Forward Control Installation - '08 FXDC
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Road Captain
Joined: Jun 2006
Posts: 593
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From: Austin, Texas
Forward Control Installation - '08 FXDC
Hey dudes, I just got in my forward control kit from Chicago Harley (the harley brand of controls) and I was wondering how tough it is to install, since you have to take off the entire primary cover? The kit came with extra gaskets, etc. and I have all tools necessary (torque wrenches,etc) except for the service manual. What I'm afraid of are leaks afterwards, since I've never done this before (I know, always a first time for everything and I'll try ANYTHING once!).
Anything to be concerned about? Any tips? The dealer claims it would be a $300+ job just in labor a lone.
I'll know once I get my service manual of course, but I'm curious if the gasket requires any sealant? I put forward controlson a sporty without a problem, but of course they are a lot different in more ways than one!
Thanks in adv.
Anything to be concerned about? Any tips? The dealer claims it would be a $300+ job just in labor a lone.
I'll know once I get my service manual of course, but I'm curious if the gasket requires any sealant? I put forward controlson a sporty without a problem, but of course they are a lot different in more ways than one!
Thanks in adv.
Elite HDF Member
Joined: Aug 2007
Posts: 4,722
Likes: 7
RE: Forward Control Installation - '08 FXDC
Someone said the other day that the HD kit now comes with the chrome cover for the old spline and a clip to lock the old shift linkage out of the way like the Kuryakyn kits come with. Does yours have these? If so, consider installing the kit without opening the primary and removing the components. Later, you could go back and do that if you decide you want to make it more permanent. If you do the install without the primary work, it will take you less time, be easier, and allow you to go back to mids if you decide to and/or if/when you sell the bike to someone that wants the factory mids...
Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
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From: From Long Island, now in So. Cal
Tourer
Joined: Oct 2007
Posts: 319
Likes: 1
From: Ventura, Ca.
RE: Forward Control Installation - '08 FXDC
congrats dude. they're great! you have to take the primary cover off. it's not too bad. starter removal was a bitch and you should have a manual. to remove drive and clutch nuts you can make the 'special tool' (used to hold sprockets in place) out of 1" aluminum anlge available to Home Depot. use loctite. way cleaner install than leaving the OEM shifter shaft and trying to cover it up with a piece of chrome.
goode luck with it.
goode luck with it.
Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
RE: Forward Control Installation - '08 FXDC
You don't have to remove the primary on the 2006 and up Dyna's. The 2006 kit comes with a longer rear shift lever that requires you to remove the primary to install it.That longer shift lever will give you more leverage for an easier shift, but it will also increase your throw.I preferthe shorter throw andit isn't any harder to shift then the original set up.I bought thethe cheaper 2005 kit because I planned on getting a custom shift rod.You have to use a longer shift rod with the 2005 kit other wise the front shift lever will hit the primary when you up shift. Also the 2005 kit comes with a bracket to bolt down the original shift lever, but it is pretty easy to remove, read below.
Removing the original shift shaft lever
Geta hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins.Tape a wrench onone end to get a better grip (on the end of the bladeso as you pull on the wrench you will be on the cutting stroke of the blade).Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom.Use your other hand to guide the top of the blade as you cut. I cut about three quarters through then wrapped a rag around the shift lever and used vise grips on the other end of the shaft splines and sheared it off.
Coverforthe original shift shaft lever hole
I used achrome carriage bolt http://www.chromebolt.com/51618-x-13...olt-p-845.html, and put atwo inchpiece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole.
Here's a photo with the 2005 kit and a 2006 polishedstainless shift rod on my 2006 Low Rider.
Part numbers here:
http://www.harley-davidson.com/gma/g...bmLocale=en_US
Check prices here:
https://www.zanottimotor.com/shopping/partLookUp.html
Removing the original shift shaft lever
Geta hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins.Tape a wrench onone end to get a better grip (on the end of the bladeso as you pull on the wrench you will be on the cutting stroke of the blade).Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom.Use your other hand to guide the top of the blade as you cut. I cut about three quarters through then wrapped a rag around the shift lever and used vise grips on the other end of the shaft splines and sheared it off.
Coverforthe original shift shaft lever hole
I used achrome carriage bolt http://www.chromebolt.com/51618-x-13...olt-p-845.html, and put atwo inchpiece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole.
Here's a photo with the 2005 kit and a 2006 polishedstainless shift rod on my 2006 Low Rider.
Part numbers here:
http://www.harley-davidson.com/gma/g...bmLocale=en_US
Check prices here:
https://www.zanottimotor.com/shopping/partLookUp.html
Outstanding HDF Member
Joined: Mar 2007
Posts: 2,167
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RE: Forward Control Installation - '08 FXDC
No need for primary removal IMO, but some guys prefer to "do it the right way" which means tearing into things alot more for what I see as a minimal gain.
I also did what WS6 did and just took a hacksaw blade to shear the old shaft off. I waited a few months before I did this, thinking I might want to change it back to mid controls if I were to sell the bike, but that idea faded and I got rid of the shaft. Looks much better with just the freeze plug I painted wrinkle black to match the primary. The cap they give you for the old shaft sticks out like a sore thumb. [:'(]
I also did what WS6 did and just took a hacksaw blade to shear the old shaft off. I waited a few months before I did this, thinking I might want to change it back to mid controls if I were to sell the bike, but that idea faded and I got rid of the shaft. Looks much better with just the freeze plug I painted wrinkle black to match the primary. The cap they give you for the old shaft sticks out like a sore thumb. [:'(]
Thread Starter
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Road Captain
Joined: Jun 2006
Posts: 593
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From: Austin, Texas
RE: Forward Control Installation - '08 FXDC
ORIGINAL: JayFromPa
I also did what WS6 did and just took a hacksaw blade to shear the old shaft off.
I also did what WS6 did and just took a hacksaw blade to shear the old shaft off.
I'll have to review these options and see which route I'm going take. The only route I CANNOT see myself taking is to let the dealer do it for $250+ just in labor. What a bummer.
Thx for the help as always. I'll also check out that link from the other post. Any other feedback or experiences fromdoing the same mod would still be appreciated!
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Outstanding HDF Member
Joined: Jan 2007
Posts: 3,438
Likes: 3
From: Chesterfield, VA
RE: Forward Control Installation - '08 FXDC
Go ahead and do it. It is intimidating to think of using a hacksaw blade.........at first. After you do it, you will feel a great sense of ssatisfaction and be really glad you did. Follow WS6's instructions and it is simple.
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