HARLEY DAVIDSON HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. 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 A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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HARLEY DAVIDSON AIRFOIL RIDER HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-04-2011

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1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1990 and later Dyna models (except 2003 and later FXDWG), •Dyna models equipped with Forward Control Kit 49080-93 or 49080-93A. Kit 50227-01 does notfit Dyna models equipped with Forward Control Kit 49080-03or Forward Control Footrest Support 33695- 03 (left) or 33697-03 (right). Proper installation of this kit also requires installing a pair of Airfoil Foot Rests, Part Number 50133-95 (large) or 50134- 95 (small), not included in this kit. Airfoil Foot Rests are available from your Harley-Davidson Dealer. See the Service Parts illustration for kit contents. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley- Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. NOTE A Service Manual for your motorcycle is available at your Harley-Davidson Dealer. Installation NOTE When performing the following step, note the location and orientation of the spring washer when removing each footrest. 1. See Figure 1. On the right side of the motorcycle, remove the fastener securing the footrest to the footrest bracket. Save the hardware for installation. NOTE On motorcycles equipped with Airfoil Foot Rests, remove the adjusting screw fastening the foot rest to its footrest mount. Save the foot rest and screw for heelrest installation. 2. Fasten the Airfoil Rider Heel Rest mount and spring washer to the footrest bracket using the hardware saved from step 1. Tighten the fastener to 19 ft-lbs (26 Nm). 3. See Figure 2 and the Service Parts illustration. Place the right-side Airfoil Rider Heel Rest (2) on the Airfoil Rider Heel Rest mount (3), positioning the heelrest at the desired angle

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HARLEY DAVIDSON DYNA GLIDE ADJUSTABLE HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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Installation 1. See Figure 1. Install setscrew (14) into lower hole on frame tube boss (2) leaving .20 in. of setscrew (or three threads) exposed. 2. Place highway peg mounting plate (1) into position. For a lower peg position, place bottom hidden hole in mounting plate over setscrew. For a higher peg position place upper hidden hole in mounting plate over setscrew. Attach mounting plate to frame tube boss using 1 in. long screw (3), lockwasher (4), and flat washer (5) from kit. Tighten screws to 33 ft-lbs. 3. Install footrest support (6) onto highway peg support plate using hex nut (7), lockwasher (8) and flat washer (9) from kit. Tighten nut (7) to 47 ft-lbs. 4. Locate spring washer (10) from kit. While holding spring washer in position on inside of footrest support (with square edge towards motorcycle), position footpeg (not included with this mounting kit) between footrest support mounting tabs, as shown. 5. Insert 1-1/2 in. long screw (12) from kit through footrest support mounting tabs, footpeg, and spring washer. Secure using locknut (13) from kit. 6. Repeat these steps for the other side of vehicle. 1 WARNING These footrest pegs must fold upward and toward the rear at about a 45°angle when retracted. If they do not, peg could contact ground while motorcycle is in a turn, causing loss of control or startling the rider, resulting in possible personal injury. If pegs do not fold up and back at a 45°angle, remove pegs and turn them over so the flat surface is facing forward.

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HARLEY DAVIDSON FL SOFTAIL FOWARD CONTROL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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INSTALLATION Shifter Side, Left Block or jack vehicle under frame in a way that the vehicle will not fall over. Failure to properly block and/or raise the vehicle could result in death or serious injury. (00462c) 1. Block the motorcycle under the frame so that it is upright and level, with the weight off of the jiffy stand. 2. Remove footpeg. 3. Remove jiffy stand, shifter linkage and bracket per applicable Service Manual instructions, retaining hardware. 4. See Figure 5. Obtain the new left side shifter bracket (2), and three TORX® screws (3) from the kit. 5. Place washers previously removed on the screws. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 40 ft-lbs (54.2 Nm) . 6. See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9). If leg stop is incorrectly installed, excessive wear can allow vehicle to fall when rested on jiffy stand, which could result in death or serious injury. (00479b) 7. Install jiffy stand and attach the spring. When properly installed, the hook on the spring side connected to the bracket will face upward. 8. Verify that rubber bumper is in place on prong of jiffy stand. Without the bumper, the stand will make hard contact with the primary drive cover when retracted, which may result in damage to the cover. 9. Extend and retract the jiffy stand leg several times to verify proper operation. The stand should swing freely to the fully extended and fully retracted positions. 10. Refer to applicable Service Manual and re-attach the shifter linkage

HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required 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 5, Figure 6 and Table 1. INSTALLATION 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 screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. 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. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

HARLEY DAVIDSON 360 DEGREE HIGHWAY FOOTPEG MOUNTING KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a) Mount the footpegs so they will not strike the ground during cornering. Foopegs striking the ground during cornering can cause loss of control, resulting in death or serious injury. (00458b) NOTE See Figure 2 for steps 2 through 6. 1. Determine what height on the engine guard you prefer for the final mounting of the footpeg mounts. Mark location, if desired. 2. See Figure 2. Obtain clamp assembly (1) from kit. Wrap the clamp halves around the engine guard and install with hinge pin head facing upward. Place the flatwasher between the ears of the clamp halves. Hold parts in posi- tion. 3. Obtain the lockwasher (13), screw (7) and one of the footpeg extensions (14) (long or short depending on kit number) from kit. 4. Position the clamp adapter (10) over the clamp assembly (1) with the “cogged” face of the adapter facing the extension arm (14). Hold clamp adapter in place. 5. Install screw (7) with internal tooth lockwasher (13) through the clamps, the clamp adapter (10) and into the extension arm (14). Position extension arm as desired. Do not tighten completely at this time. 6. Obtain the clevis/extension assembly (6) from kit. Position assembly such that footpeg pivots upward and toward the rear of the bike. NOTE: It may be necessary to loosen the screw slightly and rotate the extension to obtain this position. Tighten item 9 securely. 7 5 1 3 4 2 6 8 is02511 1. Clamp assembly 2. Arm extension 3. Clevis 4. D-washer 5. Footpeg 6. Screw 7. Clamp adapter 8. Clamp halves Figure 1. 360 Degree Footpeg Mounting Installed (Shown with Footpeg Installed) NOTE The footpeg will be a tight fit if the D-spring washer is installed correctly. 7. Refer to Figure 1. Obtain the footpeg (5), sold separately, D-spring washer (4) and screw (6) from kit. Install the D- spring washer so it is positioned inside the clevis (3) with the square “D” edge towards the inside of the mount. Hold the washer in place and slide the footpeg into position. Install the screw (6) and tighten to 19 ft-lbs (26 Nm). 8. Repeat Steps 1 through 7 for the opposite side. Position the footpeg assemblies so they are at equal heights and symmetrical. Securely tighten each assembly until it cannot be rotated on the guard with reasonable foot pressure, but do not exceed 55 ft-lbs (81 Nm) on item 7

HARLEY DAVIDSON HEEL RAISER FOOTPEG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. If the motorcycle is equipped with a pin and retaining ring, remove them and retain for future use. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs and the spring washers. Save the spring washers for installation. NOTE See Figure 1. When performing the next step, verify that the spring washer is positioned inside of the footpeg support with the square edge (2) towards the inside of the support. 1 3 2 is02094 1. Spring washer 2. Spring washer square edge 3. Footpeg support slot Figure 1. Footpeg Spring Washer Installation 3. See Figure 1. Install the new footpegs in the same manner as the old footpegs were installed. Insert a spring washer (1) and the mount end of the footpeg inside the slots (3) of the footpeg supports. 4. Secure each footpeg and spring washer to the footpeg support with the screw and locknuts or pin and retaining rings removed earlier. Tighten the locknuts to 19 ft-lb (26 Nm) . 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) Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a)

HARLEY DAVIDSON LEFT SIDE TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION NOTE While handling and installing tool box, be careful not to scratch surface. 1. See Figure 1. Attach the toolbox (4) to the toolbox mounting bracket (1) using the three pan head screws (2) and Nylock nuts (3) from the kit. 2. Remove the two button head screws (I) which secure left rear fender support (B) to motorcycle frame (C). Retain screws for reassembly. 3. On models with passenger footpegs: a. For FLSTN models: Remove button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E). b. For all other models: Remove the locknut (G), hex head bolt (J), spring washer (H) and footpeg (E). Remove the socket head cap screw (K) that secures the footrest support (F) to the frame (C). c. Remove the two bolts, nuts and washers which secure the bottom of the splash guard to the swingarm. This will allow you to move splash guard when installing the new passenger footrest bolt. d. Retain all removed components. 4. On models with passenger footboards: a. Remove the screw securing the passenger footboard assembly to the frame. Remove the footboard assembly. b. Retain all removed components. 5. Slide the top of mounting bracket (1) between rear fender support (B) and frame (C). Align top holes in bracket with fender support holes. Align lower bracket hole with footrest mounting hole in frame. Install the two screws (I), removed in Step 2, in fender support. Do not tighten screws at this time. 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) 6. On models with passenger footpegs: a. For FLSTN models: Install button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E) on top of the toolbox bracket (1). Tighten screw to 35-45 ft-lbs (47.5-61.0 Nm). b. For all other models: Refer to instructions in footpeg extension kit, Part Number 49352-00 for installation, and install the extention kit, footrest support and footpeg on top of the toolbox bracket (1). c. Install the two bolts, nuts and washers and secure the bottom of the splash guard to the swingarm. 7. On models with passenger footboards: a. Position footboard assembly, in the same orientation as removed, on top of tool box bracket. b. Install screw removed in Step 4. Tighten to 35-45 ft- lbs (47.5-61.0 Nm)

HARLEY DAVIDSON SPORTSTER FORWARD FOOT CONTROLS

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Filed Under (Harley Davidson) by admin on 03-03-2011

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LEFT (SHIFTER) SIDE 1. Remove stock footrest assembly and save footrest for reinstallation. Replace existing sockethead capscrews that attached footrest bracket to primary cover with washers (5) and shorter screws (21) from kit. 2. Remove stock shift lever and save shifter peg and mounting screw. 3. See Figure 1. Remove left side stock motor mount and save nuts, washers, and P-clamp for clutch cable. The bolts will be replaced. 4. Put Loctite 243 on threads of left side foot control support (15) and thread support into left side machine motor mount (11). Install C-clip (8) onto support where it exits the backside of machine motor mount to hold support in place. 5. Install left side motor mount assembly in place of stock motor mount using washers and nuts saved from step 3, and bolts (22 and 23) from kit. Tighten bolts to 25-30 ft-lbs (41-47 Nm). Make sure to reinstall the P-clamp and clutch cable in the same hole location they were removed from in step 3. 6. Install shift lever (14) from kit using stock fastener. 7. Put Loctite 243 on threads of clevis mounting screw (4) and install shift lever pedal (13), clevis (17), and footrest (stock), as shown. To install footrest, place a spring washer (19), along with the mount end of the footpeg, inside the slots of the clevis. Make sure the spring washer is positioned inside the clevis with the square edge towards the inside as shown in Figure 3. Secure footpeg and spring washer with bolt (2) and locknut (7). Tighten locknuts to 19 ft-lbs (26 Nm)

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HARLEY DAVIDSON SLOTTED CUSTOM FOOTPEG INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION 1. See Figure 1. Remove locknuts (1) and screws (2) that hold existing footpegs in place. Save hardware for installation of new footpegs. 2. Remove existing footpegs along with spring washers (3). Save spring washers for installation of new footpegs. 3. Install new footpegs in the same manner as old footpegs were installed: •Place a spring washer (3), along with the mount end of the footpeg, inside the slots of the footpeg supports (4). •Make sure the spring washer is positioned inside the footpeg support with the square edge toward the inside of the support. •Secure each footpeg and spring washer with a screw (2) and locknut (1). •Tighten locknuts to 19 ft-lbs (26 Nm) . 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) 4. For each footpeg, remove the screw (5) and rubber pad (6). Loosen the adjusting screw (7) until the footpeg (8) rotates. Position the footpeg (8) as desired, then tighten the adjusting screw to 19 ft-lbs (26 Nm) . Place the rubber pad (6) on the footpeg and tighten the screw (5)

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