SOFTAIL BILLET FORWARD CONTROL KIT
J022472007-08-07
GENERAL
Kit Number
33907-01
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).
NOTE
This Forward Control Kit will fit with Harley-Davidson Tunable 2-into-1 Exhaust System (Part Number 80093-03).
This kit will not fit with Harley-Davidson 16 Gauge Double Barrel Exhaust System (Part Number 64901-02).
Additional Parts Required
NOTE
This kit is designed to be used with Airfoil Peg Kit (Part Number 50346-03) or Rubber Peg Kit (Part Number 50347-03), sold separately.
FXSTD (Deuce) Models require separate purchase of Spacer Kit (Part Number 42802-03) for correct installation.
WARNINGRider 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
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.
Loctite® 243 Threadlocker and Sealant (Part Number 99642-97) and is available from a Harley-Davidson Dealer.
Loctite® 565 Thread Sealant (Part Number 99818-97) and is available from a Harley-Davidson Dealer.
INSTALLATION
NOTE
Remove Shifter, Jiffy Stand and Footrest Support Bracket Assembly
| 1. | Place motorcycle in stable frame stand so that weight can be taken off of Jiffy stand. | 
Figure 1. Remove Front Shift Linkage | ||||||||||||||||
| 2. | See Figure 1. Remove acorn nut (3) securing front of shift linkage (1) to linkage arm (2) and remove linkage from arm. Save acorn nut for installation. | |||||||||||||||||
| 3. | See Figure 2. Remove bolt (5), lockwasher (7), washer (8) and leg stop (4) and remove jiffy stand from support bracket. Save jiffy stand and mounting hardware for installation. | 
Figure 2. Remove Footrest Support Bracket Hardware | ||||||||||||||||
| 4. | Remove the three footpeg support bracket screws (1) from bracket (2). Discard screws. | |||||||||||||||||
| 5. | Detach spring (6) from jiffy stand (3) and support bracket (2). Jiffy stand (3), shifter and footrest components will drop as an assembly. |
Remove Rear Brake/Footrest Support Assembly
NOTE
It is not necessary to remove the exhaust system to perform this procedure.
| 1. | See Figure 3. Remove cotter pin and washer (1) from master cylinder push rod clevis pin (3). Discard cotter pin and washer. | |||||||||||||||||||||
| 2. | Gently tap clevis pin outward and remove it from the push rod (2) clevis. Discard clevis pin. | 
Figure 3. Remove Master Cylinder Hardware 
Figure 4. Remove Brake Pedal/Footrest Support Bracket Hardware | ||||||||||||||||||||
| CAUTION Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b) | ||||||||||||||||||||||
| 3. | See Figure 4. At the front of the rear master cylinder (6), remove the banjo bolt (1) and washers securing the brake line (5) to the master cylinder (6) and remove brake line. Discard bolt and washers. | |||||||||||||||||||||
| 4. | Remove the jam nut (2) securing the master cylinder to the brake pedal/footrest support bracket assembly and remove the master cylinder assembly (6). Discard nut and master cylinder assembly. | |||||||||||||||||||||
| 5. | Remove the brake pedal bolt (3) and large chrome flat washer (4) from brake pedal assembly. Discard bolt and flat washer. | |||||||||||||||||||||
| 6. | Remove the three bracket screws (7) securing the brake pedal/footrest support bracket to the frame. Discard brake pedal, footrest support bracket and all bracket hardware. | 
Figure 5. Remove Stoplight Switch and Rear Brake Line | ||||||||||||||||||||
| 7. | See Figure 5. Follow the brake line (4) back toward the rear of the bike to the brake stoplight switch (1). Remove the two wire terminals (2) from the switch. NOTE When performing Steps 8 and 9, make careful notes of brake line routing. The new line must be routed identically. | |||||||||||||||||||||
| 8. | Remove the screw (5) securing the stoplight switch bracket (3) to the frame and remove bracket with tee fitting (6) and switch. Unthread and save stoplight switch for installation. Discard screw and mounting bracket. | |||||||||||||||||||||
| 9. | Continue back to the rear brake caliper. Remove the brake line banjo bolt and washers securing the brake line to the brake caliper. Discard brake line (4) and washers. Save banjo bolt for installation. |
| 1 | Shifter mounting plate |
| 2 | Pivot/bearing assembly |
| 3 | Screws (4) |
Figure 6. Install Pivot/Bearing Assembly to Shifter Mounting Plate
Assemble Shifter Side Components
| 1. | See Figure 24. Obtain the shifter mounting plate (6), pivot/bearing (5) and four screws (1) from kit. See Figure 6. Orient the pivot/bearing assembly (2) onto the shifter mounting plate (1). Apply a small amount of Loctite 243 (blue) to screw threads (3) and install and tighten screws to 1.6 N·m (14 in-lbs). | 
Figure 7. Install Left Footpeg Support to Shifter Mounting Plate | ||||||||
| 2. | See Figure 24. Obtain the left footpeg support (8) and two screws (13) from kit. See Figure 7. Apply a small amount of Loctite 243 (blue) to screw threads and install the footpeg support to the shifter mounting plate. Tighten screws to 33.9–40.7 N·m (25–30 in-lbs). | |||||||||
| 3. | See Figure 24. Obtain the jiffy stand bracket assembly (9), three screws (11), three lockwashers (10) and jiffy stand with hardware saved from earlier removal step. | 
Figure 8. Install Jiffy Stand Mounting Bracket and Stand to Shifter Mounting Plate | ||||||||
| 4. | See Figure 8. Apply a small amount of Loctite 243 (blue) to screw threads and using lockwashers, install jiffy stand bracket assembly to shifter mounting plate. Tighten screws to 26.3 N·m (19 ft-lbs). | |||||||||
| 5. | Install jiffy stand to jiffy stand bracket using hardware saved during removal Step 5. Tighten jiffy stand mounting bolt to 16.3–20.3 N·m (144–180 in-lbs). |
Install Shifter Side Components
| 1. | See Figure 24. Obtain three screws (13) from kit and apply a small amount of Loctite 243 (blue) to threads. See Figure 9. Install shifter mounting plate assembly to the frame. Tighten screws to 33.9–40.7 N·m (25–30 ft-lbs). | 
Figure 9. Install the Shifter Mounting Plate Assembly and Jiffy Stand Spring 
Figure 10. Install Shift Lever | ||||||||||
| 2. | Obtain jiffy stand spring saved from removal Step 4 and install jiffy stand to frame mount opening. | |||||||||||
| 3. | See Figure 24. Obtain the shift lever (4), and one O-ring (3) from kit. See Figure 10. Install O-ring (2) onto the shaft of the shift lever (1). Insert the shaft into the pivot/bearing assembly (3) and slide in until fully seated. | |||||||||||
| 4. | See Figure 24. Obtain the second O-ring (3), non-metallic washer (2), shift link (7) and cap screw (12) from kit. Slide the second O-ring onto the inboard side of the shift lever shaft. | 
Figure 11. Align and Install Shift Link | ||||||||||
| 5. | See Figure 11. Slide the non-metallic washer (2) onto shifter shaft. Orient the shift link (3) angled relative to the shift lever as shown and slide onto shaft splines. Apply a small amount of Loctite 243 (blue) to threads and install the cap screw to secure shift link to the shift lever shaft. Tighten screw to 24.4–29.8 N·m (18–22 ft-lbs). | 
Figure 12. Install Shifter Linkage Rod | ||||||||||
| 6. | See Figure 12. Align the top of the shift link (1) with the shifter linkage rod (3) and obtain acorn nut (2) saved during earlier removal step. Apply a small amount of Loctite 243 (blue) to threads and install acorn nut (2) to stud on linkage rod (3). Tighten nut to 17.6–21.6 N·m (13–16 ft-lbs). | 
Figure 13. Install Shift Link | ||||||||||
| 7. | See Figure 13. Note position of shift lever (1) after installation. Also note relationship between shift link (2) and shift lever (1). If necessary, remove acorn nut and screw securing shift link to shift lever shaft. Slide shift link from splines, re-align to obtain the desired position, then reinstall to splines on lever shaft. Re-install screw to secure shift link and tighten to 24.4–29.8 N·m (18–22 ft-lbs). Reinstall acorn nut to linkage stud and tighten to 17.6–21.6 N·m (13–16 ft-lbs). |
Assemble Brake Side Components
| 1. | See Figure 25. Obtain the brake plate (11), two screws (20), and right footpeg support (7) from kit. NOTE When performing the next step, if you are installing this kit on FXSTD (Deuce) model, you will need footpeg spacer kit (Part Number 42802-03, sold separately). On FXSTD models, use the long bolts from the kit and mount the spacer between the footpeg support and shifter mounting plate. | |||||||||||||||||||
| 2. | See Figure 14. Orient footpeg support (2) as shown. Apply a small amount of Loctite 243 (blue) to threads of screws (3) and secure footpeg support (2) to the brake plate (1). Tighten screws to 33.9–40.7 N·m (25–30 ft-lbs). | 
Figure 14. Assemble Footpeg Support to Brake Plate 
Figure 15. Assemble Brake Lever Components to Brake Plate Pivot Shaft | ||||||||||||||||||
| 3. | See Figure 15. Obtain the brake lever/bearing assembly (4), two O-rings (1), brake pivot retainer (3) and pan head screw (2) from kit. | |||||||||||||||||||
| 4. | Following the exploded view ( Figure 25 ), install the brake lever/bearing assembly components onto the brake plate pivot shaft. Tighten the screw (2) to 16.3–21.6 N·m (12–16 ft-lbs). | |||||||||||||||||||
| 5. | See Figure 25. Obtain the master cylinder (13) and the cap screw (3) from kit. | |||||||||||||||||||
| 6. | See Figure 16. Align the master cylinder with the mount on the brake lever (3) and install cap screw (2) through the brake lever/bearing and master cylinder piston shaft (1). Tighten the screw (2) to 19.4 N·m (14 ft-lbs). | 
Figure 16. Install Master Cylinder to Brake Lever 
Figure 17. Secure Master Cylinder to Brake Plate Screws | ||||||||||||||||||
| 7. | See Figure 17. Rotate the the master cylinder on the shaft and align the holes in the master cylinder with the holes in the brake plate. | |||||||||||||||||||
| 8. | See Figure 25. Obtain the two flat head screws (19) from kit and install a small amount of Loctite 243 (blue) to threads. Install screws to secure the master cylinder to the brake plate. Tighten screws to 19.4 N·m (14 ft-lbs). | |||||||||||||||||||
| 9. | See Figure 25. Obtain the rubber pivot O-ring (5) from kit. Install the O-ring to the groove in pivot cover. See Figure 18. Obtain the chrome brake pivot cover (14) and snap into place. |
Install Brake Side Components
| 1. | See Figure 25. Obtain the brake spacer (17) and two screws (2) from kit. See Figure 18. Position the brake assembly near the frame mounting bracket. While holding the brake assembly in place, slide the brake spacer (1) with curve in spacer oriented toward front) between the brake plate (3) and frame mounting bracket. Install screws (2) through the brake plate, spacer and frame mounting bracket. Do not tighten screws at this time. | 
Figure 18. Install Brake Plate Assembly to Motorcycle 
Figure 19. Install Upper Brake Plate Spacer and Screw | ||||||||||
| 2. | See Figure 25. Obtain a third screw (2) and upper brake spacer (15) from kit. See Figure 19. Slide the upper brake spacer between the brake plate and frame mounting bracket at area of screw. Apply a small amount of Loctite 243 (blue) to threads and install the third brake plate screw through brake plate and spacer and into frame mounting bracket. Tighten screw to 33.9–40.7 N·m (25–30 ft-lbs). NOTE The upper brake plate spacer is installed behind brake plate between brake plate and frame mounting bracket. | |||||||||||
| 3. | Return to the two lower brake plate screws installed in Step 1. Back the screws out slightly and apply a small amount of Loctite 243 (blue) to threads. Tighten screws to 33.9–40.7 N·m (25–30 ft-lbs). | 
Figure 20. Install Rear Brake Line to Master Cylinder | ||||||||||
| CAUTION Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b) NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) | ||||||||||||
| 4. | See Figure 25. Obtain banjo bolt (10), two brake line gaskets (9) and the rear braided brake line (16) from kit. See Figure 20. Lubricate the new brake line gaskets with D.O.T. 5 Silicone Brake Fluid. Install the banjo bolt (1) with a brake line gasket on each side of the brake line fitting (2) to the front of the master cylinder assembly (4). Tighten banjo bolt to 23–30 N·m (17–22 ft-lbs). | |||||||||||
| 5. | Route the rear brake line along the same path as the original brake line. |
Install Rear Braided Brake Line
NOTE
The stoplamp switch manifold on the new brake line has a 1/4-20 tapped hole and a 1/4-inch diameter rod.
| 1. | 2000-2003 Models - Line up the tapped hole in the manifold to the hole in the frame mounting tab. Fit the rod into the bottom hole to orient the brake line. See Figure 25. Obtain the screw (1) from kit. Apply a small amount of Loctite 243 (blue) to the threads and secure manifold to frame tab. Tighten screw to 13.8 N·m (10 ft-lbs). 2004 and Later Models - See Figure 25. Obtain the bracket (18) and two screws (1) from kit. See Figure 21. Line up the tapped hole (1) in the stoplamp switch manifold (4) to the top hole in the bracket (2). Fit the locator pin into the center hole to orient the brake line. Apply a small amount of Loctite 243 (blue) to threads of screws (3) and attach manifold to the bracket and the bracket to the frame. Tighten screws to 13.8 N·m (10 ft-lbs). NOTE Before installing the stoplamp switch, clean the pipe threads and apply Loctite 565 Thread Sealant to threads of switch. | 
Figure 21. Install Stoplamp Switch Manifold to Frame 
Figure 22. Install Stoplamp Switch and Connectors | ||||||||||||||
| 2. | See Figure 22. Install the stoplamp switch into the threaded hole in the manifold of the new brake line. Reattach the connectors (from main harness) to the stoplamp switch terminals. | 
Figure 23. Install Brake Line to Caliper and Frame Clips | ||||||||||||||
NOTICE Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) | ||||||||||||||||
| 3. | See Figure 25. Obtain two brake line gaskets (9) from kit and the banjo bolt saved during the removal steps. See Figure 23. Lubricate the new brake line gaskets (1) with D.O.T. 5 Silicone Brake Fluid. Install the banjo bolt (2) with a brake line gasket (1) on each side of the brake line fitting into the threaded hole in the brake caliper assembly. Tighten the banjo bolt to 23–30 N·m (17–22 ft-lbs). | |||||||||||||||
| 4. | See Figure 25. Obtain the cable straps (4) from kit. Use straps to secure the brake line to the lower frame tube along the brake line route. | |||||||||||||||
| 5. | See Figure 23. Place the brake line under the frame clips (3, 4) at the locations shown. | |||||||||||||||
| 6. | Obtain footpeg, brake pedal and shift lever kits. Follow instructions in kits and install footpegs and brake and shift lever pads to new assemblies. | |||||||||||||||
| 7. | Remove the rear brake master cylinder cover. Stand the motorcycle upright so the master cylinder is in a level position. Follow the instructions in the applicable Service Manual and bleed the rear brake system. | |||||||||||||||
| WARNING Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a) | ||||||||||||||||
| 8. | Verify proper operation of the master cylinder relief port. Actuate the brake pedal. A slight spurt of fluid will break the fluid surface in the reservoir compartment if all internal components are working properly. | |||||||||||||||
| 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) WARNINGBe sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||||||||||||||||
| 9. | Turn the ignition/light key switch to IGNITION and apply the rear brake foot pedal to test operation of the brake lamp. | |||||||||||||||
| 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) | ||||||||||||||||
| 10. | Test ride the motorcycle. If the brake feels spongy, repeat the bleeding procedure. |
SERVICE PARTS
Figure 24. Service Parts: Billet Forward Foot Control Kit - Shifter Side Components
Table 1. Service Parts: Shifter Side Components
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Screw, socket head cap, 8-32 x 1/2 inch (4) | Not Sold Separately | 9 | Assembly, jiffy stand bracket | 50000-01 | |
2 | Washer, non-metallic | 6057 | 10 | Lockwasher, spring (3) | 94081-90T | |
3 | O-ring (2) | 11191 | 11 | Screw, hex socket head cap 5/16-18 x 5/8 inch (3) | 94331-91T | |
4 | Kit, shift lever | 33002-01 | 12 | Screw, hex socket button head cap 5/16-18 x 1 inch | 94394-92T | |
5 | Assembly, pivot/bearing | 33113-01 | 13 | Screw, hex socket button head cap 3/8-16 x 1 inch (6) | 94400-92T | |
6 | Plate, shifter mounting | Not Sold Separately | 14 | Service Kit (includes items 1, 5 and 6) | 45037-03 | |
7 | Shift link | 33928-01 | Reference items: | |||
8 | Support, left foot peg | 33935-01 | A | Jiffy Stand Leg and Hardware Not Included. Shown for Illustration Purposes | ||
Figure 25. Service Parts: Billet Forward Foot Control Kit - Brake Side Components
Table 2. Service Parts: Brake Side Components
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Screw, small flange 1/4-20 x 1/2 inch (2) | 3588 | 16 | Brake line, braided (rear) | 44850-01 | |
2 | Screw, button head cap 3/8-16 x 1-3/8 inch (3) | 3882 | 17 | Spacer, brake | 44855-01 | |
3 | Screw, socket head cap 1/4-20 x 1-1/4 inch | 4280 | 18 | Bracket, rear brake line (for 2003-on) | 45108-01 | |
4 | Strap, cable (4) | 10065 | 19 | Screw, flat head hex 1/4-20 x 1 inch (2) | 94203-01 | |
5 | O-ring (2) | 11364 | 20 | Screw, socket button head cap 3/8-16 x 1 inch (3) | 94400-92T | |
6 | O-ring, cover | Not Sold Separately | 21 | Assembly, brake lever/bearing | 42207-01 | |
7 | Support, right footpeg | 33935-01 | 22 | Brake lever bushing (not shown) | 33929-01 | |
8 | Screw, pan head Torx 5/16-18 x 7/8 inch | 3655A | 23 | Service kit, master cylinder clevis | 44018-01 | |
9 | Gasket, brake line (4) | 41731-88A | 24 | Service kit, master cylinder cover w/gasket | 45008-01 | |
10 | Bolt, banjo | 41747-82A | 25 | Service kit, pivot cover and O-ring | 45020-03 | |
11 | Kit, brake plate | 41963-01 | 26 | Service kit, master cylinder rebuild | 42383-04 | |
12 | Retainer, brake pivot, billet | 42792-01 | Reference items only | |||
13 | Master cylinder, billet | 42793-01 | A | Used on 2004 and Later Only | ||
14 | Cover, brake pivot (billet) | Not Sold Separately | B | Spacer Kit (Part Number 42802-03) Necessary For Correct Installation on FXSTD (Deuce) | Sold Separately | |
15 | Spacer, upper brake | 44143-01 | ||||