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FORWARD CONTROL KIT
941002172022-03-08
GENERAL INFORMATION
Table 1. General Information
Kits
Suggested Tools
Skill Level(1)
50502205
Safety Glasses, Torque Wrench
(1) DTII and dealer installation required
KIT CONTENTS
Figure 1. Kit Contents: Left Forward Control Kit
Figure 2. Kit Contents: Right Forward Control Kit
Table 2. Kit Contents: Left Forward Control Kit
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
Notes
1
1
Screw, M8
10201009
2
1
Washer, custom
10600060
3
1
Shift lever
33600285
4
1
Wear peg
50501135
5
2
Screw, button head flange, M8 Torx™
10200792
6
1
Footpeg support mount bracket
50502221
7
1
Footpeg mount bracket
50502203
8
1
Flange nut, M8
10100132
9
1
Spacer
12400209
10
1
Screw, button head cap, M8
10200929
11
2
Screw, button head cap, M8
10200929
12
1
Screw, hex socket head
3709M
13
1
Shifter rod lever
33900169
14
1
Screw, button, M8 Torx™
10200712
15
1
Shifter rod
33600377
Table 3. Kit Contents: Right Forward Control Kit
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
Notes
1
1
Footpeg mounting bracket assembly
50502200
2
1
Reservoir mounting bracket
41600361
3
1
Nut
10100018A
4
1
Screw, button head cap, M6
10200935
5
1
Screw, button head,M8 Torx™
10200792
6
1
Clamp (brake line)
10800208
7
1
Screw, button head cap, M6
10200935
8
1
Brake line, EHCU to Rear Master Cylinder
41800855
9
1
Banjo bolt
41750-06B
10
4
Gasket, brake line
41751-06A
11
1
Master cylinder reservoir, rear brake
41701112
Includes hose and spring clamps
12
1
Brake pedal
50600501
13
1
Wear peg
50501135
14
1
Screw, button head cap, M8
10200931
15
1
Washer, custom
10600060
16
1
Screw, M8
10201009
17
1
Flange nut
10100132
18
3
Screw, button head cap, M8
10200929
19
3
Spacer
12400210
20
3
Nut
10100018A
21
1
Brake line bracket
41600360
22
1
Clamp, band
41600359
23
1
Clamp, double locking
10800191
24
3
Screw, button head cap
10200934
25
1
Grommet, retaining
12100115
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
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
This instruction sheet references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:
These items are available at your Harley-Davidson dealership:
Installation by a technician at a Harley-Davidson dealership is recommended.
PREPARE
1. Remove main fuse. See service manual.
2. Remove and discard OE right and left chin spoilers. See service manual.
a. Retain screws for later use.
3. Remove left and right foot pegs. See service manual.
4. Remove exhaust system. See service manual.
REMOVE
1. Remove left rider footrest assembly. See service manual.
a. See Figure 3. Remove shift linkage (2) from shifter rod lever.
b. Remove left foot support bracket (1).
1Support bracket
2Shift linkage
Figure 3. Left Footrest Assembly
2. Remove rear master cylinder. See service manual.
a. See Figure 4. Remove banjo bolt (5). Discard brake line gasket washers.
b. Remove and discard master cylinder reservoir (1).
c. Remove and discard master cylinder reservoir hose (6).
d. Remove screws and rear master cylinder (4). Save for later use.
3. Remove right rider footrest assembly. See service manual.
a. See Figure 4. Remove and discard brake pedal (2).
b. Remove and discard support bracket (3).
c. Keep brake line assembled to vehicle Electro Hydraulic Control Unit (EHCU).
1Master cylinder reservoir
2Brake pedal
3Support bracket
4Master cylinder
5Banjo bolt.
6Master cylinder reservoir hose
Figure 4. Right Footrest Assembly
Wear Pegs
1. See Figure 2. Install wear peg (13). Tighten.
Torque: 3.5–4.5 N·m (31–40 in-lbs) Wear peg
2. Repeat procedure for opposite side.
1Wear peg (2)
Figure 5. Wear Peg
Left Footrest
1. See Figure 6. Install shift lever (3) to footpeg mount bracket (2).
2. Install washer (4) and screw (5).
3. Install flange nut (1). Tighten.
Torque: 24.5–30 N·m (18.1–22.1 ft-lbs) Flange nut
4. See Figure 7. Install footpeg mount bracket (1) and footpeg support mount bracket (6).
a. Loosely install spacer (8) and screw (7).
b. Loosely install screws (5).
c. Tighten screws (5).
Torque: 22–24 N·m (16.2–17.7 ft-lbs) Screw, Torx
d. Tighten screws (7).
Torque: 21–25 N·m (15.5–18.4 ft-lbs) Screw, button head
5. Remove and discard Original Equipment (OE) shifter rod lever and install lever from kit (10).
a. Adjust clocking of shifter rod lever (10) to achieve desired position.
b. Install screw (12). Tighten.
Torque: 19.5–51.5 N·m (14.4–38.0 ft-lbs) Screw, hex socket head
6. Install shifter rod assembly (9).
a. Install screw (14).
b. Install rod end screw (3).
c. Tighten screws (3, 14).
Torque: 10.5–12 N·m (93–106 in-lbs) Shifter rod screw
7. See Figure 8. Install screws (1).
Torque: 21–25 N·m (15–18 ft-lbs) Jiffy stand screw
a. Refer to Table 2. Item 11.
1Flange nut
2Footpeg mount bracket
3Shift lever
4Washer
5Screw
Figure 6. Left Support Bracket
1Footpeg mount bracket
2Shift lever
3Rod end screw
4Rod end
5Screw, Torx (2)
6Footpeg support mount bracket
7Screw, button head
8Spacer
9Shifter rod
10Shifter rod lever
11Transmission output shift shaft
12Screw, hex socket head
13Rod end
14Screw, button Torx
Figure 7. Left Foot Control Assembly
1Screw (2)
2Jiffy stand
Figure 8. Jiffy Stand
Right Footrest
1. See Figure 9. Install brake pedal.
a. Install brake (3) to footpeg mounting bracket (2).
b. Install washer (4) and screw (5).
c. Install flange nut (1). Tighten.
Torque: 17–21 N·m (13–15 ft-lbs) Brake pedal nut
2. See Figure 10. Install rear brake master cylinder.
a. Position reservoir mounting bracket (2) and rear brake master cylinder (4) to footpeg mounting bracket (3).
b. Install screws (1). Tighten.
Torque: 9–11 N·m (7–8 ft-lbs) Rear master cylinder screw
c. Install brake pedal (5) to master cylinder clevis (8).
d. Install clevis pin (6) and cotter pin (7).
3. See Figure 11. Install rear brake master cylinder reservoir assembly.
a. Install reservoir (4).
b. Apply threadlocker to screw (5).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
c. Install screw (5) and nut (3). Tighten.
Torque: 4–7 N·m (3–5 ft-lbs) P-Clamp screw
d. Reposition spring clamp (1) on brake hose (2) that installs to master cylinder.
e. Install brake hose (2) to master cylinder from reservoir (4).
f. Move spring clamp (1) to lock down brake hose.
4. See Figure 11. Install brake line to rear master cylinder.
a. See Figure 12. Position brake line as shown.
b. See Figure 11. Install new gasket washers (7).
c. Loosely install banjo bolt (6).
d. See Figure 13. Install p-clamp (2) to brake line (1).
e. Loosely install screw (3).
f. See Figure 12. Check that brake line is properly routed as shown.
g. See Figure 13. Tighten screw (3).
Torque: 4–7 N·m (3–5 ft-lbs) P-Clamp screw
h. See Figure 11. Tighten banjo bolt (6).
Torque: 23–26 N·m (17–19 ft-lbs) Banjo bolt
5. See Figure 14. Install footpeg mounting bracket assembly (1) to vehicle.
a. Install screws (2). Tighten.
Torque: 22–24 N·m (16–18 ft-lbs) Footpeg mounting bracket assembly screw
1Flange nut
2Footpeg mounting bracket
3Brake pedal
4Washer
5Screw
Figure 9. Brake Pedal
1Screw (2)
2Reservoir mounting bracket
3Footpeg mounting bracket
4Rear brake master cylinder
5Brake pedal
6Clevis pin
7Cotter pin
8Master cylinder clevis
Figure 10. Rear Brake Master Cylinder
1Spring clamp (2)
2Brake hose
3Nut
4Reservoir (with hose assembly)
4Screw
5Banjo bolt
6Gasket washer
7Brake line
Figure 11. Rear Brake Master Cylinder Reservoir
1Rear brake master cylinder
2Brake line
3Reservoir
Figure 12. Top View, Brake Line Clocking
1Brake line
2P-Clamp
3Screw
Figure 13. P-Clamp
1Footpeg mounting bracket assembly
2Screw (2)
Figure 14. Install Assembly
Brake Line Bracket
1. See Figure 15. Install retaining grommet (9) and double locking clamp (10) around hard section of brake line (12).
a. Use lower slot in retaining grommet (9) for brake line.
2. Position brake line (12) and clamp (10) on top of brake line bracket (11).
3. Install band clamp (6) around groove of brake line manifold.
4. Apply threadlocker to screws (5, 8).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
5. Install screws (5, 8) and nuts (4, 7).
a. Adjust brake line and clamps as needed.
b. Tighten.
Torque: 4.5–8.5 N·m (40–75 in-lbs)
6. See Figure 16. Install brake line bracket (3).
7. Apply threadlocker to screws (2).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
8. Install spacers (2) and screws (1). Tighten.
Torque: 21–25 N·m (15–18 ft-lbs)
9. See Figure 15. Install banjo bolt (1).
a. Install new gasket washers (2).
Torque: 23–26 N·m (17–19 ft-lbs) Banjo bolt
1Banjo bolt
2Gasket washer
3Brake line (to EHCU)
4Nut (2)
5Screw (2)
6Band clamp
7Nut
8Screw
9Retaining grommet
10Double locking clamp
11Brake line bracket
12Brake line (to rear Master Cylinder)
Figure 15. Banjo Bolt
1Screw (3)
2Spacer (3)
3Brake line bracket
Figure 16. Brake Line Bracket
COMPLETE
1. Install exhaust system. See service manual.
2. Install left and right foot pegs. See service manual.
3. Install main fuse. See service manual.
4. Service rear brake master cylinder. See service manual.
5. Bleed brake system. See service manual.
a. Flash Anti-lock Braking System (ABS).