INSTRUCTIONS - Harley
Contents
1. lt MOTOR2 HARLEY DAVIDSON NB J01234 INSTRUCTIONS REV 4 30 98 Kit Number 57912 98 hardware kit STREET STALKER REAR FENDER ASSEMBLY General The following instruction explains mounting the Street Stalker Rear Fender Assembly See Service Parts for kit contents NOTE A Service Manual for your motorcycle is available from your Harley Davidson Dealer AWWARNING Read this entire instruction sheet before beginning Rider safety depends on the correct installation of this kit Follow the procedures in the appropriate Service Manual when directed to do so If any procedures are not within your capabilities or you do not have the correct tools have your Harley Davidson Dealer perform the installation Improper installation could result in personal injury Installation Stripping Motorcycle Awarninc To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following pro cedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in personal injury 1 Remove the seat and disconnect battery cables negative cable first Remove saddlebags if equipped Disconnect the brake light turn signal wiring harness connector under the seat 4 Remove electrical box cover containing circuit breakers and starter relay Later i2. Components part numbers correspond to Service Parts illustration b Remove screws that attach lenses to rear lamp f Secure harness wires at locations shown with assemblies 37 adhesive backed clips 2 in kit and place brackets 19 over lamp lamp bracket assemblies as shown c Attach lamps to lamp brackets 20 with small screws shown with lamp assemblies 37 in Figure 4 NOTE d In right side strut cover install turn signal unit 38 When installing strut covers route wires between fender with screws 10 and washers 15 Shown supports and fender See Figures 5 and 6 assembled in Figure 3 6 Install screws 7 8 9 30 washers 13 14 29 and nuts 24 26 as shown in Figure 3 to secure fender and strut covers to fender supports Be careful not to pinch any wires To achieve the best fit alternately tighten hardware from side to side Tighten to 21 27 ft lbs J01234 2 of 4 e Install lamp lamp bracket assemblies into strut covers The brackets will slide into slots in strut covers 7 Reassemble lenses to rear lamp assemblies 8 Install fusebox boot 23 over circuit breakers then slide mounting plate 18 into slot on back of circuit breakers Mount circuit breakers to rear fender with well nut 11 washers 16 and screw 6 9 Remove ignition module mounting screws from well nuts in frame Rotate module 180 degrees Reinstall left side screw loosely Reinstall right side screw loosely with clamp 3 unde
3. ar reflector bracket tape 40 which attaches reflector bracket to underside of fender AwarninG Failure to install side and rear reflectors will lead to reduced visibility This loss of visibility to other motorists could result in an accident and possible per sonal injury i01211 Right side tail light connection 3 place i Left side tail light connection 3 place Main harness connector 8 place Figure 6 3 of 4 Part No 57912 98 Date 4 98 SMOTORZ Service Parts Street Stalker Rear Fender Assembly Item Description Part No Item Description Part No 1 Cable straps 6 10006 23 Fusebox boot 74427 98 2 Adhesive backed clips 3 10102 24 Flange locknuts 2 7531 3 Clamp 10134 25 Locknut 7572W 4 Hole plugs 2 10219 26 Locknuts 2 7667 5 Tapping screw 2567 27 Blind rivets 2 8483 6 Panhead screw 2806 28 Buttonhead screws 2 868 7 Hexhead patch screws 2 3445 29 3 8 chrome washers 4 94067 90T 8 Buttonhead screws 2 4118 30 Buttonhead screws 2 94399 92T 9 Hexhead capscrews 2 4724 31 Circuit breaker clip 9989A 10 Tapping screws 2 5209 32 Solo seat not shown 52381 98 11 Well nut 5210 33 Rear fender extension 12 Washers 2 6047 not shown not sold 13 Washers 4 6701 34 Reflectors 3 not shown 59263 79 14 Washers 2 6702 35 RH strut cover not shown not sold 15 Washers 2 6716 36 LH strut cover not shown not sold 16 Washers 2 6717 37 Rear lamps 2 not shown 68858 98 17 Taillamp gas
4. inG Please observe this warning when applying the adhesive in this kit EYE IRRITANT BONDS SKIN IN SECONDS CONTAINS CYANOACRYLATE ESTER Avoid contact with skin and eyes In case of eye or mouth contact hold eyelid or mouth open and flush with water Call physician immediately If fingers become bonded soak in warm soapy water Avoid prolonged breathing of vapors Use with adequate ventilation KEEP OUT OF THE REACH OF CHILDREN AcauTION The set up time for the gasket adhesive provided in this kit is short and the adhesive is very strong Use care not to apply an excessive amount of adhesive Using too much adhesive may cause the adhesive to run and damage painted surfaces 5 Assemble strut covers as follows a See Figure 1 Apply gasket material from kit around the edge of the strut covers as shown and cut to length The inside corners can be carefully notched to eliminate buckling of outside edge of gasket Use one drop of adhesive from kit on inside surface of strut cover at each of the four locations shown Do not try and apply adhesive to the entire length of the gasket 101227 one drop at each corner one drop at each end Figure 1 Strut Cover With Gasket Applied 1 of 4 i01210 IMPORTANT Side and rear reflectors 34 are required to meet D O T visibility regulations Ignition module Starter relay mounts to frame with right side ignition module well nut Figure 2 Rear Fender Assembly
5. kets 2 68859 98 38 Turn signal module not shown 68864 98 18 Mounting plate 68861 98 39 Rear reflector bracket 19 Lamp mounting brackets 2 68862 98 not shown 59711 98 20 Lamp bracket 68863 98 40 Rear reflector 21 Lockwashers 2 7068 bracket tape not shown 58581 99 22 Relay splash cover 71600 93 J01234 Hardware kit PN 57912 98 consists of items 1 through 31 above 4of 4
6. n these instructions procedures will be provided to mount the circuit breakers on the new rear fender and mount the starter relay on the frame adjacent to the ignition module 5 Remove the hardware securing the rear fender to the frame s fender supports then remove the fender fender support covers and turn signals as a complete assembly 6 Remove the main circuit breaker from its holder on the lower plastic fender extension then remove the fender extension from the motorcycle Save the hardware to remount the fender extension included in this kit Installing Rear Fender Assembly see Figure 2 for items called out below unless otherwise noted 1 Remove rear footpegs and plug frame holes with hole plugs 4 On models with shotgun exhaust install lock nut 25 over footpeg mount 2 Use rivets 27 and washers 12 to mount circuit breaker clip 31 to rear fender extension 33 3 Install rear fender extension using hardware saved from step 6 under Stripping Motorcycle 4 Carefully place rear fender in position between fender supports on frame The easiest way to do this is to begin by placing the front of the fender in position with the fender vertical then gently squeeze the sides of the fender and carefully lower the rear of the fender into position Once the fender is in position it can be held in place as desired by temporarily putting some of the kit fasteners through the fender and fender support holes Awarn
7. r module Tighten module mounting screws Install starter relay and splash cover 22 on clamp using small screw 5 10 Mate connectors See Figure 4 5 and 6 for locations of connectors The 3 place connectors coming from the strut covers three on the right side and one on the left side mate with each other The 8 place connector coming from the right side mates with the main harness located near the right side of the battery Neatly tuck wiring as shown in Figures 5 and 6 11 Check function of turn signals and brake light Also check function of hazard lights in both Accessory and Figure 3 Turn Signal Unit Installed Black white brown connects to right side tail light connector Black white purple connects to left side tail light connector i Connects to license plate light h rl see Instruction Sheet J01235 Connects to black white brown harness on this right side strut cover Connects to main harness 101228 Figure 4 Right Side Strut Cover Assembled J01234 Ignition modes 12 Install seat using new washers 21 and screws 28 from kit Be careful not to pinch any wires Awarnine After installing seat be sure it is locked in position If seat is loose it could shift position during vehicle operation and startle the rider causing loss of control and personal injury 13 Install side reflectors 84 at locations shown in Figure 2 Install rear reflector 34 using rear reflector bracket 39 and re
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