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Legends Forward Controls Installation

981 views 5 replies 5 participants last post by  BigJake  
#1 ·
Hi Everyone,

I'm new to the forum and also a recent new owner of an '03 Warrior. I'm 6'3" and looking to add the Legends Forward Controls. Because I'm not a grease monkey[/emoticons/emotion-2.gif], are there some instructions for installation anywhere or would I be better off taking to the dealer? Shop time is pretty expensive!

Thanks for your help!
 
#2 ·
quote from Bdogg from following post
http://www.rswarrior.com/forums/topic.asp?TOPIC_ID=4269&SearchTerms=legend,forward,controls

I am assuming these are the controls from Phat. If not, some of what I say may not apply or be different. Installation is fairly simple. Shifter side is easy, brake side much more complicated, but very doable. Once you remove the stock rear brake system, you are somewhat committed, so be sure you are ready to go for it.
- Shifter side is easy. Remove old; insall new, connect shift linkage.
- Remove the stock brake side controls, brake lines, pressure switch and horn. You will need to reuse the brass washers (or by new ones) on both ends of the stock brake line banjo bolt connections, as well as the stock rear banjo bolt. The brake lines are loaded with fluid, so be ready to collect it or make a really big mess. This will take a bit of time, but it's really not tough.
- Install new brake side forward controls
- You'll have to strip the old pressure switch connections and connect the new banjo bolt pressure switch wires (I don't think it matters which wire to which, but I could be wrong. They are the same color)
- Install the banjo bolt pressure switch with the brake line attatched and a washer on either side of the brake line into the master fluid cylnder on the controls. DO NOT over tighten. I broke off my banjo bolt and had to remove it with an extractor bit.
- Run the brake cable inside the frame and attatch to rear brake with a washer on either side of the brake line on the stock banjo bolt.
- Fill the master fluid cylinder with new, clean brake fluid (DOT 4) and bleed the brakes. There are bleeder kits available at a auto parts store. The rear brake is easy to bleed, just losen the bleeder screw (on the rear caliper just behind the banjo bolt) one turn and attach a bleeder resevior (from the part store) to collect the fluid. Pump the rear brake pedal repeatedly to start a flow of fluid through the system. You should hear it pumping and the fluid level in the master fluid cylinder will begin to lower. Keep that full... if you let it start to suck air, you have to start over. The fluid will begin to drain out of the bleeder screw into your resevior and you will see air bubbles. Continue pumping the fluid throught the system until you have a steady clear flow without bubbles. Once you have this, tighten the bleeder screw and press the brake lever. After a few presses, it should be very firm and the rear brakes should be engaging the rear disc.
- Make sure the brake light comes on when you press the brake and then go have fun on it.