side turn signal if mounted on the hand lever bracket. Save all parts for later
installation.
2. Remove the right-side saddlebag, if so equipped.
3. To access the transmission side cover assembly, remove the exhaust system as per your service manual.
4. Remove the magnetic drain plug at the bottom-right side of the oil pan, and drain the transmission lubricant into a suitable container.
5. Remove and retain the filler plug/dipstick (5) for later installation. Remove the six socket-head screws with washers (6) to free the transmission side
cover (1) from the transmission case. Retain two screws and discard the remaining four. See Figure 1.
NOTE: If the hollow locating pins stay in the cover when removed, install pins back into the bearing housing.
6. Actuate the clutch lever to break the cover seal. Remove the cover. Remove and discard the cover gasket (2).
7. Remove the clutch ramp retaining ring (8). Rotate the inner ramp (7) to a position that will allow the clutch coupling to be disconnected. Disconnect the
clutch coupling and disconnect the cable end from the coupling.
8. Unscrew the cable fitting from the transmission side cover. Remove the clutch cable and fitting, and discard the cover. Leave the clutch cable in place
at this point.
9. Remove the oil slinger (4) as an assembly from the transmission mainshaft. Discard the oil slinger.
NOTE: After the clutch cable has been disconnected at both ends, but before pulling the cable out, note the entire cable routing and the location of all cable
straps and "P"-clamps (if used). In many cases, you will be installing the new hydraulic fluid line the same way.
10. See Figure 2. Remove the retaining ring (9) from the clutch hand-lever pivot pin (4). Remove the pivot pin and clutch hand-lever (7) from the clutch-
lever bracket (3).
11. Remove the anchor pin (8) and the clutch-cable eyelet (2) from the clutch hand-lever. Remove any clamps retaining the clutch cable to the bike, and
remove the cable. Discard all components and hardware removed in this step.
12. Using a T27 TORX drive head, remove the two screws (6) with flat washers securing the handlebar clamp (5) to the clutch-lever bracket.
13. If necessary, remove the left-side passenger footpeg or footboard. See Figure 3. Using a T27 TORX drive head, remove the clutch-inspection (derby)
cover (8) from the primary chaincase (1).
14. Remove the clutch release plate retaining ring (4) and discard. Remove the release plate (3), adjuster rod (5) and nut (6) as an assembly, and discard.
15. Extract the pushrod (2) by pushing it through from the right (transmission side cover) side until it can be grasped through the clutch pressure plate
(10). Pull the pushrod out of the chaincase opening and discard it.
Final Assembly
1. Check the O-ring on the transmission drain plug removed earlier for tears, cuts or general deterioration, and replace if necessary.
2. Install the drain plug and torque to 14-21 ft-lbs.
3. Fill the transmission with the proper transmission lubricant.
4. Check the O-ring on the filler plug/dipstick removed from the old transmission side cover for tears, cuts or general deterioration, and replace if
necessary. Install the filler plug/ dipstick into the new transmission side cover assembly.
5. Re-install and tighten all exhaust-system components.
6. For ALL models: Install the left-side rear-view mirror and tighten the acorn nut to 12 ft-lbs. Check mirror adjustment and reposition if necessary.
7. Refer to the Service Manual, and follow instructions to connect the battery cables, positive cable first.
8. Follow the instructions in the Service Manual to install the seat.
9. If necessary, install the right-side saddlebag.
10. Test ride the motorcycle. If the clutch does not work properly, it may be necessary to re-bleed the clutch fluid line and re-measure the clutch-plate lift.
Item Description (Quantity)
1 Clutch master cylinder
Clutch lever/master cylinder assembly, chrome
1a Clutch reservoir assembly
1b Lever assembly Includes lever, pivot pin bushing, retaining ring, bushing, and roller
kit.
2 Clamp, handlebar control, chrome
3 Bolt, banjo
4 Gasket, brake line (2)
5 Gasket, transmission side cover
6 Screw, 1/4-20 x 1-3/4 inch (4)
7 Side cover assembly (includes items 8 through 10)
8 Cover, side
9 Bleeder screw
10 Cap, bleeder screw
11 Clutch line assembly (braided stainless steel w/chrome fittings)
12 P-clamp (2)
13 Screw, 1/4-20 x 3/8 inch (2)
14 Locknut, 1/4-20 (2)
15 Cable strap (6)
16 Release plate
17 Bearing
18 Pushrod service kit (includes items 19, 20 and 21)
19 Pushrod, clutch release
20 Retaining ring, internal, 2 inch
21 Retaining ring, internal, 3/8 inch
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