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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #11  
Old 25th July 2021
Andy56 Andy56 is offline
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Quote:
Originally Posted by Folkie View Post
The original screws are Harley part no 3658.
You are assuming the screw was lost from the switch housing and not the lever housing. The OP didn't tell us.
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  #12  
Old 25th July 2021
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You're right; I'm assuming he means the screws for the switch housing. I thought that's what he meant by 'hand control cluster'.
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  #13  
Old 25th July 2021
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And you could be correct.

Irrespective it is vital that the driver be inserted fully before attempting to do up or undo whichever fastener type you go for.

I mentioned before I have seen plenty of hex head cap screws rounded out. Probably more so by using cheap drivers that are not quite the right size.
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  #14  
Old 25th July 2021
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As for the brake and clutch lever perch clamp screws:

On 2004-5 they're:
# 4262: Screw, M6 X 1mm X 22mm
.
(no washer)
On 2006 onwards:
# 4535M: Screw, M6 X 1mm X 25* torx button head
.
# 6101: Washer, 27/64" X 17/64" X 1/16"
.
Kit # 42425-05 includes 2 × # 4535M and 2 × # 6101.
Edit:

*: Harley say it's T25, but it's actually T27!

Last edited by Folkie; 25th July 2021 at 15:27.. Reason: Corrected incorrect info from Harley
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  #15  
Old 25th July 2021
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Quote:
Originally Posted by Andy56 View Post
#42425-05 is the larger size and is T27.
Quote:
Originally Posted by Folkie View Post
# 4535M: Screw, M6 X 1mm X 25 torx button head
(# 4535M is the screw that is {supposedly?} in kit # 42425-05)

Hmmm, what gives?

Well, it seems that although the Harley Parts Catalogs (2006-9) say T25, it's actually a T27!
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  #16  
Old 26th July 2021
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  #17  
Old 26th July 2021
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Quote:
Originally Posted by Andy56 View Post
You are assuming the screw was lost from the switch housing and not the lever housing. The OP didn't tell us.
Hi Yes, thank I should have been more clear. It is the switch housing screws that I meant.

I got back from Lowes a couple days ago with the right Allen head screws and we are all good now. I kept a couple of spares in the tool box too.

Thanks, Slick
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