Sportster Forward Control Kit Instruction Sheet - Harley
Contents
1. 685 04 Assembly brake pedal black 42649 07 J04006 4of5 Table 1 Service Parts Table Item Description Quantity Part Number 9 Bracket right rider footpeg support chrome 42707 04 Bracket right rider footpeg support black 42652 04 10 Bracket left rider footpeg support chrome 42706 04 Bracket left rider footpeg support black 42651 04 11 Clevis footpeg right chrome 42566 04 Clevis footpeg right black 42504 07 12 Clevis footpeg left chrome 42541 04 Clevis footpeg left black 42503 07 13 Lever shift shaft arm chrome 34670 06 Lever shift shaft arm black 34614 07 14 Assembly shift lever chrome 34650 04 Assembly shift lever polished 34572 04 Assembly shift lever black 34636 07 15 Assembly brake rod 34581 04 Assembly brake rod black 42645 07 16 Assembly shift rod link 34573 04 Assembly shift rod link black 34577 07 17 Ring footpeg clevis pin retaining 2 11304 18 Ring footrest mount clevis retaining 2 11390 19 Wear peg 2 for XL883L and XL1200L Models only 33188 08 Items mentioned in text but not included in kit A Stock footrest B Stock J clip C Stock footrest XL883L Models only separate purchase for XL1200L Models J04006 5 of 52. acket and install screw 6 Tighten the screw to 18 22 ft lbs 24 4 29 9 Nm 4 Install the footrest mount clevis retaining ring 18 to the groove at the end of the footpeg clevis 5 Position the J clip from Step 1 against the frame aligning the mounting holes Mount the footrest brake pedal support bracket 9 and J clip to frame using the new screws 3 Tighten the bracket to 45 50 ft lbs 61 1 67 9 Nm 6 Obtain the brake rod 15 from kit and thread one end into the master cylinder bell crank Tighten to 120 180 in Ibs 13 6 20 3 Nm WARNING Footrests must fold up and toward rear of motorcycle if struck Failure to set footrests to fold up and back could result in death or serious injury 00366a 7 For All Models Install footpeg on clevis with spring washer 2 Make sure spring washer is positioned inside clevis 11 with the square edge toward the inside Align holes and push clevis pin 7 from top down through hole 2of5 in clevis Secure clevis pin using the new retaining ring 17 Footpegs must be installed so they fold up and back For XL1200L Models Install new footpegs and install wear peg 19 For XL883L and XL1200N Models Install wear peg 19 8 Install exhaust following the instructions in the service manual Install Forward Control Shift Lever Assembly 1 See Figure 6 Obtain shift link arm 13 and screw 6 from kit Orient shift link arm pointing straight down and slide onto shift shaf
3. cMOTOR HARLEY DAVIDSON WY J04006 INSTRUCTIONS REV 2008 09 23 SPORTSTER FORWARD CONTROL KITS GENERAL Kit Numbers 33398 06A 33395 06A 33397 07A 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 XL1200L models require the purchase of footpegs part num bers 33134 07CAZ and 33135 07CAZ WARNING 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 6 Figure 7 and Table 1 REMOVAL Remove Stock Shift Lever and Footrest Assembly 1 See Figure 1 Loosen the shift lever retaining screw 2 securing the shift lever 1 to the shifter shaft Slide the shift lever off the splined shaft Remove shifter peg from lever and save for installation Discard shift lever 2 Remove the two socket head screws 4 securing the footrest bracket 3 to the frame and remove footrest Discard scr
4. els Install wear peg 19 Adjusting Shift Lever If the gears do not engage fully or the toe shifter travel is incorrect the shift linkage must be adjusted See Figure 5 Adjust the shift rod until the shift pedal is at 45 degrees as described 1 See Figure 5 Remove screw 1 securing the ball joint 2 to shift pedal 5 2 Turn ball joint or shift rod 4 to adjust rod length Tempor arily attach ball joint to shift pedal and check pedal angle Make sure an equal number of threads are visible on both ends of shift rod 3 When pedal angle is at 45 degrees install screw 1 Tighten to 120 180 in Ibs 13 6 20 3 Nm 4 Holding shift rod 4 so that it does not turn tighten lock nuts 3 on each end securely Screw 2 Ball joint 2 Lock nut 2 Shift rod Sie Nr Shift pedal Figure 5 Adjusting Shift Pedal 3of5 SERVICE PARTS is05468 is05469 Za Figure 7 Service Parts Forward Control Right Brake Side Table 1 Service Parts Table Item Description Quantity Part Number 1 Plug hole 4 740 2 Washer footpeg spring 2 50912 72 3 Screw 3 8 16 x 1 1 4 inch 4 4748 4 Screw 5 16 18 x 7 8 inch 4359 5 Screw hex button lock 5 16 18 x 1 inch 4016 6 Screw hex socket 5 16 18 x 1 1 4 inch 3 3210A 7 Pin footpeg clevis 2 45041 01A 8 Assembly brake pedal chrome 42702 04 Assembly brake pedal polished 42
5. ews 3 See Figure 7 Firmly press hole plugs 1 into frame screw holes remaining from footrest removal 4 See Figure 2 and Figure 3 Remove the retaining ring 1 from the clevis to free the footrest clevis pin 4 Remove the clevis pin and footrest 3 from the footrest support Discard retaining ring clevis pin spring washer and footrest bracket For All Models Except XL1200L Save footrest for installation For XL883L and 1200N Models Remove and discard wear peg 6 J04006 For XL1200L Models Discard footrest is03193 Shift lever Retaining screw Footrest bracket Socket head screw 2 7 Figure 1 Remove Shift Lever and Footrest is03194 Retaining ring Spring washer Footrest Clevis pin Footrest bracket Pena or Figure 2 Remove Left Footrest All Models except XL883L and XL1200N 1of5 is05731 Retaining ring Spring washer Footrest Clevis pin Footrest bracket Wear peg PaPenna Figure 3 Remove Left Footrest XL883L and XL1200N Models Remove Stock Brake Pedal and Footrest Assembly 1 See Figure 4 At the right footrest remove the retaining ring 1 clevis pin 2 footrest 3 and spring washer Dis card all hardware For All Models Except XL1200L Save footrest for installation For XL883L and XL1200N Models Remove and discard wear peg 6 For XL1200L Models Discard footrest 2 Remove the exhaust to access the brake r
6. od 4 Follow the instructions in the service manual 3 Remove brake rod 4 from brake pedal and master cyl inder bell crank Discard brake rod 4 Remove the two screws 5 and right footrest brake pedal support bracket with attached brake assembly from frame Discard footrest support bracket and entire brake pedal assembly 5 See Figure 6 and Figure 7 Install hole plugs 1 in holes left from support bracket removal J04006 is05732 Retaining ring Clevis pin Footrest Brake rod Screw 2 So Ns Figure 4 Remove Footrest Support Pedal and Brake Pedal INSTALLATION Install Forward Control Brake Pedal and Footrest Assemblies 1 See Figure 6 and Figure 7 At the lower front of the right frame downtube remove the two screws securing the J clip B to the frame Discard the screws but save J clip for installation 2 Install the other end of the brake rod into the brake pedal assembly 8 Tighten to 84 144 in Ibs 9 5 16 3 Nm NOTE Assemble the brake pedal and footpeg clevis onto the footrest support bracket as described in the next step prior to mounting the support bracket to the frame This will allow easier installa tion of the footrest mount clevis retaining ring installed to grooved end of footrest mount clevis 3 Slide the brake pedal 8 onto footrest mount clevis 11 then slide clevis into footrest orake pedal support bracket 9 Align hole in the clevis with hole in the support br
7. t exiting engine side cover Install screw 6 and tighten to 96 156 in Ibs 11 18 Nm 2 Mount footrest shift pedal support bracket 10 to frame using screws 3 Tighten to 45 50 ft lbs 61 1 67 9 Nm 3 Slide shift pedal 14 onto clevis 12 Mount clevis on footrest shift pedal support bracket 10 Align hole in clevis with hole in support bracket and secure using screw 6 Tighten screw to 18 22 ft lbs 24 4 29 9 Nm 4 Install retaining ring 18 to the relief at the end of the clevis 12 to further secure it in place 5 Install screw 4 in far end of the shift rod 16 and into shifter arm 13 Tighten to 120 180 in Ibs 13 6 20 3 Nm 6 Install screw 5 in opposite end of shift rod 16 into shift lever 14 Tighten to 120 180 in Ibs 13 6 20 3 Nm 7 Install shifter peg into new shift lever Tighten securely IWIN NIN Footrests must fold up and toward rear of motorcycle if struck Failure to set footrests to fold up and back could result in death or serious injury 00366a 8 Install footpeg on clevis 12 with spring washer 2 Make sure spring washer is positioned inside clevis with the square edge toward the inside Align holes and push clevis pin 7 from top down through hole in clevis Secure clevis pin using the new retaining ring 17 Footpegs must be installed so they fold up and back J04006 For XL1200L Models Install new footpegs and install wear peg 19 For XL883L and XL1200N Mod
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