1. Jaybrake's forward control parts can be ordered with different options, such as brake/shift-arm and peg styles. Clockwise from top left we have the Sportster mounting kit (100-44), full rubber peg kit (6K-33), FXR forward control basic kit (100-523), and the classic solid lever kit (100K-3), all in black anodized finish.
2. Here's a shot of the aged mid-mount stock Sportster footpeg and master cylinder.
3. On the left side the badly worn peg mount and shifter arm before removal.
4. To adapt the forward controls to a Sportster, Jaybrake makes mounting arms that attach to the front lower motor mounts. The shifter and master cylinder directly attach to these arms.
5. On the shifter side the bracket was affixed to the mounting arm. The shift linkage was then attached to the boomerang arm on the shift splines.
6. All that was left to finish the left side was attach the shift peg and footpeg.
7. Moving back to the right, the master cylinder was attached to the arm with the two supplied bolts.
8. This was followed by attaching the brake arm and footpeg, and...
9. ...finally finishing the install by adding the rubber brake pedal to the arm.
10. The master cylinder outlet is on the front of the master cylinder. Due to the custom nature of this rat bike we decided to make a brake line. We chose an angled fitting from Goodrich that would clear the master cylinder.
11. After routing and measuring the length of brake line we'd need, we used a sharp hacksaw to cut each end flush. The blue tape on the end helped get cleaner results.
12. These are the fittings we used on either end of the braided brake hose. They consist of three parts: the socket, the olive, and the main fitting body.
13. After cutting both ends, the protective clear shrinktube had to be cut back to allow fitment of the socket over the cable.
14. A Goodrich mandrel tool was used to flare the end of the hose in preparation of adding the olive.
15. After flaring the end, the olive was pushed onto the end of the hose and seated in the inner part of the brake hose. The main body was then simply inserted into the hose, before...
16. ... the socket was tightened down. One end was complete.
17. Moving back to the bike, we prepared the new brake line for installation. Two brake washers were placed on either end of the main body fitting, held by the banjo bolt and tightened to the master cylinder.
18. Since the brake line routing was a tight fit from the front of the bike to the rear caliper, the second fitting had to be done on the bike. Just as before the mandrel was used to flare the end of the brake hose.
19. To aid in tightening the socket, the banjo bolt was attached to the main body and caliper.
20. The brake line was a perfect fit that literally took minutes to make. It took longer to route and measure than it did to make the line.
Here at Street Chopper we love Sportsters. It's a great chassis to build a cool scoot without a lot of cash, and they're quicker and more agile than their big brothers. One downside to the Sporty is the sometimes-cramped riding position that is somewhat caused by the midmount 'grasshopper' footpegs. Some of the factory bikes come with forward controls, but they're kind of cheesey cast metal units. There aren't a ton of aftermarket foot control options available for XLs.
When rebuilding a Sportster project in our shop, we noticed the 20-year-old peg-mounts for the shifter and brake were badly worn. The footpegs were crooked and flopping all around in the worn-out mounting bores. H-D doesn't make the peg supports anymore for the older Sportys. After a lengthy search we found that Jaybrake offers a Sportster Mounting Kit (for '86-present) that allows the use of any of its Jaybrake FXR model controls. We went with a black anodized set of the Classic Series Solid Forward Controls, complete with a 5/8-inch master cylinder. The controls are also available in polished or chromed finish. Along with different style options for the controls, there are numerous footpeg options available at the time of purchase: wide band, dovetail, full rubber, and factor.
Jaybrake controls and pegs are CNC-machined out of solid billet aluminum and assembled with stainless steel hardware. The controls also feature adjustable lever positions to create that perfect riding position. Two-inch extension plates for a roomier cockpit are available for pre-'00 XLs.
After installation we wanted to make a custom brakeline to clean up the look of the lines. Goodrich provided everything we needed to make our own brakeline. We took a ride over the Bennett's Performance in Signal Hill, California, to make sure the assembly of the brakeline went smoothly. SC