SOFTAIL EXTENDED REACH CONTROLS KITS
J044132007-10-08
GENERAL
Kit Number
49171-08 - Chrome; 49223-08 - Black
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
In addition to the parts from the kit, LOCTITE® 243 (blue) Threadlocker and Sealant (Part Number 99642-97), Harley-Davidson Wheel Bearing Grease (Part Number 99855-80) and DOT 4 Silicone Brake Fluid (Part Number 99953-99A) is also required for installation.
This kit requires the separate purchase of the Extended Reach Brake Line Kit: For 2007 models: Part Number 44970-07. For 2008 models: Part Number 44972-08).
For accessories and kit part numbers see your local Harley-Davidson dealer, www.harley-davidson.com or your Harley-Davidson Genuine Motor Accessories and Parts catalog.
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.
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)
PREPARE THE MOTORCYCLE
| 1. | For models equipped with saddlebags: Remove the saddlebags following the instructions in the appropriate Service Manual. | |
| 2. | Remove the seat following the directions in the Owner's Manual. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 3. | Disconnect the negative battery cable. | |
| 4. | Secure motorcycle in upright position. NOTE This kit is not compatible with engine guards. | |
| 5. | If the engine guard is present, remove and discard it. |
LEFT SIDE
Component Removal
| 1 | Pretzel clip |
| 2 | Bushing (2) |
| 3 | Screw (6) |
| 4 | Jiffy stand bracket |
| 5 | Bumper |
| 6 | Jiffy stand leg |
| 7 | Clevis pin |
| 8 | Spring |
Figure 1. Jiffy Stand
| 1 | Jam nut |
| 2 | Shifter rod end |
| 3 | Acorn nut |
| 4 | Shifter rod |
| 5 | Shifter arm |
Figure 2. Shifter Linkage
- For HDI Vehicles: Remove the left side foot control support, and jiffy stand sensor, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. For all other models: Remove the left side foot control support, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual.
- Remove rod ends and jam nuts from the shifter rod. Save the rod ends and jam nuts for installation.
NOTE
Two bearing sleeves will remain inside the footrest bracket. The extended controls bracket from the kit will include two sleeves pressed into the bore of the shift lever arm support.
Component Installation
| 1. | See Figure 9. Select shifter mounting assembly (6), O-rings (5), nylon washer (4) and the shift rod (1) from the kit. | |
| 2. | Install the shift arm and new O-rings in the bracket. | |
| 3. | Apply LOCTITE 243 Threadlocker and Sealant to the three mounting screws and mount the shifter bracket with shift arm to the frame. Tighten the mounting screws to 33.9–40.7 N·m (25–30 ft-lbs) | |
| 4. | Apply LOCTITE Anti-Seize Lubricant to the shaft of the jiffy stand. | |
| 5. | Install the jiffy stand following the instructions in the appropriate Service Manual. For HDI Vehicles: Install the jiffy stand sensor. NOTE See Figure 1. Ensure the hook of the spring (9) is installed so the forward hook faces up and the rear hook faces down when the jiffy stand is retracted. | |
| 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) | ||
| 6. | Check that the jiffy stand operates correctly. | |
| 7. | Assemble the shifter rod from the kit with the original rod ends and jam nuts. | |
| 8. | Thread the shifter rod into the shifter rod lever at the transmission and adjust the shifter rod rod ends for the rider posture. Tighten jam nuts to 9–13.5 N·m (80–120 in-lbs). | |
| 9. | Install the shifter rod to the shifter arm with a washer and acorn nut. Tighten the acorn nut to 10.2–12.4 N·m (90–110 in-lbs). | |
| 10. | Install the nylon washer and shift lever over the shift arm shaft. Tighten clamp bolt to 24–30 N·m (18–22 ft-lbs). | |
| 11. | Install the footrest with the bolt, spring washer and locknut. Tighten the locknut allowing the footrest to fold. |  Figure 3. Extended Reach Controls - Left Side (engine guard not included in kit) |
RIGHT SIDE
Removal of Components
| 1. | Remove the right side foot control support, rear brake line, rear brake lever, rear master cylinder and footpeg following the instructions in the appropriate Service Manual. | 
Figure 4. Brake Line Bracket and Stoplamp Switch | ||||||||||
| 2. | See Figure 4. Pull the wire lead connectors and disconnect stoplamp switch (3). NOTE Brake lines are different on 2007 and 2008 models. Refer to the appropriate Service Manual. | |||||||||||
NOTICE Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) WARNINGBe sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d) | ||||||||||||
| 3. | Remove brake line following the instructions in the appropriate Service Manual. | 
Figure 5. Brake Line Routing (2007 Models Shown) 
Figure 6. Brake Line Clamp |
Installation of Components
| 1. | Install the right side foot control support, rear brake lever, rear master cylinder and footpeg following the instructions in the appropriate Service Manual. | |
| 2. | Install the rear brake line and stoplamp switch following the instructions in the separate brake line kit. | |
| 3. | See Figure 5. Route the braided wire section over the rear fork pivot and clip to the lower rear fork tube in the original location. Verify that the brake line runs parallel to the rear of the brake lever bracket and that the brake line does not rub against any part of the bracket. | |
| WARNING Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury. (00291a) | ||
| 4. | See Figure 6. Install the clamp around the brake line following the instructions in the brake line kit. | |
| 5. | See Figure 7. Install the cable straps at locations (1). |
| 1 | Cable strap locations |
Figure 7. Cable Strap Location
Figure 8. Extended Reach Controls - Right Side (engine guard not included in kit)
BLEEDING THE REAR BRAKE
WARNINGBe sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)
| 1. | Check the brake fluid level and refill if necessary following the instructions in the Owner's Manual. NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill brake master cylinder through the bleeder valve. Remove the master cylinder reservoir cover so that the system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place. | |
NOTICE DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c) WARNINGClean reservoir filler cap or cover before removing. Use only DOT 4 brake fluid from a sealed container. Contaminated fluid can adversely affect braking or clutch disengagement, which could result in death or serious injury. (00504d) WARNINGContact 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.
| ||
| 2. | Bleed the brakes following the instructions in the appropriate Service Manual. |
RETURN TO SERVICE
| 1. | For models equipped with saddlebags: Install the saddlebags following the instructions in the appropriate Service Manual. | |
| 2. | Connect the negative battery cable. | |
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||
| 3. | Install the seat following the instructions in the Owner's Manual. | |
| 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) WARNINGBe sure jiffy stand is fully retracted before riding. If jiffy stand is not fully retracted, it can contact the road surface causing a loss of vehicle control, which could result in death or serious injury. (00007a) | ||
| 4. | Verify jiffy stand operation. | |
| 5. | With the ignition/light key switch turned to IGNITION, actuate the rear brake pedal to verify 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) | ||
| 6. | Test ride the motorcycle. If the brake feels soft, repeat the rear brake bleeding procedure. |
Service Parts
Figure 9. Service Parts: Extended Reach Controls Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Shift rod | 11744 |
2 | Washer (6) | 6812 |
3 | Cap screw, button head (6) | 94606-98 |
4 | Washer, nylon | 6057 |
5 | O-ring (2) | 11191 |
6 | Shifter mounting assembly, black | 33723-08 |
Shifter mounting assembly, chrome | 33650-08 | |
7 | Brake lever mounting assembly, black | 42564-08 |
Brake lever mounting assembly, chrome | 42525-08 | |
8 | O-ring (2) | 11364 |
9 | Cotter pin | 515 |
10 | Pin, clevis, black | 33952-08 |
Pin, clevis, chrome | 33948-08 | |
11 | Pin, clevis, black | 33958-08 |
Pin, clevis, chrome | 33951-08 |