Installation Instructions

Step 1: The controls came to you partially assembled (if you got the pro axles).  The right extension is with the right arm.  Easiest if you just leave them together.  Make sure they rotate freely.

Step 2: Protect the radiator shroud by putting cardboard or something to prevent scratching when doing assembly.  When you remove the controls or put the new ones on, they have a bunch of wiggle room and you can hit the shroud.

Step 3: Shift side is easiest. Remove the 10mm bolt on the outside of the extension (big one in the center).  The entire controls will come off at that point but still be attached to the shift rod.  Then remove the shift rod 8mm bolt.  

Step 4: (This to me is the hardest part) Remove the footpeg from the stock extension by removing the c-clip on the cotter pin.  Try not to mangle it.  If you do tweak it (you will) just bend it back into shape and flatten it back up.  If it is really mangled get new ones from hd.

Step 5: Install the new toepegs on both arms.  It has an allen bolt in it so tighten it on by hand and then use an allen wrench on the back to make it nice and tight.

Step 6: You can install the footpegs now as well or after they are on the bike.  I find it easier now instead of when the controls are installed.

(if you did not get the pro axle option, follow the pro axle installation instructions below now)

Step 7: Attach the new arm to the shift rod.  You don't need to really tighten it at this point.

Step 8: Insert the assembly back in the frame like the stock ones and attach with the bolt and bevel washer you got with the controls.

Step 9: Tighten the outside bolt and the shift rod bolt.  Test to make sure nothing catches.  I have had people that the shift rod hit the kickstand but it was because the shift rod was bent.  Make sure shifting up and down rebounds.

Step 10:  Other side is the same but you have a cotter pin holding the controls to the brake reservoir.  This can be a little tricky because you have to disassemble it while it is still really close to the shroud.  This is where the cardboard is very important.  The split pin is bent around the cotter pin.  Just straighten it out and pull it through.  I usually use pliers.  

Step 11: Flatten out the split pin.  If it looks fatigued or messed up you may want a new one.  

Step 12: Do the same thing with the toe and footpegs

Step 13: You may want to remove the arm from the extension to install the cotter pin.  Just make sure when it goes back in you put it in straight.  You should not have to force it in.  I have had a guy that gouged the inside of the arm because he pushed the axle back in crooked and just manhandled it to get it through.  Created a burr and he had to sand the burr out.

Step 14: Install the extension and arm onto the bike same as the other side.  Tighten everything down.  Test to make sure brake rebounds freely.

Step 15: Take it out for a spin and enjoy!

Pro axle instructions

Step 1: Make sure the bevel on the back of the instructions is clear of powder coating

Step 2: You must press the axles in with a proper hydraulic press.  Do not use a vise.  The axles must be pressed in straight.

Step 3: Protect the extension with tape or other covering to protect the finish.  Clean axles thoughly.

Step 4: Press the axles in slowly, making sure they go in straight.  Stop as soon as the lip reaches the extension.  DO NOT OVER PRESS!  If you press too much or too hard you can bow the axles and cause them to not fit in the arms smoothly.  

Step 5: Use the included spacer between the extensions and the arm.  The spacer is a very tight fit.

Step 6: Make sure the arm fits on the axle without binding and turns freely.

2012+ Controls Instructions

 

This is the instructions for installing the 2012+ forward controls.  

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