Kuryakyn 9063 Standard Forward Control Kit Installation and Usage Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of the Kuryakyn 9063 Standard Forward Control Kit. These controls are designed for a clean, uncluttered appearance and offer an ergonomic riding position for compatible Harley-Davidson Dyna models. Please read all instructions thoroughly before beginning installation to ensure proper fitment and safe operation.

2. Compatibility

The Kuryakyn 9063 Standard Forward Control Kit is compatible with the following models:

• Harley-Davidson Dyna Models: 1991-2017 (excluding 2012-2016 FLD Dyna Switchback).

Important Compatibility Notes:

• Not compatible with most engine guards.
• Not compatible with stock exhaust on 2008-2017 FXDF, 2009-2010 FXDFSE, 2010-2017 FXDWG, or 2014-2017 FXDL models.
• Recommended for riders with a 33-inch or shorter inseam for optimal comfort and control.

3. Parts Included

Verify all parts are present before beginning installation:

• (1) Shift Assembly, Standard Forward Control
• (1) Brake Assembly, Standard Forward Control
• (1) Assembly, Brake Rod and Jam Nuts
• (1) Shift Peg
• (1) Hardware Kit, containing:
  • (1) Shift Arm Retainer for 2006-up Dyna
  • (1) #8-32 x 3/16” Setscrew
  • (1) Anti-Seize Packet
  • (2) 5/16”-24 Nylock Nut
  • (2) Ball Joints
  • (4) 3/8-16 x 1” Flat Socket Cap Screws
  • (1) 5/16-18 x 1/2 Hex Head Cap Screw
  • (1) Cotter Pin, Steel, 1/16 x 1”
  • (1) 0.256 x 0.406 x 0.030 Flat Washer
  • (1) 1” Clevis Pin
  • (1) Anti-Rattle Clip, Rubber Coated
  • (1) Female Clevis, 3/8-24 Internal Thread

4. Suggested Tools (Not Included)

The following tools are recommended for installation:

• Set of Hex Wrenches
• Set of Combination Wrenches
• Socket Set and Ratchet
• Needle Nose Pliers
• Small Flat Tip Screwdriver
• Vice Grip or Large Pliers
• Torque Wrench (FT/LBS) and Hex Bit Socket Set
• Blue and Red Loctite (threadlocker)

5. Setup and Installation

Follow these steps for proper installation of the Kuryakyn 9063 Standard Forward Control Kit. It is recommended to have a service manual for your specific motorcycle model for reference during this process.

5.1 Preparation

1. Ensure the motorcycle is stable and secure on a stand.
2. Disconnect the battery to prevent accidental electrical activation during installation.
3. Carefully remove the existing foot controls, noting the routing of brake lines and shift linkages.

5.2 Installing the Control Assemblies

The main control plates mount to the motorcycle frame. Use the provided 3/8-16 x 1” Flat Socket Cap Screws. Apply Blue Loctite to the threads of these bolts before tightening. Ensure the bolts are securely tightened using a torque wrench to the manufacturer's specifications for your motorcycle model.

Figure 1: Kuryakyn 9063 Standard Forward Controls installed on a Harley-Davidson Dyna motorcycle. This image illustrates the chrome finish and the extended position of the foot controls, providing a visual reference for the installed product.

5.3 Shift Assembly Installation

1. Attach the Shift Assembly to the left control plate using the appropriate hardware.
2. Connect the shift rod to the shift arm and the transmission lever. Adjust the length of the shift rod to achieve the desired shift lever position.
3. Secure all connections with the provided Nylock Nuts and Cotter Pin where applicable.
4. Install the Shift Peg onto the shift arm.
5. For 2006-up Dyna models, install the Shift Arm Retainer.

5.4 Brake Assembly Installation

1. Attach the Brake Assembly to the right control plate.
2. Connect the brake rod to the brake pedal and the master cylinder. Ensure the brake rod is properly adjusted to allow for full brake engagement without binding and without applying constant pressure to the master cylinder plunger when the pedal is at rest.
3. Use the 1” Clevis Pin and Anti-Rattle Clip to secure the brake rod to the brake pedal.
4. Install the foot peg onto the brake pedal arm.

Figure 2: Animated view of the Kuryakyn 9063 Standard Forward Controls. This animation demonstrates the articulation of the foot pegs and the overall design of the chrome control units.

5.5 Final Checks

1. Verify all fasteners are tightened to the appropriate torque specifications. Apply Blue Loctite to all non-nylock threaded fasteners to prevent loosening from vibration.
2. Ensure the brake and shift linkages operate smoothly and without interference.
3. Check for proper brake light activation.
4. Reconnect the battery.
5. Before riding, perform a static test of the brake and shift functions.

6. Operating Instructions

The Kuryakyn 9063 Standard Forward Controls reposition your feet further forward compared to stock controls. This can alter your riding posture and the feel of the brake and shift levers. Take time to familiarize yourself with the new foot position and control feel in a safe, controlled environment before riding in traffic.

• Braking: Apply the rear brake smoothly and progressively. Ensure full brake engagement is possible without excessive foot travel.
• Shifting: Engage the shift lever firmly. Confirm that all gears can be selected smoothly.
• Foot Placement: Position your feet comfortably on the pegs, ensuring clear access to both the brake and shift levers.

7. Maintenance

Regular maintenance will ensure the longevity and proper function of your Kuryakyn 9063 Standard Forward Controls.

• Cleaning: Clean chrome surfaces regularly with a non-abrasive chrome cleaner and a soft cloth to maintain their finish. Avoid harsh chemicals that can damage the plating.
• Fastener Checks: Periodically inspect all mounting bolts and fasteners for tightness. Vibration from motorcycle operation can cause fasteners to loosen over time. Re-torque as necessary, applying Blue Loctite if a fastener shows signs of loosening.
• Lubrication: Apply a small amount of grease or lubricant to the pivot points of the brake and shift levers annually, or as needed, to ensure smooth operation.
• Inspection: Check foot pegs for any signs of wear or damage. Ensure they are securely attached.

8. Troubleshooting

This section addresses common issues that may arise with your forward controls.

• Loose Foot Pegs: If a foot peg feels loose or wobbly, inspect its mounting bolt. Ensure the bolt is properly tightened. If the peg has a single shaft bolt, ensure it is securely fastened and consider applying Red Loctite for a more permanent hold, if desired, after confirming proper alignment.
• Difficulty Shifting/Braking:
  • Check the adjustment of the shift rod and brake rod. They should allow for full range of motion without binding.
  • Ensure pivot points are clean and lubricated.
  • Verify that no components are interfering with the movement of the levers.
• Control Plate Loosening: If the main control plates become loose, re-torque the mounting bolts to specification. Always use Blue Loctite on these bolts to prevent future loosening due to vibration.
• Incorrect Peg Orientation: If a foot peg does not swing correctly (e.g., swings forward instead of up and back), check the installation of the peg mount. It may have been installed backwards. Refer to installation diagrams or professional assistance for correct orientation.

9. Specifications

10. Warranty and Support

For specific warranty information or technical support regarding your Kuryakyn 9063 Standard Forward Control Kit, please refer to the official Kuryakyn website or contact Kuryakyn customer service directly. Keep your purchase receipt for warranty claims.

Kuryakyn Official Website: www.kuryakyn.com