Reduced Reach Conversion Kit
J053212011-06-02
GENERAL
Kit Number
50700005
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
Separate purchase of LOCTITE® Anti-Seize Lubricant (Harley-Davidson Part No. 98960-97) is required for proper installation of this kit. This can be purchased from any 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)
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.
INSTALLATION
Shifter Assembly
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Disconnect battery cables, negative (-) cable first. | |
| 2. | Remove the two fasteners from the left side footrest bracket, leaving the shifter lever assembly, linkage and footpeg attached. Discard fasteners. NOTE See Figure 1. The reduced reach plate (1) is installed between the shifter bracket and frame. | |
| 3. | Position the reduced reach plate (1) on the frame where the shifter bracket was mounted with the tapped holes toward the rear and the counter bores facing out. Secure using two new screws (2) and tighten to 41–47 N·m (30–35 ft-lbs). | |
| 4. | Install the shifter bracket onto the reduced reach plate using two new screws (2). Tighten to 41–47 N·m (30–35 ft-lbs). | |
| 5. | Adjust foot shift lever for rider comfort. Tighten pinch bolt to 24.4–29.8 N·m (18–22 ft-lbs) NOTE After all shifter components are installed, move shifter through entire range of motion and check for interference with other components. The length of shift rod can be adjusted for clearance to primary case. |
Brake Pedal and Linkage Assembly
| 1. | Remove the right side rider footrest from the mount clevis. Retain the footrest and hardware for installation. | |
| 2. | See Figure 1. Loosen the brake rod jam nut (D) at the rear brake master cylinder. NOTE Use the flats on the push rod (E) to remove the brake rod from the master cylinder. | |
| 3. | Rotate the master cylinder push rod to remove the original brake rod. | |
| 4. | Remove jam nut and retain for installation. Discard the original brake rod. | |
| 5. | Remove the two fasteners from the right side footrest bracket. | |
| 6. | Remove footrest clevis (B) and brake pedal pivot shaft (4). Discard pivot shaft and retain clevis and screw (C) for assembly. NOTE The reduced reach plate (3) is installed between the brake pedal bracket (A) and frame. | |
| 7. | Position the reduced reach plate (3) on the frame with the tapped hole toward the front and the counter bores facing out. Secure using screw (2) in the lower hole and align the upper hole with the threaded hole in the frame. Tighten to 41–47 N·m (30–35 ft-lbs). | |
| 8. | Fasten the brake pedal bracket (A) to the frame and reduced reach plate using screws (2 and 5). Tighten the screws to 41–47 N·m (30–35 ft-lbs). | |
| 9. | Coat the new brake pedal pivot shaft (4) with Loctite Anti-Seize. | |
| 10. | Fasten the new brake pedal pivot shaft (4), brake pedal and footrest mount clevis (B) to the brake pedal bracket (A) using the long Torx screw (C). Tighten the screw to 44–47 N·m (32–35 ft-lbs). | |
| 11. | Install the jam nut (D) all the way onto the new brake rod (6). | |
| WARNING When adjusting brake control rod, never allow more than nine threads to be exposed between control rod and jam nut. If more than nine threads are exposed, brake rod can come apart resulting in loss of rear brake, which could cause death or serious injury. (00306c) | ||
| 12. | Turn the master cylinder push rod onto the brake rod until about half the threads are used. | |
| 13. | Connect the brake rod (6) to the brake pedal using the original clevis pin, washer and cotter pin. Bend the legs of the cotter pin around the clevis pin shaft. | |
| 14. | Verify that the water drain hole in the rubber boot (covering the brake rod) is on the bottom of the rubber boot. | |
| 15. | Turn the push rod on 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 jam nut against the master cylinder push rod. | |
| 16. | Fasten the original footrest to the footrest mount clevis (B) using the original fasteners. NOTE After all brake components are installed, move brake pedal through entire range of motion and check for interference with other components. The length of the brake rod can be adjusted for clearance to the exhaust system if needed. | |
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||
| 17. | Connect the battery cables, positive (+) cable first. | |
| 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) WARNINGBrakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a) | ||
| 18. | Test brakes for proper operation before riding vehicle. |
SERVICE PARTS
Figure 1. Service Parts: Reduced Reach Conversion Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Plate, reduced reach, left | Not sold separately |
2 | Torx screw, 3/8-16 x 1.0 in. (6) | 4512A |
3 | Plate, reduced reach, right | Not sold separately |
4 | Brake pedal pivot shaft | Not sold separately |
5 | Torx screw, 3/8-16 x 1.5 in. | Not sold separately |
6 | Brake rod | Not sold separately |
Items mentioned in text, but not included in kit: | ||
A | Brake pedal bracket | Reference only |
B | Footrest mount clevis | Reference only |
C | Torx screw, 3/8-16 x 2-3/4 in. | Reference only |
D | Jam nut | Reference only |
E | Master cylinder push rod | Reference only |