I'm swapping out bars on my 2007 NT and decided to have the levers/perches powdercoated while it was apart since the paint has seen better days.


I got the rebuild kit, put it in, pretty straight forward. I also got the new top cap PN 46423-05B. I'm waiting for my lines to come in from Magnum Shielding so I figured I'd mount everything up to save time later.


I put the new cap on and I notice it doesn't sit down over the top lip of the resivoir like the old one does leaving the cast visible where the guy masked off when prepping the MC. I could care less about the small section that's not powdercoated, I'm more concerned about this thing pissing all over the place once I fill it and start riding.


I've searched the the forums looking for an answer but no one mentioned the fitment of the new improved MC cover kit. Looking at it from the bottom there doesn't seem that there is a recessed channel that the lip of the resivoir sits into. I'm heading to the HD shop after work, just thought I'd put my feelers out there in the meantime.


Thanks in advance.

 

You might have some how bought the wrong part dude. HD did recently redesign the rubber seal on those from MC caps.

My bike is an 08 and the redesigned cap fit just fine. Maybe they are not meant to be used on 07 models ?

 

My 2 cents. The cap doesn't sit on the reservoir. It sits on the gasket. The gasket prevents metal to metal contact.

 

Sorry for the derail, but...

Trying to rebuild the MC on a 98 Road King, which should be the same, just a little larger bore. How the **** did you get that last seal in over the plunger? It's giving me freakin' fits. Got the spring in, the plunger with the wiper and o-ring, then the plunger, but that stinkin' last seal... nope.

 

Make sure you coat the inside of the bore and the surface where the last seal thoroughly with the provided lube. Also be sure to coat all the seals on the piston assembly before you slide it into the bore. Once it's on place use something flat, I used a small Allen wrench, and just worked my way around the seal carefully pushing it into place. The lube really helped. Once the larger diameter part of the last seal was pushed in past the lip, it was all good.

 

Thanks. Do NOT know what I was doing differently the other day, as that's what I tried to do. After I read your comment, I went back down to the garage to give it a shot again with a lot less frustration and distraction, and 15 seconds later, it was done. Fill it, bleed it, and I'll be back on the road tomorrow.

 

Great, glad to hear it all worked out.


As for the replacement cap assembly, I stopped by the HD dealer after work. They didn't have another in stock but I did find a used bike on the floor with the replacement style cap; looks just like mine does and there appear to be no leaks. My cables ship out this morning, should be back on the road by the end of the week.