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 Forward Control Extension Install  
 

Install Walkthrough - Click Pictures for Full Size

  Package List

4 x 10mm bolts (plates to frame)
4 x 3/8" dia long bolts (footpegs)
4 x 3/8" nyloc locking nuts
13 x 3/8" washers
(3 groups of 3 washers stacked together to get correct thickness)
4 x 8mm nuts (for shift rod extension)
2 x 1" dia thich aluminum spacers
1 shift rod extension
1 complete brake rod


  Tools you need

8mm Socket
14mm Socket
17mm Socket
12mm Wrench (for V&H rear exhaust bolts)
13mm Wrench
9/16" Socket
9/16" Wrench
Needle-nose pliers


 
 
  Exhaust, Brake Rod and Brake-side Control Removal
  • Begin by removing the exhaust. Since I have a Vance & Hines exhaust you may see some slight varations in the install but most are going to be pretty much the same process.
  • Remove the 2 bolts holding the exhaust to the manafolds.
  • Remove the 2 rear exhaust mounting bolts. Then wiggle the exhaust free from the manafolds and set it asside.
  • Disconnect he two springs attached to the brake rod (one is a tension spring, the other is the brake light switch).
  • Remove the 2 bolts holding the brake-side control set (save the washers and remember the order they were in).
  • Remove the cotter-pins from the brake rod connecting it to the brake pedal.
  • Using a large allen wrench (I do not recall the size but it was metric), remove the brake pivot point bolt (careful not to loose the washer) to get access to the rear cotter-pin
  • Dismantle the brake-side controls and set them asside.

 
 
  Shift Rod and Shift-side Control Removal
  • Remove the 2 bolts holding the shift-side control set (save the washers and remember the order they were in).
  • Loosen the shift rod bolt and turn the shift-control assembly to disconnect it from the shift rod.
  • Using an 8mm socket remove the bottom bolt from the chain cover.
  • Remove the safety-clip from the top cover peg and pull the cover free.
  • Dismantle the shift-side controls and set them asside.

 
 
  Install Brake-side Control Extension Plate and Brake Rod Extension
  • Reassemble the brake-side controls and use the provided long bolts and locking nuts to connect the controls to the extension plate.
  • Be sure to allign the hole in the plate with the brake lever mount point to assure the proper orientation of the extension plate.
  • Remember to place a washer between the peg plate and the control plate as well as between the lcoking nuts and the extension plate.
  • Using the 1" spacers between the control assembly and the extension plate secure everything together.
  • Mount top of the extension plate to the frame using one of the provided short bolts and 3 washers as a spacer.
  • Before installing the bottom bolt install the new brake rod extension.
  • Loosen the brake tension bolt at the rear break to allow for more movement in the brake rod.
  • Lengthen the brake switch adjustment screw to accomidate the new brake rod and to assure the brake light will trigger when the pedal is pushed (you can fine-tune this after everything is put back together again).
  • Reinstall the cotter-pins in the brake rod and put the pivot bolt back into the frame (don't forget the washer between the frame and the pivot point).
  • Now install the bottom bolt in the extension plate, no spacer washers are needed.



  Install Shift-side Control Extension Plate and Shift Rod Extension
  • Reassemble the shift-side controls and use the provided long bolts and locking nuts to connect the controls to the extension plate.
  • Be sure to allign the hole in the plate with the shift lever mount point to assure the proper orientation of the extension plate.
  • Remember to place a washer between the peg plate and the control plate as well as between the lcoking nuts and the extension plate.
  • Using the 3 washers as spacers (I used an aluminum spacer I had) between the control assembly and the extension plate for the bottom bolt, secure everything together.
  • Mount the extension plate to the frame using the provided short bolts and 2 washers as a spacer for the top bolt.
  • Attach the shift rod extension to the shift lever and use the supplied nuts to attach the extension rod to the factory shift rod.

 
 
  Chain Cover, Brake Tension Bolt, Springs and Exhaust
  • Double check that all springs are reattached and all cotter-pins are spread apart and secure.
  • Replace the chain cover with the 8mm bolt and be sure to put the safety pin back into the top fastner.
  • Adjust the rear brake tension nut so that the brake lever is not applying the break when in the neutral position.
  • Adjust the brake light switch nut so that it properly triggers the brake light when the right amount of pressure is applied to the lever.
  • Secure the top section of the exhaust pipe and refasten the rear mounting bolts.
  • Verify one last time that all nuts and bolts are tight and everything is clear of obstructions.
You're all done, give her a test run and enjoy the nice stretch your legs get with your new front control extension plates.