I just installed a Boarzilla #503-32B on my new 120R in my 08 Street Glide and there is a clearance issue at the rear brake pedal. The ear portion of the rear brake pedal where is attaches to the rear brake master cylinder shaft is hitting the head pipe. I have loosen the exhaust system and tried to readjust but no luck. Nobody out there run into this problem??? Any suggestions?

 

It is a common problem. The only resolution I have seen is to flatten the contact area with a hammer. Not a very eloquent solution, but it is effective. It is not just a problem with the 120 either, I have seen it on 110's as well.

 

I got to snooping around looking for another way to gain clearance and am going to tig-weld up the hole in the rear brake reservior rod and redrill it a 1/4" closer to the reservior and also machine it so the brake pedal ear will have rotation clearance. This is a pain in the **** but I just don't want to dent a high $$ dollar pipe. I'll post results whethere it's successful or not for future reference.