FOWARD CONTROL FOR FL SOFTAIL
J045362010-07-28
GENERAL
Kit Number
33909-08
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit requires Loctite® 243 (Blue), P/N 99642-97.
New steel/rubber brake line gaskets will be needed for the rear master cylinder. See you Harley-Davidson Dealer for the correct part number for your motorcycle.
WARNING
Rider and passenger safety depend 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. (00333b)
NOTE
If engine guard fitment is desired, this kit is only compatible with FX Softail Engine Guards, P/N 49200-07A or 49023-02A.
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.
New banjo bolt gaskets and cotter pin are NOT supplied with this kit.
Kit Contents
See Figure 5 and Table 1.
INSTALLATION
Shifter Side, Left
WARNING
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 54.2 N·m (40 ft-lbs).
6. See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9).
WARNING
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.
Brake Side, Right
1Bracket*
2Washer
3Screw (3)*
4Master cylinder
5Clevis pin
6Washer
7Cotter pin
8Nut
9Steel/rubber gaskets (2)
10Banjo bolt
11Brake lever
12O-rings
13Washer
14Screw
15Clip* (2011 and later)
Figure 1. Right Side Footboard Mounting Bracket and Brake Lever Components
NOTE
In above illustration items with Asterisk* are in kit. Other items shown for reference only.
Set aside original hardware that is removed. All of it except screws for the mounting brackets will be reused.
1. See Figure 1. Remove FL brake lever (11) and footpeg (not shown).
2. Remove master cylinder (4) per applicable Service Manual instructions.
3. Remove FL bracket from frame.
4. Obtain the new right side chrome bracket (1), and three chrome screws (3) from the kit.
NOTE
See Figure 2. 2011 and later models must use mounting clip either from kit or re-use from stock vehicle. Install as shown.
5. See Figure 1. Place the washers (2) previously removed over the screw threads. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 54.2 N·m (40 ft-lbs).
6. Obtain the new brake lever (11) and make sure the O-rings (12) remain in position. Slide the new brake lever onto the mounting bracket shaft. Install the screw (14) and washer (13). Tighten to 16–22 N·m (12–16 ft-lbs).
1Slot
2Mounting clip
Figure 2. Clip Location
1Banjo bolt
2Steel/rubber gaskets
3Brake line banjo fitting
4Nut
5Footboard mounting bracket
Figure 3. Rear Brake Reservoir Mount
7. See Figure 3. Fit the collar of the master cylinder cartridge body into the hole of the new right-side footboard mounting bracket (5). Apply LOCTITE® 243 (Blue) to the threads of the nut (4). Install the nut on the cartridge body until finger tight. Tighten to 40.7–54.2 N·m (30–40 ft-lbs).
WARNING
Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a)
8. Lubricate new steel/rubber gaskets (2) with the appropriate brake fluid for your year and model of motorcycle. See your Owner's Manual for the proper brake fluid specification. Position a gasket on each side of the brake line banjo fitting (3). Insert the banjo bolt (1) through the gaskets and fitting. Tighten to 23–30 N·m (17–22 ft-lbs).
1Cotter pin
2Washer
3Clevis pin
Figure 4. Rear Brake Control: Rear Mount
9. See Figure 4. Install master cylinder assembly on brake lever. Install washer (2) and new cotter pin (1) on clevis pin (3).
10. Lubricate the brake lever fitting with Wheel Bearing Grease (Part Number 99856-92) until a small amount of grease is visible around the edges of the brake lever.
NOTE
The rear brake is nonadjustable. When brake system components are properly assembled, brake lever is correctly adjusted.
11. See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9).
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240d)
12. Make sure that the rear brake master cylinder is in a level position. Remove the master cylinder cover.
13. Bleed the brakes. See BLEEDING HYDRAULIC BRAKES in the Service Manual.
WARNING
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
14. Install the gasket and cover to the master cylinder. Tighten the cover screws to 0.7–0.9 N·m (6–8 in-lbs).
WARNING
The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result in death or serious injury. (00006a)
15. Move the jiffy stand to the full forward (down) position. Carefully remove the support from beneath the motorcycle frame and rest the motorcycle on the jiffy stand.
16. Make sure the jiffy stand operates correctly prior to riding the motorcycle.
WARNING
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)
17. Turn the Ignition/Light Key Switch to IGNITION. Pump the rear brake foot lever to verify proper operation of the brake lamp.
SERVICE PARTS
Figure 5. Service Parts: Foward Control Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Brake pedal mounting assembly, gloss black
42508-11BHP
2
Gear shifter bracket assembly
33683-07A
3
Button head TORX screw, 0.375-16 x 1 in. (6)
4512A
4
Foot shifter lever assembly
34564-90B
5
Shifter peg/stud assembly
34611-65A
6
Foot brake lever assembly
42515-07
7
Foot gear shifter assembly
33660-07
8
Spring washer (2)
50912-72
9
Retaining ring (2)
11304
10
Clevis pin (2)
45041-01A
11
Clip (2011 and later)
10866