DYNA RIDER FOOTBOARD KIT

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1 -J0 REV DYNA RIDER FOOTBOARD KIT GENERAL Kit Number 000 Models For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of (English only). Additional Parts Required Separate purchase of LOCTITE Threadlocker and Sealant - Blue (Harley-Davidson -) is required for proper installation of this kit. LOCTITE can be purchased from any Harley-Davidson Dealer. The rider's safety depends 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. (00a) This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure, Figure, Figure and Table Reference. INSTALLATION Shifter Assembly. See service manual and disconnect main fuse.. See service manual and remove the left side rider footrest assembly. Discard the footrest and fasteners.. See Figure. Remove plugs from forward frame footboard mount (E) and discard plugs.. See Figure. Remove the foot shifter lever (A) and shifter peg (D). Save the foot shifter lever and shifter peg and hardware for future installation.. See Figure. See service manual and remove the outer cover assembly (A) and inner cover assembly (B).. See Figure. Before removing the gear shifter lever (): a. Using a marking tool, draw a location marking () on the end of the splined shaft () across from the casting split (). This will allow the new gear shifter lever to be installed in the same orientation as the old lever. b. After marking the gear shifter lever orientation, loosen the lever bolt () and remove the gear shifter lever (). c. Discard the gear shifter lever and lever bolt. d. See Figure. From the kit, install the new gear shifter lever () and bolt () onto the splined shaft in the same orientation as the old shifter lever. e. See Figure. Tighten the lever bolt () to - ft-lbs (.-. Nm).. See Figure. Install the front and rear footrest brackets ( and ) to the frame using the buttonhead TORX screws (). Tighten screws to - ft-lbs (.-. Nm). is00. Gear shifter lever. Splined shaft. Casting split. Location marking. Lever bolt Figure. Gear Shifter Lever Orientation -J0 Many Harley-Davidson Parts & Accessories are made of plastics and metals which can be recycled. Please dispose of materials responsibly. of

2 . See Figure. Install the front inner gear shifter () and washer () to inside of the front footboard bracket.. Install the previously saved gear shifter (A) with a coat of light lubricant. Install washer (B), screw (C), and shifter peg (D) to the gear shifter. Tighten screw (C) to - ft-lbs (.-. Nm). 0. Using a small amount of Loctite, install the new shifter rod assembly (0) onto the gear shifter lever (). Also install washer () and acorn nut () to inner gear shift assembly (). Tighten acorn nut () and rear of shift linkage (0) to - ft-lbs (0.-. Nm).. Tighten rear gear shifter lever threaded swivel stud. After all shifter components are installed, move shifter through entire range of motion and check for interference with other components.. See Figure. Put inner primary cover (B) and primary cover (A) in position and check for proper clearance with shifter linkage components.. See Figure. Clean the area around primary cover () hole, removing all dirt, oil and grease. Apply Loctite around opening (). Insert primary hole plug () into opening. Remove any excess adhesive from surface. Allow Loctite to cure for hours before operating vehicle.. Moisten four rubber anchors on bottom of new footboard pad with soapy water.. See Figure. Place pad () into position on footboards (). From bottom of footboards, use pliers to pull rubber anchors through holes in footboards.. See Figure. See service manual. Install primary cover using new gaskets from the kit. is00. Primary cover. Shifter shaft hole (original position). Loctite area (X). Primary hole plug Figure. Outer Cover Plug Installation. See Figure. Install footboards () to brackets ( and ) using shoulder bolts () and flange nuts (). Tighten screws to -0 ft-lbs (0- Nm). Rear Brake and Footboard Assemblies It may be helpful to remove the exhaust to access the rear brake components. Refer to the service manual for the exhaust removal.. See Figure and service manual. Remove the right side rider footrest fasteners. Discard the fasteners.. Loosen the brake rod jam nut () at the rear brake master cylinder. The master cylinder piston has flats for a wrench.turn the flats on the piston to unscrew the brake rod from the master cylinder.. Unscrew the master cylinder piston from the stock brake rod.. Remove and discard the stock brake rod, footrest and brake pedal assembly.. Remove the rear bracket footrest hole plugs and discard.. Fasten the new front () and rear () footboard supports to the frame using TORX screws (). Tighten screws to - ft-lbs (-0 Nm).. Install the jamnut () all the way onto the new brake rod ().. Fasten the brake rod to the master cylinder piston. When installing the brake rod make sure that brake rod does not have any interference from the clamps on the exhaust. The clamps could scrape the paint on the brake rod.. Coat the pivot shaft () with a light coating of lubricant. Install the brake pedal () to the front footboard support () with long TORX screw (), foot brake lever cap (), pivot shaft (), clevis pin () and circular cotter (0). 0. With a wrench on the master cylinder piston flats, turn the piston onto the brake rod until the brake pedal is elevated to an effective rider angle, using at least half the threads available on the brake rod. Tighten the jam nut against the master cylinder piston.. Install brake pedal pad (). Verify brake pedal and rod travel through entire range of motion without binding or interference.. Place the footboard into position between brackets and install shoulder bolts (), so that the flange locknuts () will be on the inboard side.. Install flange locknuts onto shoulder bolts and tighten to 0-0 in-lbs (.-.0 Nm). After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00a). Return the motorcycle to service: a. Refer to service manual and install main fuse. b. Test lights and brakes. If the brakes feel spongy, bleed the system. -J0 of

3 SERVICE PARTS is00a B A C Figure. Primary Chaincase Cover and Housing Components Table. Service Parts Table Hole plug Hole plug, black 0-ring Primary gasket, crankcase housing Inner primary seal Seal bolts, / inch () Tower gasket Primary cover gasket Clutch cover seal s mentioned in text, but not included in kit: A Primary cover B Inner primary cover assembly C Clutch cover Y -0 0A Not Sold Separately Not Sold Separately -J0 of

4 is00 0 E F A B C D Figure. Dyna Rider Footboard Kit Table. Service Parts Table 0 Shoulder bolt () Button head TORX screw.- x.00 () Flange nut () Right front footboard bracket Left rear footboard bracket Spring washer Inner gear shift lever assembly Acorn nut Plain washer, type A Shift rod assembly Gear shifter lever Hex socket head cap screw (lever bolt) Footboard pad Footboard assembly (with pad) 0000 A A J0 of

5 Table. Service Parts Table s mentioned in text, but not included in kit: A Foot shifter lever B Washer C Bolt D Shifter peg E Forward frame footboard mount F Rear frame footboard mount is00 0 Figure. Dyna Rider Footboard Kit 0 Table. Service Parts Table Footboard pad Button head TORX screw,.- x.00 () Shoulder bolt () Footboard assembly (with pad) Button head TORX screw,.- x. Foot brake lever cap Flange nut () Right front footboard support Clevis pin Cotter, circular Rear brake pedal Pivot shaft 0-0 A B J0 of

6 Brake pedal pad Rear brake pushrod Hex jam nut Right rear footboard support Table. Service Parts Table -0 Not Sold Separately - -J0 of

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