Here are the photos that were taken of Tommy "Road Runner's" rear passenger peg conversion that we made.
Tommy had installed the Custom Chrome pegs on the front of his Kawasaki Vulcan 800 Classic and decided to install the Custom Chrome Model 46-011 pegs on the passengers mount. They are Chrome and Rubber Ribbed pegs with a hex mounting screw in the end.
Make sure to purchase the mount that will work for your bike. The model 46-011 will require a little machining but nothing that the local home work shop will not have.
You will need a pair of needle nose pliers, a 3/16" allen wrench, drill with a 1/8" and 17/64" drill bit, 5/16-18 tap, hack saw or knife, and drill. A drill press is best with a vice but if careful a hand drill will work.
Here we see the Custom Chrome peg beside the stock peg that has been removed. Tommy's pegs were in the "spare parts" drawer since he had been running a Mustang Solo seat.
Here we see the Custom Chrome peg taken apart. The three main parts are the outer rubber ribbed peg, the inner mounting peg and the 5/16" mounting screw.
Here we see the stock peg with the two mounting screws removed to allow the outer rubber cover to be removed. Notice the stock washer that helps hold the peg in place. It will be used later so place it aside in a safe place.
Insert the new peg over the stock center shaft as it will become the new peg mount. With a felt tip pen mark the opening for drilling. Make sure to mark the exact opening. Once marked remove the outer peg and we are now ready to drill the mounting hole.
At this point we will cut the rubber stock peg with a knife or hack saw. Cut in the second groove on the bike side of the cover. Here I am using a bone saw in my leatherman, but a knife, hack saw, or razor knife will work. The part cut off will act as a shock absorber and apply pressure to make the peg fit tight.
Now comes the part that it is important to take your time and do right. If it is possible mount the stock peg in a vice to keep it vertical while drilling. We will drill about 1"-1 1/4" deep. Once mounted in the vice I drilled a dimple in the end of the peg to center the 17/64" drill bit. Drill 1/16" to 1/8" deep as this is just to keep the larger bit from wandering on the peg surface.
It is now time to drill out the mounting hole. It is important to keep the bit well oiled as it will build up a great deal of heat. Drill slowly and approximately 1/4"-3/8" into the inner cast space. This is on the opposite side from the original screw holes as seen above.
Now we will tap the new shaft to accept the 5/16-18 mounting screw. Use the 5/16-18 tap and tread the peg. It is important to tap the hole slowly. For every 1/4 turn in back up at least 1/2 turn. From time to time remove the tap completely. Oil the shaft well to ease the tapping. Keeping the new treads clean of any cuttings will produce high quality treads. It will be necessary to have someone help to hold the peg or place it in a vice to aid in cutting the treads.
We now are ready to assemble the peg. We found it necessary to shim out the peg with a 5/16" or 3/8" lock washer. Here we see it being placed in the inner opening. It should just fit but not slide down the opening. Using the old stock peg seat the lock washer at the bottom.
Remove the stock peg again and install the original washer and short section of rubber peg with the wider rib to the rear of the peg. Then push the peg all the way in the outer peg. We are now ready to install the foot pegs on the bike.
Since Tommy already had removed his pegs we now have to remove the mounting pin. You must remove the lock clamp from the pin first with the needle nose pliers then remove the pins.
Now it is time to mount the pegs ... they may be tight when installing the pegs. I found it necessary to hold the bike while Tommy pushed in the pegs far enough to slide in the mounting pin. Becareful not to push the bike over. When the pins are in remember to reinstall the locking clamp.
Well here is the picture of the passenger peg installed. This photo shows it folded rearward. The rubber spacer really keeps them tight and stops vibrations.
Well here we see the pegs in the down position. They are again here tight on the mount. No vibrations here no matter how rough the road might get. A nice looking addition to the bike and as we all know there is never too much chrome!!!
Well here we are all finished with the installation ... all you have to do now is to find a friend and go for a ride ... Hummmm ... looks like Tommy might have picked out someone from Bike Week 2000 ... HeeHee.
You are welcome to make comments and suggestions on this and other modifications ... if you would like to do so drop me a line at the address below.
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This page last updated: March 29th, 2000