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| techtalk:ref:body01c [2019/06/17 01:03] – [1986 to 2003 forward controls modified to fit a 1980 frame] hippysmack | techtalk:ref:body30c [2024/01/09 20:32] (current) – hippysmack |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] |
| ====== REF: Body Parts - Sub-01C ====== | ====== REF: Body Parts - Sub-30C ====== |
| ====== 1986 to 2003 forward controls modified to fit a 1980 frame ====== | ====== 1986 to 2003 forward controls modified to fit a 1980 frame ====== |
| Article by IronMick of the XLFORUM® ((http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) \\ | Article by IronMick of the XLFORUM® ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/99656-forward-controls-85xlh1000#post2068972)) \\ |
| In the event that you cannot find forward controls specifically for your year model, you can find something that you can modify to work. \\ | In the event that you cannot find forward controls specifically for your year model, you can find something that you can modify to work. \\ |
| However, working well can be a challenge. \\ | However, working well can be a challenge. \\ |
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| Shift side should be no problem. Brake side would require some work. | Shift side should be no problem. Brake side would require some work. |
| <blockquote>When I looked at an 86 to 03 custom Sportster it occurred to me that I could make the forwards work on my 1980. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997)) \\ | <blockquote>When I looked at an 86 to 03 custom Sportster it occurred to me that I could make the forwards work on my 1980. ((IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) \\ |
| It was looking at the brake side that convinced me - the way they fit between the case and the exhaust. \\ | It was looking at the brake side that convinced me - the way they fit between the case and the exhaust. \\ |
| (and the similar rear brake master cylinder) \\ | (and the similar rear brake master cylinder) \\ |
| </blockquote> | </blockquote> |
| |
| |Re-locating the left peg position, see red circle ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) ((http://xlforum.net/forums/showthread.php?t=717997))|Right side Assembly ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) ((http://xlforum.net/forums/showthread.php?t=717997))| | |Left side assembly ((photo by IronMick of the XLFORUM® https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))|Right side Assembly ((photo by IronMick of the XLFORUM® https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))| |
| |{{:techtalk:ih:body:forward_mods_11_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_1_by_ironmick.jpg?direct&300|}}| | |
| |{{:techtalk:ref:body:forward_mods_14_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_13_by_ironmick.jpg?direct&300|}}| | |{{:techtalk:ref:body:forward_mods_14_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_13_by_ironmick.jpg?direct&300|}}| |
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| * E-clip | * E-clip |
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| | Motor mounts and parts. ((photos by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997)) || | | Motor mounts and parts. ((photos by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) || |
| |{{:techtalk:ref:body:forward_mods_15_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_16_by_ironmick.jpg?direct&300|}}| | |{{:techtalk:ref:body:forward_mods_15_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_16_by_ironmick.jpg?direct&300|}}| |
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| | Template for lower front motor mount hole to be drilled: \\ |
| | {{:techtalk:ref:body:forward_mods_25_by_ironmick.jpg?direct&300|}} ((drawing by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) |
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| <blockquote>To restore the strength lost by drilling the hole, the largest 1" ID steel washer that would not be too large OD was used. \\ | <blockquote>To restore the strength lost by drilling the hole, the largest 1" ID steel washer that would not be too large OD was used. \\ |
| It might be a good idea to fabricate a mount from thick cardboard, cut the hole, and check to see if it is good. \\ | It might be a good idea to fabricate a mount from thick cardboard, cut the hole, and check to see if it is good. \\ |
| |
| |Right side spacer (partly hidden by oil line) ((photo by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997))|Right side nut and E-clip ((photo by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997))| | |Right side spacer (partly hidden by oil line) ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))|Right side nut and E-clip ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))| |
| |{{:techtalk:ref:body:forward_mods_17_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_18_by_ironmick.jpg?direct&200|}}| | |{{:techtalk:ref:body:forward_mods_17_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_18_by_ironmick.jpg?direct&200|}}| |
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| And it would allow a close fit of the E-clip. More precision measuring. \\ | And it would allow a close fit of the E-clip. More precision measuring. \\ |
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| | Left side nut and E-clip. ((photos by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997)) || | | Left side nut and E-clip. ((photos by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) || |
| |{{:techtalk:ref:body:forward_mods_19_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_20_by_ironmick.jpg?direct&200|}}| | |{{:techtalk:ref:body:forward_mods_19_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_20_by_ironmick.jpg?direct&200|}}| |
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| The shift lever that came with the kit was not usable here. \\ | The shift lever that came with the kit was not usable here. \\ |
| So, some length was trimmed and the hole drilled from a 1998 Sportster lever. \\ | So, some length was trimmed and the hole drilled from a 1998 Sportster lever. \\ |
| | |
| The 1980 rear brake master cylinder does not have a mechanism to hold the brake rod in. \\ | The 1980 rear brake master cylinder does not have a mechanism to hold the brake rod in. \\ |
| So the brake rod just falls out. \\ | So the brake rod just falls out. \\ |
| With mid-controls this is prevented by the brake stop. \\ | With mid-controls this is prevented by the brake stop. \\ |
| To solve this a hose clamp was attach to a 3/4" length of 1/2" copper pipe to the front exhaust pipe as a band-aid. \\ | To solve this a hose clamp was attach to a 3/4" length of 1/2" copper pipe to the front exhaust pipe as a band-aid. \\ |
| Later on, a newer style rear brake master cylinder replaced the '80 version to eliminate this band-aid. \\ | |
| The big hole in the brake stop below goes over the footpeg stud and the adjustable screw sets the foot pedal height. \\ | The big hole in the brake stop below goes over the footpeg stud and the adjustable screw sets the foot pedal height. \\ |
| | There is no part number for the brake stop as HD never made them as a separate part. \\ |
| | They were a welded-on part of the muffler. \\ |
| | You can / could order them from the Cycle Shack website. \\ |
| |
| | Rear Brake Stop for mid-controls. ((photos by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997)) || | | Rear Brake Stop for mid-controls. ((photos by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) || |
| |{{:techtalk:ref:body:forward_mods_21_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_22_by_ironmick.jpg?direct&300|}}| | |{{:techtalk:ref:body:forward_mods_21_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_22_by_ironmick.jpg?direct&300|}}| |
| |Brake stop band-aid. ((photo by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997)) |Newer rear brake master cylinder. ((photo by IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=717997))| | |
| |
| | A better idea might be to use a later model rear brake master cylinder. \\ |
| | It has a different design which holds the brake rod in with a snap ring (circlip). \\ |
| | It also is easier to repair as it uses a one-piece kit. There have been lots of these on eBay in the past. |
| | |
| | With 86 to 03 forwards, the master cylinder stays in the stock location on the sprocket cover. ((IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/93684-just-a-update-on-my-79-project-opinion-poll-pics/page2?highlight=forwards#post2167215)) \\ |
| The M/C pic below was taken before realizing that the fluted connection would not work. \\ | The M/C pic below was taken before realizing that the fluted connection would not work. \\ |
| Later a brake line was fabricated with a banjo fitting for this. \\ | Later a brake line was fabricated with a banjo fitting for this. ((photos by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) \\ |
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| | |Brake stop band-aid. ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) |Newer rear brake master cylinder. ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))| |
| |{{:techtalk:ref:body:forward_mods_23_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_24_by_ironmick.jpg?direct&300|}}| | |{{:techtalk:ref:body:forward_mods_23_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_24_by_ironmick.jpg?direct&300|}}| |
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| | Left side shift lever ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) || | |
| |{{:techtalk:ih:body:forward_mods_8_by_ironmick.jpg?direct&250|}}|{{:techtalk:ih:body:forward_mods_9_by_ironmick.jpg?direct&250|}}| | |
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| | Left side shifter pedal. ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) || Brake pedal. ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) | | |
| |{{:techtalk:ih:body:forward_mods_7_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_10_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_4_by_ironmick.jpg?direct&200|}}| | |
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| |Brake side mods ((photos by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|| | |
| |{{:techtalk:ih:body:forward_mods_3_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_2_by_ironmick.jpg?direct&300|}}| | |
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| |Pedal ends ((photos by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|| | |
| |{{:techtalk:ih:body:forward_mods_5_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_6_by_ironmick.jpg?direct&300|}}| | |
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