Dyna Rider Footboard Kit Instruction Sheet - Harley
Contents
1. clamps could scrape the paint on the brake rod 9 Coat the pivot shaft 12 with a light coating of lubricant Install the brake pedal 11 to the front footboard support 8 with long TORX screw 5 foot brake lever cap 6 pivot shaft 12 clevis pin 9 and circular cotter 10 10 With a wrench on the master cylinder piston flats turn the piston onto the brake rod until the brake pedal is elevated to an effective rider angle using at least half the threads available on the brake rod Tighten the jam nut against the master cylinder piston 11 Install brake pedal pad 13 Verify brake pedal and rod travel through entire range of motion without binding or interference 12 Place the footboard into position between brackets and install shoulder bolts 3 so that the flange locknuts 7 will be on the inboard side 13 Install flange locknuts onto shoulder bolts and tighten to 60 80 in lbs 6 8 9 0 Nm After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 14 Return the motorcycle to service a Refer to service manual and install main fuse b Test lights and brakes If the brakes feel spongy bleed the system 2 of 6 J05615 SERVICE PARTS 3 2 5 C 9 8 4 B 7 1 6 6 A 6 is03209a Figure 3 Primary Chaincase Cover and Housi2. J05615 REV 2012 05 04 DYNA RIDER FOOTBOARD KIT GENERAL Kit Number 50500247 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Separate purchase of LOCTITE 243 Threadlocker and Sealant Blue Harley Davidson Part Number 99642 97 is required for proper installation of this kit LOCTITE can be purchased from any Harley Davidson Dealer The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 3 Figure 4 Figure 5 and Table Reference INSTALLATION Shifter Assembly 1 See service manual and disconnect main fuse 2 See service manual and remove the left side rider footrest assembly Discard the footrest and fasteners 3 See Figure 4 Remove plugs from forward frame footboard mount E and discard plugs 4 See Figure 4 Remove the foot shifter lever A and shifter peg D Save the
3. askets from the kit 1 4 3 2 is02085 1 Primary cover 2 Shifter shaft hole original position 3 Loctite 243 area X 4 Primary hole plug Figure 2 Outer Cover Plug Installation 17 See Figure 4 Install footboards 14 to brackets 4 and 5 using shoulder bolts 1 and flange nuts 3 Tighten screws to 15 20 ft lbs 20 27 Nm Rear Brake and Footboard Assemblies NOTE It may be helpful to remove the exhaust to access the rear brake components Refer to the service manual for the exhaust removal 1 See Figure 5 and service manual Remove the right side rider footrest fasteners Discard the fasteners 2 Loosen the brake rod jam nut 15 at the rear brake master cylinder NOTE The master cylinder piston has flats for a wrench Turn the flats on the piston to unscrew the brake rod from the master cylinder 3 Unscrew the master cylinder piston from the stock brake rod 4 Remove and discard the stock brake rod footrest and brake pedal assembly 5 Remove the rear bracket footrest hole plugs and discard 6 Fasten the new front 8 and rear 16 footboard supports to the frame using TORX screws 2 Tighten screws to 32 37 ft lbs 43 50 Nm 7 Install the jamnut 15 all the way onto the new brake rod 14 8 Fasten the brake rod to the master cylinder piston NOTE When installing the brake rod make sure that brake rod does not have any interference from the clamps on the exhaust The
4. foot shifter lever and shifter peg and hardware for future installation 5 See Figure 3 See service manual and remove the outer cover assembly A and inner cover assembly B 6 See Figure 1 Before removing the gear shifter lever 1 a Using a marking tool draw a location marking 4 on the end of the splined shaft 2 across from the casting split 3 This will allow the new gear shifter lever to be installed in the same orientation as the old lever b After marking the gear shifter lever orientation loosen the lever bolt 5 and remove the gear shifter lever 1 c Discard the gear shifter lever and lever bolt d See Figure 4 From the kit install the new gear shifter lever 11 and bolt 12 onto the splined shaft in the same orientation as the old shifter lever e See Figure 1 Tighten the lever bolt 5 to 18 22 ft lbs 24 4 29 8 Nm 7 See Figure 4 Install the front and rear footrest brackets 4 and 5 to the frame using the buttonhead TORX screws 2 Tighten screws to 25 35 ft lbs 33 9 47 5 Nm 5 3 4 1 2 is02083 1 Gear shifter lever 2 Splined shaft 3 Casting split 4 Location marking 5 Lever bolt Figure 1 Gear Shifter Lever Orientation 1 of 6 J05615 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Please dispose of materials responsibly 8 See Figure 4 Install the front inner gear shifter 7 and was
5. her 6 to inside of the front footboard bracket 9 Install the previously saved gear shifter A with a coat of light lubricant Install washer B screw C and shifter peg D to the gear shifter Tighten screw C to 7 9 ft lbs 9 5 12 2 Nm 10 Using a small amount of Loctite 243 install the new shifter rod assembly 10 onto the gear shifter lever 11 Also install washer 9 and acorn nut 8 to inner gear shift assembly 7 Tighten acorn nut 8 and rear of shift linkage 10 to 8 12 ft lbs 10 8 16 3 Nm 11 Tighten rear gear shifter lever threaded swivel stud After all shifter components are installed move shifter through entire range of motion and check for interference with other components 12 See Figure 3 Put inner primary cover B and primary cover A in position and check for proper clearance with shifter linkage components 13 See Figure 2 Clean the area around primary cover 1 hole removing all dirt oil and grease Apply Loctite 243 around opening 2 Insert primary hole plug 4 into opening Remove any excess adhesive from surface Allow Loctite to cure for 24 hours before operating vehicle 14 Moisten four rubber anchors on bottom of new footboard pad with soapy water 15 See Figure 5 Place pad 1 into position on footboards 4 From bottom of footboards use pliers to pull rubber anchors through holes in footboards 16 See Figure 3 See service manual Install primary cover using new g
6. ng Components Table 1 Service Parts Table Part Number Description Quantity Item 90357 89 Hole plug 1 6943 Hole plug black 2 27444 00Y 0 ring 3 34934 06 Primary gasket crankcase housing 4 12052A Inner primary seal 5 Not Sold Separately Seal bolts 5 16 inch 5 6 63869 06 Tower gasket 7 60547 06 Primary cover gasket 8 Not Sold Separately Clutch cover seal 9 Items mentioned in text but not included in kit Primary cover A Inner primary cover assembly B Clutch cover C 3 of 6 J05615 D A B C E F 1 10 11 12 2 5 9 7 1 13 8 4 3 2 6 14 is07370 Figure 4 Dyna Rider Footboard Kit Table 2 Service Parts Table Part Number Description Quantity Item 10500023 Shoulder bolt 2 1 4512A Button head TORX screw 375 16 x 1 00 4 2 7354 Flange nut 2 3 54172 12 Right front footboard bracket 4 54173 12 Left rear footboard bracket 5 34625 90 Spring washer 6 33789 12 Inner gear shift lever assembly 7 7736 Acorn nut 8 6702 Plain washer type A 9 34887 06 Shift rod assembly 10 33900004 Gear shifter lever 11 856A Hex socket head cap screw lever bolt 12 50614 06 Footboard pad 13 50621 06 Footboard assembly with pad 14 4 of 6 J05615 Table 2 Service Parts Table Part Number Description Quantity Item Items mentioned in text but not included in kit Foot
7. shifter lever A Washer B Bolt C Shifter peg D Forward frame footboard mount E Rear frame footboard mount F 3 16 6 5 12 1 15 14 13 4 3 9 8 10 11 2 2 7 is07320 Figure 5 Dyna Rider Footboard Kit Table 3 Service Parts Table Part Number Description Quantity Item 50614 06 Footboard pad 1 4512A Button head TORX screw 375 16 x 1 00 4 2 10500023 Shoulder bolt 2 3 50621 06 Footboard assembly with pad 4 4997 Button head TORX screw 375 16 x 2 25 5 38160 12 Foot brake lever cap 6 7354 Flange nut 2 7 54172 12 Right front footboard support 8 42460 80B Clevis pin 9 51938 04 Cotter circular 10 38157 12 Rear brake pedal 11 42665 03 Pivot shaft 12 5 of 6 J05615 Table 3 Service Parts Table Part Number Description Quantity Item 42416 06 Brake pedal pad 13 Not Sold Separately Rear brake pushrod 14 7744 Hex jam nut 15 54165 12 Right rear footboard support 16 6 of 6 J05615
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