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General Category >> Rubber Side Down! >> Got my Ed L. forward controls installed
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Message started by PTRider on 04/22/09 at 20:28:32

Title: Got my Ed L. forward controls installed
Post by PTRider on 04/22/09 at 20:28:32

First, thanks to Ed L. for developing and selling the forward controls. The 4" forward extension makes things more comfortable for me.[smiley=thumbsup.gif]
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1202177312/0

Installing the controls is a moderately difficult job. It'll go OK for anyone with patience, ability to follow instructions, and the ability to figure out how to make things fit.

The plates were mill finish aluminum with rough cut edges. I (very carefully) rounded the edges on my router table with a 1/8" carbide roundover bit using very slow feed and very, very shallow depth of cut. I put a piece of crocus cloth in my palm sander and smoothed the outside faces, then polished them on a buffing wheel.

The right side plate was hard up against the exhaust pipe and didn't match the mounting bolt. I had to cut away about 3/16" of the plate to clear the exhaust and meet the lower mounting bolt, plus about an 1/8" cut away in the notch so the footpeg nut would clear. By the way, coat any cutting tools intended for steel with kerosene or silicone lube so the aluminum doesn't load them up right away.

The left side plate needed the two holes drilled out a 64th oversize so the 10mm through bolts would pass. Both the right side bolt for the brake cable bracket and the cross brace were too short for the threads to engage the nylon in the lock nuts. The shifter rod threads worked OK, but were ragged. Either the dies were dull, or the initial cut was too deep, or cutting oil was lacking. I had to chamfer the end of the upper through bolt so it would slide back through the engine case. I didn't need all the 15 washers on the list, and the instruction to put the bolt into the brake cable mounting bracket should have had the bolt installed before the cables were in the bracket. Installing the clip for the brake light cable on the outside of the pin vs. the inside as shown results in a straighter pull on the cable. I'd like the brake lever to be a bit more upright, and may have to use the acetylene wrench to get that. And, I'd like to keep metric things all metric, not mix metric and fraction nuts.

So, yes, I'd do it again, and I like the result for my long legs. :)

Title: Re: Got my Ed L. forward controls installed
Post by matt_savage on 04/23/09 at 05:41:52

I ran into many of the snags you mention of as well. I also ran into a bigger snag, as it appeared my Savage has been wrecked before I got it. The lower engine mount thru bolt was bent pretty badly after I whacked it out with a BFH. I had to trim the outside of both plates so they wouldnt get in the way of the case bolts and I also had to elongate the left side plate mounting holes so they would line up. The left lower engine mounts were pushed back approx. 1/4" from what I would guess would have been a pretty hard hit on something. I had to smack the lower engine mount bolt thru with an 8 lb sledge hammer!! I wrapped the threads with thread tape so they wouldnt get all boogered up going thru the engine mount. It all turned out ok and I'm very pleased with the results but a 3-4 hour job turned into a 2 week job!

-Matt

Title: Re: Got my Ed L. forward controls installed
Post by NewThumperGuy on 04/23/09 at 12:42:46

Sent my money order to Ed this week, did everyone experience these snags or just a select few. My mouthed drop when Ed wrote saying it should take me 5-6 hrs to install depending on mechanical skills!! :o
Not sure if I'm looking forward to this anymore. :-/

Title: Re: Got my Ed L. forward controls installed
Post by Yonuh Adisi on 04/23/09 at 13:04:19

No offense meant to Ed who is actually providing a very good service with his forward controls. But the few hick-ups that some are experiencing is why I built my own. So I could measure them specifically for the FireLizard. Unfortunately, there are small differences in frame tolerances even if the bikes were build in the same batch. Sometimes the tolerances are negligible, sometimes not. It has nothing to do with the quality of Ed's product which I hear is very high.

But no, everyone is not having the same problems, it is just a few.

Title: Re: Got my Ed L. forward controls installed
Post by diamond jim on 04/23/09 at 13:27:18

Mine went on just fine. The instructions were great.

Title: Re: Got my Ed L. forward controls installed
Post by thumperclone on 04/23/09 at 13:30:04

less than 3 hours for my install...

Title: Re: Got my Ed L. forward controls installed
Post by prechermike on 04/23/09 at 14:10:43

I sent my check this week I will let you know how mine go on. I hope I get the easy to install ones! :)

Title: Re: Got my Ed L. forward controls installed
Post by bluesavage218 on 04/23/09 at 14:13:57

Mine went on fine with a little finagling, but nothing major. Took one Saturday afternoon.

Title: Re: Got my Ed L. forward controls installed
Post by NewThumperGuy on 04/23/09 at 16:58:49

Prechermike I'm with you on this one. Have my fingers crossed!

Title: Re: Got my Ed L. forward controls installed
Post by Jimmer on 04/23/09 at 16:58:55

DID MINE IN ABOUT THREE HOURS. JUST FOLLOW ED"S INSTRUCTIONS AND IT WILL GO FINE.

Title: Re: Got my Ed L. forward controls installed
Post by PTRider on 04/23/09 at 18:58:04

5B494E495E41452C0 wrote:

My Universal Laws---
---Nothing is as easy as it looks.
---Most half-hour jobs take ninety minutes.

Be patient. Look everything over closely. Study Ed's photos he sends with the kit and the Chilton manual photos he refers to...print them if you choose. Lay things out in logical order. Get your tools ready. Do put the 1" long bolt (not 3/4") through the brake cable bracket before you put the cables into the slots, contrary to Ed's instructions. Find a local hardware store or fastener supplier (nuts & bolts) for the list of fasteners in Ed's instructions. Buy a new 1/16" diameter x 3/4" long cotter pin for the brake cable keeper. If something really does not fit, contact this forum, or Ed, or a friend who's a craftsman about what to do.

Title: Re: Got my Ed L. forward controls installed
Post by Jay on 04/23/09 at 21:55:45

Not too troublesome an install. Ed's instructions are great, and it took me about 5 hours to do. I don't have the greatest mechanical ability, so I count that as not too bad. Good quality product.

Title: Re: Got my Ed L. forward controls installed
Post by NewThumperGuy on 04/24/09 at 05:17:59

Well after reading all the replies I'm breathing easier again ;D
Thanks to all.

PTrider thx to you for your input, where do I find this Chilton manual??

If I was to eliminate Kick stand safety on this install, what do I have to do?

Title: Re: Got my Ed L. forward controls installed
Post by prechermike on 04/24/09 at 05:59:29

NewGuy

I got a Clymer manuel, which I think is more motorcycle specific, Chiltons is more for cars and trucks. I order mine from ebay, but you can get them at some parts stores, especially where they sell motorcycle parts.

I have an 87 bike and the book i bought was for the early years, not that that matters. It was used but I have added my own greasy fingerprints as well.

Title: Re: Got my Ed L. forward controls installed
Post by thumperclone on 04/24/09 at 06:03:55

If I was to eliminate Kick stand safety on this install, what do I have to do?[/quote]

tye the two wires together from the bike side
i extended the wires on mine and am still training mysef to keep my heel from hittin the stand and killin the engine ::)

Title: Re: Got my Ed L. forward controls installed
Post by PTRider on 04/24/09 at 07:39:33

Yeah, Clymer
http://www.myacrobatpdf.com/2122/suzuki-ls-650-savage-86-a-04---service-manual-clymerpdf---the-.html#

Ed's instructions have us eliminate the sidestand safety. The two wires are twisted together and taped.

Title: Re: Got my Ed L. forward controls installed
Post by matt_savage on 04/24/09 at 08:30:40

Having just done Ed's 4" forward controls on mine, I can say that all I had to do was undo the factory wire ties holding the side stand wiring to the frame and up through the side of the engine and I was easily able to extend the factory wiring keeping the side stand switch functional. You do have to take off the front pully cover but it's only 3 bolts. Be careful though cuz the bolts only go in 1 way and are different lengths.

I prolly had another inch or two on the wiring when I undid all the wire ties for the record!

-Matt

Title: Re: Got my Ed L. forward controls installed
Post by Ed L. on 04/24/09 at 16:48:32

Well everyone, first I'm sorry about some of the kits that haven't be just right, I will replace any part that doesn't fit. I've added some quality control checks with the last two batches, Matt got the last one of three batches ago and I offered to recut or replace his set, yeah it seems it wasn't right, I ended up reworking my templates to get it corrected after some PM's with Matt. I've also replaced that bad die that was giving the rough threads on the shifter rod. I need to thank everybody who has let me know about the problems that they have encountered, i can't make improvements if I don't know that it's not right. Ride Safe
Ed

Title: Re: Got my Ed L. forward controls installed
Post by Big Nix on 04/24/09 at 18:25:44

Ed I did mine this morning and I did encounter a few little snap-foos but nothing real major. On the right hand side my bracket was trimmed down to where it needed to be but i just got the bolts in and made it work. That and the cross brace, i put everything back together and then i realized i'd forgot the said cross brace.... :P duh so i had to take the right side real loose but i got it in there. All in all for a kit that Ed L makes up in his garage I was really really impressed. High quality parts and the instructions can be a little confussing but after you get all the pieaces out and look them all over they'll make alot more sense. Only took me about 2 hours including my tard attack with the cross brace.

Title: Re: Got my Ed L. forward controls installed
Post by matt_savage on 04/24/09 at 20:07:03

I was very impressed with Ed's forward controls as well as his 'customer service' ;)...I ended up trimming the outside edges of my brackets as well as some other custom mods on my behalf...seems the left side stock bracket was kinda bent from a crash by the PO >:(

I got mine installed and they are awesome!! Thanks so much Ed, and I highly recommend these to anyone interested in forward controls.

-Matt

Title: Re: Got my Ed L. forward controls installed
Post by clueless on 04/25/09 at 17:54:59

Someone post a pic of the controls with the crossbrace. I got a VERY early set from Ed. 3/4 thick aluminum. I've never needed a brace but would like to see the effect.

Thaks,

Jim

Title: Re: Got my Ed L. forward controls installed
Post by Big Nix on 04/26/09 at 14:52:52

4546421B1D1C171F2F0 wrote:

Someone post a pic of the controls with the crossbrace. I got a VERY early set from Ed. 3/4 thick aluminum. I've never needed a brace but would like to see the effect.

Thaks,

Jim

Here yah go, it ain't much just a pieace of threaded rod from what i can see with a small section of PVC around it, correct me if I'm wrong Ed.

http://p1.bikepics.com/pics/2009/04/26/bikepics-1648022-full.jpg

8-)

Title: Re: Got my Ed L. forward controls installed
Post by PTRider on 04/26/09 at 20:11:17

The crossbrace is a piece of 3/8" tubing the length to fit just right between the plates. A piece of 3/8-16 all-thread the right length to fit all the way through and protrude slightly beyond the ends of the nuts, a bit under 14". As you see in Nix's photo, the threaded rod to too short to engage the nylon locking part of the nuts and isn't as secure as it could be.

My plates are 1/4" aluminum. 3/4" would be really stout!

*3/8" inside diameter (ID) and about 1/2" OD.

Title: Re: Got my Ed L. forward controls installed
Post by prechermike on 04/28/09 at 18:09:27

My controls (and my savage compaion CD) came yesterday. All I had time to do was look at them yesterday. But today . . .

I got metric bolts in stainless to put my stuff on. I really like the idea of it all being metric as opposed to having to have two sets of wrenches. A small thing, I know, butthat is just me. I go 10 mm and they fit fint.

It took me about five hours to put them on. But I had to stop for supper and the first hour I spent getting down, then up and waking to the shop to get my tools then walking back and getting down and getting up and, well you get the picture. (I will be glad to get my shop cleaned out, but it is too much fun riding and there is too much other stuff to do.)

I got a set that were pretty easy to put on, just a couple of hitches, but nothing that I couldn't figure out. I do suggest looking at the pictures first to make sure you know which way is up. I did have to adjust the gear shift and I need to adjust the brake, but the exhaust was too hot to mess around. I will take care of that tomorrow. Oh, boy, she rides like an easy chair now!

Highly recommended. Ed sells a good product and shipping was super fast.

Title: Re: Got my Ed L. forward controls installed
Post by prechermike on 04/29/09 at 05:13:02

Oh yeah, I also rewired the sidestand to work as well. It was simple enough to splice a wire in, solder and heat shrink it.

Title: Re: Got my Ed L. forward controls installed
Post by prechermike on 04/29/09 at 17:53:38

Update!

I rode about 70 miles today and the forward controls really make alot of difference for me. I highly reccommend them.
:D

Title: Re: Got my Ed L. forward controls installed
Post by NewThumperGuy on 05/05/09 at 18:04:17

Well I received my set today, can u say fast!!! Guess they were eager to get to me. ;D
Looking forward to seeing how smooth (or not) the install goes.
Off to gather the hardware tomorrow that I'll need for the controls and my bike stand. Will post my results.

Thanks for the tips everyone.

Title: Re: Got my Ed L. forward controls installed
Post by NewThumperGuy on 05/09/09 at 20:07:23

Mission complete!! ;D

It took some time, patience and a little reworking but I got them on. To anyone else wanting to install these I cant stress enough go slow and read the directions from Ed carefully. They look good, the stretch felt nice although I could not get a good feel since my seat was off for recovering. Hope to finish the seat so I can take her out for a test ride.
Thanks Ed L.

Title: Re: Got my Ed L. forward controls installed
Post by Toymaker on 05/10/09 at 05:02:38

Last year when we (the dragon ride Riders) where getting ready, I got a set from Ed. When he got to my place, he put them on. I think watching him do it, I think it was about 90 minutes. Just the day before, I did a look around at a H-D stealership and sat on a Sportster. With the forward controls, the Savage sits like a Sporty. Much longer feeling....

My wifey likes them too and she is 5'5"

T

Title: Re: Got my Ed L. forward controls installed
Post by diamond jim on 05/10/09 at 07:33:43

For reference- I'm 6' tall with 32" inseam. I have the seat modded to where the rider position is about 2.5" lower than with a stock, onmodded seat. With the 4" controls and my stock peg mod my upper legs (knees to hip) are horizontal to the ground which is perfect for me. If my seat was stock I imagine my knees would be about an 2" lower than my hips.