ended forward control kit on 58-86
FLH, FX four-speed and 86-99 five-speed Softail models.
Review instructions carefully before beginning, as they
contain important information. Please retain for future
reference. Particularly important information is distinguished
in these instructions by the following notations:
NOTE: A NOTE provides key information to make
procedures easier or clearer.
CAUTION: A CAUTION indicates special procedures
that must be followed to avoid damage to the motorcycle
and/or accessories.
WARNING:
A WARNING indicates special procedures
that must be followed to avoid injury to a motorcycle operator
or person inspecting or repairing the motorcycle.
12. Check all fasteners to make sure they are securely tightened.
13. Install the rear brake mounting bracket on the right side of
the motorcycle.
14. Install the rear brake lever on the mounting bracket, checking
to make sure that the lever rotates freely on the bracket. Make sure
to install the brake return spring at the same time. The brake lever is
installed correctly when it is under the foot peg mount, allowing the
spring to hold the lever up against the foot peg mount.
15. Install the foot peg and the brake lever peg on the mounting bracket.
16. Assemble the brake plunger and the plunger Heim joint together,
making sure to use the included lock nut. Screw the plunger Heim
joint as far into the brake plunger as possible. Install the brake plunger
on the brake lever.
17. Install the brake master cylinder to the mounting bracket. Make
sure to place the brake plunger into the end of the master cylinder.
18. Adjust the length of the brake plunger into the master cylinder.
The brake plunger is adjusted correctly when there is approximately
1
/
2
" of free movement of the brake lever BEFORE the brake plunger
contacts the piston in the master cylinder. The piston in the master
cylinder must be allowed to return completely to the rear and seat
against the retaining ring for correct operation.
WARNING:
Failure to adjust the brake plunger correctly may
cause the rear brake to drag, overheat, or cause brake failure.
We suggest that you have an experienced mechanic check this
adjustment before you operate the motorcycle.
19. Install the brake line kit. In certain circumstances you may
be required to fabricate a custom brake line.
20.
Check all fasteners and connections to make sure that
they are tight.
21. Using DOT 5 brake fluid only, fill the master cylinder
reservoir and bleed the rear brake system. Keep bleeding
until you obtain a flow of brake fluid clear of any air bubbles
from the bleeder screw on the caliper. Maintain the correct
fluid level in the master cylinder during the bleeding operation.
22. Allow the brake to sit for approximately 5 minutes and
then test the brake system again, making sure that the brake
lever is firm with no softness.
23. Again check all fasteners for the correct tightness.
Check the brake fluid for the correct level.
24.
Apply steady pressure to the brake lever and check all brake
line fittings for any leaks.
25. Check for adequate clearance between forward controls
and front fender with forks bottomed.
26. Test ride the motorcycle and check for correct shifter
and brake operation. Check brake operation at low speed
in a low traffic area.
WARNING:
Check the rear caliper and disc for overheating.
Make sure that the rear wheel rotates freely. Any dragging will cause
the brake to overheat and fail.
WARNING:
Before operating motorcycle, be sure all hardware
is tight.
TOOLS REQUIRED
7
/
16
" wrench
1
/
2
" wrench
9
/
16
" wrench
External snap ring pliers
Needlenose pliers
DOT 5 brake fluid
PROCEDURE:
1. Support the motorcycle so that it is in a vertical position and
the side stand is not used.
2. Remove the existing brake and shifter controls from the motorcycle.
3. Remove the side stand from the motorcycle.
4. Install the shift arm into the shift bracket. Lubricate and make sure
that it rotates freely.
5. Install the shift bracket onto the motorcycle. Place the regulator
mount between the frame and the shift bracket.
6. Install the side stand on the outside of the shift bracket.
NOTE: Make sure that you install the bolts through the shift bracket
that are hidden under the side stand. Failure to install these bolts will
cause side stand failure. We recommend that you use a thread locking
adhesive on all nuts and bolts.
7. Tighten all mounting bolts securely.
8. Assemble the correct shift linkage rod for your application.
See schematic for the correct linkage rod. The five-speed Softail
models use the FX type linkage.
9. Install the linkage rod using the correct rod ends and retaining rings.
10. Install the foot peg and shift lever on the shifter bracket. Position
the shift lever to allow ample room to place your foot onto the footpeg.
11. Rotate the shift lever, making sure that it allows the transmission
to shift entirely into both higher and lower gears. Reposition the shift
lever or adjust the linkage rod as necessary.
INSTALLATION INSTRUCTIONS
Updated 4/02
Page 1 of 2
Box 9336, Minneapolis, MN 55440
DRAG SPECIALTIES
EXTENDED FORWARD CONTROL KIT FOR BIG TWINS
P/N DS-243523
DRAG SPECIALTIES INSTALLATION INSTRUCTIONS
Updated 4/02
Page 2 of 2
Box 9336, Minneapolis, MN 55440
DRAG SPECIALTIES
EXTENDED FORWARD CONTROL KIT FOR BIG TWINS
P/N DS-243523
DRAG SPECIALTIES
NO.
QTY.
DESCRIPTION
1
1
Plate, brake lever
2
1
Brake lever
3
1
Plunger Heim joint
4
1
Master cylinder
5
1
Brake return spring
6
1
Master cylinder plunger
7
2
Foot peg
8
2
Foot peg mounting kit
9
1
Brake line kit
10
1
Shifter bracket
11
1
Shift arm
12
1
Shift lever
13
1
Shifter rod, FX type
14
1
Shifter rod Heim joint, FX type
15
1
Shifter rod Heim joint, FL type
16
1
Shifter rod, FL type
17
2
Peg, shifter and brake
18
1
3
/
4
" nylock nut
19
1
3
/
8
" - 16 x 4" bolt
20
4
3
/
8
" - 16 x 1" bolt
21
2
5
/
16
" - 24 x 2
1
/
4
" bolt
22
4
5
/
16
" - 24 x 1
1
/
4
" bolt
23
1
1
/
4
" - 28 x
5
/
16
" set screw
24
9
5
/
16
" - 24 acorn nut
25
3
3
/
8
" int. tooth lockwasher
26
1
5
/
16
" - 24 x 1" bolt
27
2
3
/
8
" lockwasher
28
8
5
/
16
" lockwasher
29
1
3
/
8
" flatwasher (1
3
/
8
" o.d.)
30
1
Retaining ring
31
3
Cable tie, black 7"
32
1
1
/
4
" - 28 UNF nut
33
1
1
/
4
" - 20 x 1" bolt
34
1
1
/
4
" flatwasher
35
4
5
/
16
" flatwasher
36
1
Clevis pin kit
OPTIONAL MASTER CYLINDER FOR
DRUM BRAKE APPKICATION
79 THRU 86 TRANSMISSIONS FX MODELS
79 THRU 86 TRANSMISSIONS
FL AND FXWG MODELS