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[1abastarsmda]

These parts came out of the inside of my clutch lever today.  How?  I noticed the pin starting to come out today and one friend was trying to fit a retaining ring to it when another friend said "Let's pull the pin out" and did it before I could react and stop him.  Anyway, putting it back together these are the pieces that didn't survive.  The curved piece was attached to the little rolling pin like piece that appears to act as a plunger to pressurize the clutch hose.  I don't know if it's supposed to limit it's turn or what it does.  The other small black plastic piece looks like it broke off with part of it probably still remaining inside there somewhere.  There's a hole in the center of it, so I assume it fits onto some sort of rod in there that controls something.

At first, I thought that maybe it was what controls shutting down the cruise control by pulling in the clutch, but that still works.  I can't find anything yet that doesn't work properly.  The clutch itself seems to work fine.  Does anybody know what these are and if I am looking forward to problems coming soon.  Sorry, but this is the best I could get with photos. That piece is pretty small.

[Chains]

Here is the parts breakdown drawing.

[HDGearHead]

that doesn't look like the correct parts drawing for a 2012 FLHTCUSE7.  See the following online micro fiche instead:

http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?Type=13&make=hdmc&a=886&b=22&c=0&d=-CLUTCH-LEVER-ASSEMBLY

[1abastarsmda]

I already looked at this and piece #22 is what the one piece looks like that the little McDonald's like arch broke off of.  Nothing else looks remotely like the setup on my 2012 FLHTCUSE7.  The exploded page that I looked at before was the one for my bike and I still can't figure how either piece functions, much less which pieces they actually are.  I did figure that they are both part of the lever assembly and not available as separate pieces.  That much I could tell from the page for my bike.

[Twolanerider]

Dave, my best guess it's part of the bushing and roller.  I think it's the little plastic two ended wire tie type thingie (forgive the overly technical description there) that helps guide and hold the little roller.  Just checked and it's a kit part number of 46246-01 if that's it.  $18 for a pair of tiny little parts.  See if this parts breakdown looks right (check part # 19)

[1abastarsmda]

that doesn't look like the correct parts drawing for a 2012 FLHTCUSE7.  See the following online micro fiche instead:

http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?Type=13&make=hdmc&a=886&b=22&c=0&d=-CLUTCH-LEVER-ASSEMBLY

That 's the one I looked at and the one part I can identify on there, but it doesn't show the arch on it.  The other is still a mystery and I still don't know what they do.

[1abastarsmda]

My guess is that you are correct.  On the page I looked at before, part #19 wasn't available separately.  Thanks.  I'd still like to know if I'm going to have a problem with it the way it is, but I think I'll order that and hopefully that will be what I need.  Thanks again.

[1abastarsmda]

Twolane...where is that exploded view from?  The two others I looked at didn't have that part listed separately.  Thanks Don.

[Twolanerider]

My guess is that you are correct.  On the page I looked at before, part #19 wasn't available separately.  Thanks.  I'd still like to know if I'm going to have a problem with it the way it is, but I think I'll order that and hopefully that will be what I need.  Thanks again.

The older bikes with the prior clutch master cylinder used the same roller and plastic thingie.  Have messed with a couple that had the plastic thingie break but on neither did the roller come out.  It's been long enough that I've dealt with a broken one that I can't remember if I was concerned or not that it might come out (since I can't remember it being a worry it probably wasn't).  But I do know of two that ran for awhile with that broke and they never gave a problem.

[1abastarsmda]

The older bikes with the prior clutch master cylinder used the same roller and plastic thingie.  Have messed with a couple that had the plastic thingie break but on neither did the roller come out.  It's been long enough that I've dealt with a broken one that I can't remember if I was concerned or not that it might come out (since I can't remember it being a worry it probably wasn't).  But I do know of two that ran for awhile with that broke and they never gave a problem.

Thanks.  It's working for now and I guess I have all winter to put it back together the right way.  Today may have been the last of the good riding days in these parts.

[Twolanerider]

Twolane...where is that exploded view from?  The two others I looked at didn't have that part listed separately.  Thanks Don.

You have to be pickie about the years you choose to view the breakdowns from.  At time of publication for different models Mother Harley was changing her mind on what was serviceable and to what extent.  So some years the master cylinders are shown broken down with service parts and in some years they're not.  Same with the clutch lever. 

From messing with one before I remembered that roller and plastic thingie was the same all the way back to 2001.  But on yours if you check the parts manuals for a bike one year newer than yours you'll find the breakdown I posted with the extra part numbers.  So a year later than yours Mother Harley decided to sell it all differently again... (oy vey).

[1abastarsmda]

You have to be pickie about the years you choose to view the breakdowns from.  At time of publication for different models Mother Harley was changing her mind on what was serviceable and to what extent.  So some years the master cylinders are shown broken down with service parts and in some years they're not.  Same with the clutch lever. 

From messing with one before I remembered that roller and plastic thingie was the same all the way back to 2001.  But on yours if you check the parts manuals for a bike one year newer than yours you'll find the breakdown I posted with the extra part numbers.  So a year later than yours Mother Harley decided to sell it all differently again... (oy vey).

I see that now.  They show it as serviceable in 2013 but not 2012.  That helps.  I'll get it ordered.

[Chains]

Thanks Don. Now I know why I couldn't find the part. Man your right there are a ton of parts drawings out there.

[Classic Beast]

It looks like a broken tyrap to me but maybe if the photo was a bit more of a close up.

[grc]

You guys are causing me to become confused again.  The roller is supposed to contact the plunger rod of the master cylinder, and similar to how a roller rocker arm works it should reduce side loading of the rod as the lever is functioned as well as protect the rubber grommet that seals the end of the plunger to the actual master cylinder casting.  If the roller falls out, I would expect a big enough difference in feel and actual operation to be quite noticeable since there is nothing to press on the plunger once the roller falls out except the metal that holds the roller.  That would add extra play in the system, and would probably tear up the rubber grommet in no time.  If I read the first post correctly, you're saying the clutch still works without the roller?  I'm not sure how that could be, but there again I've never tried it.  Or is the roller still in there and just the little bushings that are attached by the "springy looking" plastic strap are missing?  Anywho, I'd suggest inspecting the rubber grommet carefully for damage. 

Jerry

[MrSurly]

grc posted exactly what I was going to post. I also don't understand how there's no noticeable change in feel or effort.

and a secondary point: Those friends of yours...keep them AWAY from your bike!

[Twolanerider]

You guys are causing me to become confused again.  The roller is supposed to contact the plunger rod of the master cylinder, and similar to how a roller rocker arm works it should reduce side loading of the rod as the lever is functioned as well as protect the rubber grommet that seals the end of the plunger to the actual master cylinder casting.  If the roller falls out, I would expect a big enough difference in feel and actual operation to be quite noticeable since there is nothing to press on the plunger once the roller falls out except the metal that holds the roller.  That would add extra play in the system, and would probably tear up the rubber grommet in no time.  If I read the first post correctly, you're saying the clutch still works without the roller?  I'm not sure how that could be, but there again I've never tried it.  Or is the roller still in there and just the little bushings that are attached by the "springy looking" plastic strap are missing?  Anywho, I'd suggest inspecting the rubber grommet carefully for damage. 

Jerry

Jerry, the couple of times I've dealt with this the roller stayed in place after the plastic broke.  It is my (admittedly vague) recollection that the plastic piece was there more for assistance in assembly?  Could definitely be mistaken there as it's been years since I had reason to deal with that issue and even then it wasn't a pressing problem.  The roller did stay in place after breakage of the plastic though.  Twice in my experience.  That much I am sure of.

[grc]

Jerry, the couple of times I've dealt with this the roller stayed in place after the plastic broke.  It is my (admittedly vague) recollection that the plastic piece was there more for assistance in assembly?  Could definitely be mistaken there as it's been years since I had reason to deal with that issue and even then it wasn't a pressing problem.  The roller did stay in place after breakage of the plastic though.  Twice in my experience.  That much I am sure of.

I think you're right Don, the little strap is probably superfluous once the two bushings attached to it are installed on the roller and inserted into the lever.  That photo that was posted wasn't clear enough to be able to tell if the piece over to the right was one of the bushings or not, but if the bushing is broken or missing it would be a very good idea to replace the bushings and roller soon, IMHO.

Jerry

[1abastarsmda]

yes the roller is still in there but the other pieces are what's broken out.