FXD CHROME FORWARD FOOT CONTROL KIT
J024642007-11-01
GENERAL
Kit Number
49080-03A
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
Additional Parts Required
Proper installation of this kit requires the use of LOCTITE® 243 Threadlocker and Sealant - Blue (99642-97) and LOCTITE Anti-Seize Lubricant (98960-97).
WARNINGRider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
Kit Contents
See the Service Parts section for kit contents.
INSTALLATION
Stock Shifter Assembly
| 1. | See Figure 1. Remove the left side rider footpeg assembly. Save the footpeg and fasteners for installation. Discard the remaining hardware. | |
| 2. | Push hole plugs (8) into the screw holes on the frame where the stock footpeg assembly was mounted. | |
| 3. | Loosen the retaining screw fastening the stock shift lever to the shifter shaft. Save the shift lever assembly for installation. | |
| 4. | Remove and discard the linkage connecting the primary shift lever to the transmission shift lever. NOTE For the following step, note the difference in bracket (13) orientation on 1993-1998 Evolution and 1999-2000 Twin-Cam 88 models, and bracket (10) for 2001 and later models. | |
| 5. | Fasten the primary shift lever retainer bracket (10 or 13) for your vehicle to the primary shift lever with a screw (14) and nut (3). Do not tighten the fasteners at this time. | |
| 6. | Loosen the left rear crankcase bolt, located at the bottom of the rear cylinder. | |
| 7. | Slide the slotted end of the primary shift lever retainer bracket (10 or 13) onto the bolt, between the washer and crankcase. Tighten the crankcase bolt to 20–23 N·m (15–17 ft-lbs). | |
| 8. | Fasten the shifter shaft cover (9) to the shifter shaft, using a set screw (12). | |
| 9. | Tighten the retainer bracket screw installed in Step 5. | |
| 10. | Install a spring washer (6) on the shifter lever (4) shaft. Coat the shaft with Loctite Anti-Seize Lubricant and slide the shaft into the shifter bracket. | |
| 11. | Install the shifter bracket (7) with Torx® screws (11). Tighten the screws to 41–47 N·m (30–35 ft-lbs). | |
| 12. | Apply Loctite 243 to the shifter rod (1) short stud. Fasten the short stud to the transmission shift lever. Tighten the short stud to 8–10 N·m (70–90 in-lbs). | |
| 13. | Apply Loctite 243 to the shifter rod (1) long stud. Fasten the long stud to the shifter lever (4) using a washer (2) and acorn nut (5). Tighten the nut to 8–10 N·m (70–90 in-lbs). | |
| 14. | Fasten the stock shift lever to the splined shaft on the new shifter lever assembly (4, 7). Tighten the shift lever retaining screw to 25–29 N·m (18–22 ft-lbs). | |
| 15. | Fasten the stock footpeg to the shifter bracket (7) using the stock fasteners from Step 1. |
Rear Brake Assembly
| 1. | See Figure 2. Remove the right side rider footpeg. Save the footpeg and fasteners for installation. | |
| 2. | Loosen the brake rod jamnut (26) 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 and brake pedal assembly. | |
| 5. | Push hole plugs (8) into the screw holes on the frame where the stock brake pedal assembly was mounted. | |
| 6. | Fasten the brake pedal bracket (18) to the frame with Torx screws (11). Tighten the screws to 41–47 N·m (30–35 ft-lbs). | |
| 7. | Install the jamnut (26) all the way onto the new brake rod (25). | |
| 8. | Fasten the brake rod to the master cylinder piston. Do not adjust the brake rod length at this time. | |
| 9. | Connect the brake rod (25) to the new brake pedal (16) using the clevis pin (24), washer (22) and cotter pin (20). Bend the legs of the cotter pin around the clevis pin shaft. | |
| 10. | Coat the brake pedal pivot shaft (19) with Anti-Seize Lubricant. | |
| 11. | Fasten the brake pedal pivot shaft (19), brake pedal (16) and footpeg mount clevis (21) to the brake pedal bracket (18) using the long Torx screw (23). Tighten the screw to 44–47 N·m (32–35 ft-lbs). | |
| 12. | 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, and using at least half the threads available on the brake rod. Tighten the jamnut against the master cylinder piston. | |
| 13. | Fasten the brake pedal pad (15) to the brake pedal (16) using the locknut (17). Tighten the nut to 6–9 N·m (50–80 in-lbs). | |
| 14. | Fasten the stock footpeg to the footpeg mount clevis (21) using the stock fasteners from Step 1. |
SERVICE PARTS
Figure 1. Service Parts for FXD Forward Foot Controls (Shifter Side Parts)
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Shifter rod | 11739B |
2 | Washer, 5/16 x 11/16 x 1/16 | 6702 |
3 | Locknut | 7710W |
4 | Shifter lever | 33789-03 |
5 | Acorn nut | 7736 |
6 | Spring washer | 34625-90 |
7 | Shifter bracket | 33695-03 |
8 | Hole plug (4) | 740 |
9 | Shifter shaft cover | 34640-93 |
10 | Primary shift lever retainer bracket (2001 and later models) | 34639-01 |
11 | Torx® screw, 3/8-16 x 1 (4) | 4059 |
12 | Shaft cover set screw | 3231B |
13 | Primary shift lever retainer bracket (1993-2000 models; see note below) | 34639-93 |
14 | Hex head screw, 5/16-18 x 5/8 | 2882W |
Items mentioned in text, but not included in kit: | ||
A | Transmission shift lever | |
B | Primary shift lever | |
C | Shifter lever | |
Notes: | ||
D | Shown positioned for models 1993-1998 Evolution engines. | |
E | Shown positioned for models 1999-2000 Twin Cam 88 engines. | |
Figure 2. Service Parts for FXD Forward Foot Controls (Brake Side Parts)
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
15 | Brake pedal pad | 42532-82 |
16 | Brake pedal | 42542-03 |
17 | Locknut, 1/4-20 | 7742 |
18 | Brake pedal bracket | 33697-03 |
19 | Brake pedal pivot shaft | 42665-03 |
20 | Cotter pin | 515 |
21 | Footpeg mount clevis | 42664-03 |
22 | Washer, 1/4 x 7/16 x 1/16 | 6099 |
23 | Torx® screw, 3/8-16 x 2-3/4 | 4339 |
24 | Clevis pin | 42460-80B |
25 | Brake rod | 41955-03A |
26 | Jamnut, 5/16-24 | 7744 |