silverbullet2005
05-15-2007, 12:01 AM
This is my first try at doing a write-up. I found bits and pieces about installing forward controls on the 06-07 Dyna models but I figured there should be a decent write-up with more info in one place. there are other members on this site with great info and different ways of doing it so do a search and you may find what your looking for. This install was done on a 2006 Dyna Street Bob model, I will add pictures within the next few days.
CLICK ON THELINK FOR PICTUREShttp://smg.photobucket.com/albums/v721/silverbullet2005/My%20Harley%20Street%20Bob/
TOOLS NEEDED
1/2" and 3/8" torque wrenches
torx bits and/or drivers
allen head bits and/or drivers
phillips screwdriver
13/16 socket
30mm socket
seal removing tool or large flathead screwdriver
basic hand tools and socket sets
special sprocket holding tool Harley part number HD-47977 or make your own from measurements given in write-up
zip tie
Forward Control Installation For 06-07 Dyna Models
*****USE ALONG WITH KIT INSTRUCTIONS*****
REMOVAL PROCESS
-Remove seat.
-Remove battery cover by unscrewing Phillips head from bottom of cover.
-Disconnect both battery terminals and battery retaining strap.
-Remove battery tray housing (three torx screws) (unhook plastic retainers from backside)
-Disconnect starter cables and unclip solenoid connector. Remove starter (2 allen bolts)
-With the bike on the jiffy stand remove drain plug from primary cover and drain oil.
-Remove left mid mounted foot rest and install supplied black plugs from kit.
-Back off the lock nut on brake rod at master cylinder piston. Disconnect brake rod from master cylinder piston by turning flats on piston. Remove right mid mounted foot rest then install black plugs from kit.
-Mark original shifter shaft per kit instructions then remove original shifter lever.
-Get a large trash bag and lay it down under the primary cover/engine area to catch oil and debrit.
-Remove all primary cover allen bolts and place them on a flat surface in the order removed so you can reinstall them into the same location you removed them from later.
-Gently remove primary cover, you may have to tap on it with the palm of your hand. Place it on a trash bag to let the oil drain off it.
-Remove the five T27 bolts from derby cover on primary cover, remove derby cover.
-Use a good sized zip tie to go around the right side of the automatic chain tensioner and pull it tight as possible. This will keep the tensioner from separating when removed and make it simple to install later.
-Mark chain link/sprocket and case housing at a point on both the compensating sprocket assembly and clutch assembly to keep everything located correctly.
-Remove the automatic chain tensioner (two bolts)
[font="times new roman"][size=3]-Remove nut from clutch adjusting plate bolt then use snap ring pliers to remove snap
CLICK ON THELINK FOR PICTUREShttp://smg.photobucket.com/albums/v721/silverbullet2005/My%20Harley%20Street%20Bob/
TOOLS NEEDED
1/2" and 3/8" torque wrenches
torx bits and/or drivers
allen head bits and/or drivers
phillips screwdriver
13/16 socket
30mm socket
seal removing tool or large flathead screwdriver
basic hand tools and socket sets
special sprocket holding tool Harley part number HD-47977 or make your own from measurements given in write-up
zip tie
Forward Control Installation For 06-07 Dyna Models
*****USE ALONG WITH KIT INSTRUCTIONS*****
REMOVAL PROCESS
-Remove seat.
-Remove battery cover by unscrewing Phillips head from bottom of cover.
-Disconnect both battery terminals and battery retaining strap.
-Remove battery tray housing (three torx screws) (unhook plastic retainers from backside)
-Disconnect starter cables and unclip solenoid connector. Remove starter (2 allen bolts)
-With the bike on the jiffy stand remove drain plug from primary cover and drain oil.
-Remove left mid mounted foot rest and install supplied black plugs from kit.
-Back off the lock nut on brake rod at master cylinder piston. Disconnect brake rod from master cylinder piston by turning flats on piston. Remove right mid mounted foot rest then install black plugs from kit.
-Mark original shifter shaft per kit instructions then remove original shifter lever.
-Get a large trash bag and lay it down under the primary cover/engine area to catch oil and debrit.
-Remove all primary cover allen bolts and place them on a flat surface in the order removed so you can reinstall them into the same location you removed them from later.
-Gently remove primary cover, you may have to tap on it with the palm of your hand. Place it on a trash bag to let the oil drain off it.
-Remove the five T27 bolts from derby cover on primary cover, remove derby cover.
-Use a good sized zip tie to go around the right side of the automatic chain tensioner and pull it tight as possible. This will keep the tensioner from separating when removed and make it simple to install later.
-Mark chain link/sprocket and case housing at a point on both the compensating sprocket assembly and clutch assembly to keep everything located correctly.
-Remove the automatic chain tensioner (two bolts)
[font="times new roman"][size=3]-Remove nut from clutch adjusting plate bolt then use snap ring pliers to remove snap