1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of the Kuryakyn 9649 Girder Extended Brake Pedal. This product is designed to enhance rider comfort and control by providing an extended brake pedal with a more natural operating angle compared to stock pedals.
Image 1.1: Kuryakyn 9649 Girder Extended Brake Pedal in Gloss Black.
2. Compatibility
The Kuryakyn 9649 Girder Extended Brake Pedal is compatible with the following Harley-Davidson models:
- 2014-2018 Electra Glides (with Fairing Lowers)
- 2014-2018 Road Glides (with Fairing Lowers)
- 2014-2018 Road Kings (with Fairing Lowers)
- 2014-2018 Street Glides (with Fairing Lowers)
- 2014-2018 Trikes (with Fairing Lowers)
3. Parts List
Ensure all components are present before beginning installation:
- 1 x Kuryakyn Girder Extended Brake Pedal (Gloss Black)
- 1 x Cotter Pin
4. Tools Required (Not Included)
The following tools are suggested for installation:
- Set of Hex Wrenches
- Set of Hex Bit Sockets
- Set of Sockets
- Set of Combination Wrenches
- Grease
- FT LBS (Nm) Torque Wrench
- Needle Nose Pliers
5. Installation Instructions
Note: Installation may require removal or loosening of surrounding components for easier access. Exercise caution to avoid damage to brake lines or other parts.
- Prepare the Motorcycle: Park the motorcycle on a level surface and ensure it is stable. Turn off the engine and allow any hot components to cool.
- Access the Stock Brake Pedal:
- Remove the floorboard by unfastening its mounting bolts.
- To improve access to the cotter pin and brake pedal shaft, it may be necessary to loosen the top bolt of the crash bar and remove the two lower bolts. This allows the crash bar to swing forward slightly.
- For optimal access, consider carefully removing the master cylinder bolts and sliding the master cylinder slightly forward. This can significantly ease the removal of the stock cotter pin. Exercise extreme care to avoid bending or damaging the brake line attached to the master cylinder.
- Remove the Stock Brake Pedal: Using needle nose pliers, carefully remove the cotter pin securing the stock brake pedal to its shaft. Slide the stock brake pedal off the shaft.
- Install the New Brake Pedal:
- Apply a small amount of grease to the pivot point of the new Kuryakyn Girder Extended Brake Pedal.
- Slide the new extended brake pedal onto the shaft.
- Insert the new cotter pin through the shaft and bend its ends to secure the pedal in place. Ensure it is fully seated and secure.
- Reassemble Components:
- Carefully reposition and reattach the master cylinder, if it was moved. Tighten its bolts to the manufacturer's specified torque settings.
- Realign and secure the crash bar, tightening all bolts to the manufacturer's specified torque settings.
- Reinstall the floorboard, ensuring all mounting bolts are securely fastened.
- Test Functionality: Before riding, thoroughly test the brake pedal's operation. Ensure it moves freely, returns to its resting position, and activates the rear brake correctly. Check for any leaks around the master cylinder if it was disturbed.
Image 5.1: Close-up view of an installed Kuryakyn extended brake pedal, showing its position relative to the footboard.
6. Operation
The Kuryakyn Girder Extended Brake Pedal is designed to provide a more comfortable and natural braking experience. Its extended length and flatter angle position the brake pad for easier engagement, reducing the need to lift your foot significantly. The pedal accepts both stock and custom brake pedal pads designed for the original equipment.
Image 6.1: Illustration of the extended reach provided by the Kuryakyn brake pedal.
7. Maintenance
To ensure optimal performance and longevity of your Kuryakyn Girder Extended Brake Pedal:
- Regular Inspection: Periodically check the pedal for any signs of wear, damage, or looseness. Ensure the cotter pin is secure.
- Lubrication: If your pedal features a Zerk fitting, apply appropriate grease periodically to maintain smooth pivot action. If no Zerk fitting is present, occasional disassembly and re-greasing of the pivot shaft may be beneficial.
- Cleaning: Clean the pedal regularly with a mild soap and water solution, then dry thoroughly. Avoid harsh chemicals that may damage the finish.
8. Troubleshooting
If you encounter issues with your Kuryakyn Girder Extended Brake Pedal, consider the following:
- Difficulty with Cotter Pin Removal/Installation: This is a common challenge. Refer to Section 5, Step 2 for suggestions on loosening surrounding components to gain better access. Patience and appropriate tools are key.
- Pedal Sticking or Not Returning: Ensure the pivot point is clean and adequately lubricated. Check for any obstructions or misaligned components that might be impeding its movement. Verify that the cotter pin is not binding the pedal.
- Brake Malfunction: If the brake pedal does not properly engage the rear brake or if you notice any brake fluid leaks, immediately cease operation of the motorcycle and consult a qualified mechanic. Do not attempt to ride with a malfunctioning brake system.
9. Specifications
| Feature | Detail |
|---|---|
| Model Number | 9649 |
| Brand | Kuryakyn |
| Material | Alloy Steel |
| Color | Gloss Black |
| Item Weight | 2.43 Pounds |
| Vehicle Service Type | Street Bike |
| Fit Type | Specific |
10. Warranty and Support
This Kuryakyn product is covered by a 1-year manufacturer's warranty from the date of purchase. This warranty covers defects in materials and workmanship under normal use.
For warranty claims, technical assistance, or further support, please contact Kuryakyn customer service through their official website or authorized dealers. Please have your proof of purchase and product model number (9649) available when contacting support.
