detachable windshield and docking hardware kit - Harley
Contents
1. J02826 the upper bushing Before checking the clearance place a piece of masking tape against the fuel tank to eliminate the possibility of scratching the fuel tank paint Repeat this process with the front forks rotated fully to the right fork stop If clear ance is less than 5 32 inch 4 mm contact your Harley Dav idson Dealer for additional information reference P amp A Service Bulletin P 40 6 Hook the two top windshield assembly jaws into the grooves of the top bushings 4 in Figure 4 then slide the lower clamp assemblies up until the lower bushings firmly fit into the lower windshield jaws Ta With windshield in place tighten lower mounting clamp 8 hardware by first tightening clamp nut to 10 ft lbs 14 Nm Be sure the clamp does not rotate during tightening NOTE The mounting bushings must be parallel to the windshield brackets 0 Remove windshield by grabbing windshield edges parallel with center brace and firmly pulling windshield loose from upper bushing grooves Lift windshield assembly off of lower bushings o Reattach brake line clamp to upper fork triple clamp 10 If necessary follow directions provided in Turn Signal Relocation Kit and install the turn signals WARNING Improper installation of accessories or loading of cargo can affect motorcycle stability and handling which could result in death or serious injury 00455b WARNING Failure to provide adequate clearance2. J02826 4of5 is02110 Figure 5 Service Parts Windshield Kit Table 3 Service Parts Windshield Kit Item Description Quantity Part Item Description Quantity Part Number Number 1 Windshields 10 Outer horizontal trim strip 58051 78A Kit Number 58865 03 clear 58265 03 11 Inner horizontal trim strip 58050 78A Kit Number 58880 03 smoked 58264 03 12 Wireform left 58329 96 2 Panhead screws TORX 2 2452 13 Wireform right 58328 96 3 Panhead screws TORX 5 2921 14 Horizontal tape 2 58052 78 4 Washers 4 58152 96 15 Vertical tape 2 59415 03 5 __ Nylon bushings 4 58272 95 16 Buttonhead screws 2 94426 95 6 Bracket right 58881 03 17 Acorn nuts 7 7651 7 Bracket left 58913 03 18 Acorn nuts 1 4 20 2 94004 90T 8 Outer trim strip right 58979 03 19 Flatwashers 2 6703 9 Outer trim strip left 59073 03 J02826 5of5
3. cover gas tank and front fender before installation J02826 Figure 1 New Clutch Cable Routing For FXSTB Models Proceed to Step 3 For all except FXSTB See Figure 1 Relocate the clutch cable to the inside of the handlebars as follows a Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Locate cable adjuster halfway along clutch cable by the front frame downtube and slide off rubber boot Holding cable adjuster with 1 2 inch wrench loosen jam nut using a 9 16 inch wrench Back jam nut away from cable adjuster Move adjuster toward jam nut to introduce a large amount of free play at hand lever Remove small snap ring from pivot pin groove at bottom of clutch lever bracket Remove pivot pin and clutch hand lever from bracket Remove anchor pin and clutch cable eyelet from clutch hand lever See Figure 1 Route clutch cable to the inside of the handlebars and reconnect clutch cable to clutch lever See Figure 2 Turn cable adjuster away from jam nut until slack is eliminated at hand lever Pull clutch cable ferrule away from clutch lever bracket to check free play Turn cable adjuster to obtain 1 16 1 8 inch 1 6 3 2 mm free play between end of cable ferrule and clutch lever bracket Hold adjuster with 1 2 inch wrench Using 9 16 inch wrench tighten jam nut against cable adjuster Cover cable adjuster mechanism with rubber boot 1of5 Please dispose of materials
4. responsibly is01986 Figure 2 1 16 1 8 inch 1 6 3 2 mm Clutch Cable Free Play 3 On FXSTB models only Remove existing turn signal clamps from fork tubes Remove the original turn signal standoff from the turn signal The original clamp and standoff will not be used during re assembly 4 See Figure 4 Assemble mounting hardware for lower windshield mounting Assemble in the following order and leave assembly loose a Locate the mounting hardware supplied in the docking hardware kit b Place flatwasher 5 and bushing 4 on bolt 3 and install on clamp c Install clamp assembly onto the fork tube with the clamp nut forward toward the headlamp 5 See Figure 5 Assemble hardware for upper windshield mounting as shown in illustration and tighten buttonhead screws to 15 ft lbs 20 Nm The spacer 1 not visible in the illustration fits between the retainer wire bracket 6 7 and the upper fork triple clamp is01988 Ly gt gt AN Figure 3 Measuring Clearance looking down on docking point from above NOTE Check for proper clearance between upper bushing and fuel tank before installing windshield as follows See Figure 3 Turn the front forks to the left allowing the fork to rest against the fork stop Measure the clearance between the fuel tank and the upper bushing We recommend using the shank end of the proper size drill bit as a feeler gauge between the fuel tank and
5. between stationary and moving parts can cause loss of control which could result in death or serious injury 00378a NOTE Inspect windshield upon completion of installation Be sure windshield mounting does not restrict full left or full right movement of front fork assembly Restricted movement could affect handling resulting in death or serious injury If restriction does occur adjust windshield as needed until proper clearance is obtained Have experienced Harley Davidson service per sonnel correct any problems before riding with this accessory installed NOTE Check mounting hardware periodically Never ride with loose mounts A loose mounting causes extra stress on all other mounts as well as the windshield itself and could result in premature failure of components CARE AND CLEANING NOTE Sunlight reflections off of the inside curvature of a windshield can at certain times of the day cause extreme heat build up on motorcycle instruments Exercise care in parking Park facing the sun place an opaque object over the instruments or adjust the windshield to avoid reflections 2of5 NOTICE Harley Davidson windshields are made of Lexan Lexan is a more durable and distortion resistant material than other types of motorcycle windshield material but still requires attention and care to maintain Failure to maintain Lexan properly can result in damage to the windshield 00230a NOTICE Do not use harsh chemicals i
6. cMOTOR HARLEY DAVIDSON WY J02826 INSTRUCTIONS REV 2005 11 29 DETACHABLE WINDSHIELD AND DOCKING HARDWARE KIT GENERAL Kit Number 58865 03 58880 03 58362 03 Models These kits fit 1984 and later FXST FXSTB FXSTC and 1993 and later FXDWG model motorcycles when equipped with passing lamps Table 1 Models Kits Contents is01985 58865 03 58880 03 Clear standard height windshield Smoked standard height windshield Kit 58362 03 contains the docking hardware required to mount the above windshields kits Additional Parts Required NOTE If passing lamps are being installed at the same time you will need the Turn Signal Relocation Kit Harley Davidson Part No 68603 01 available at any Harley Davidson dealer WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 4 and Table 2 Figure 5 and Table 3 INSTALLATION 1 To protect against scratches
7. ncluding rain sheeting products on Harley Davidson windshields They can cause dulling or hazing If you want to use a windshield pro tectant on your windshield try Harley Glaze Polish and Sealant 00231a J02826 NOTICE Do not use benzine paint thinner gasoline or any other type of harsh cleaner on the windshield Doing so will damage the windshield surface 00232a Do not clean Lexan polycarbonate in hot sun or high temper ature Powdered abrasive or alkaline cleanser will damage the windshield Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result NOTES Covering the windshield with a clean wet cloth for about 15 minutes before washing will make dried bug removal easier Harley Davidson Windshield Water Repellent Treatment Part Number 99841 01 is approved for use on Harley Davidson Lexan windshields 3 of 5 SERVICE PARTS is02108 Figure 4 Service Parts Docking Hardware Kit Table 2 Service Parts Docking Hardware Kit ltem Description Quantity Part Number 1 Spacer 2 behind bracket 58349 96 2 5 16 24 x 7 8 inch buttonhead screws 2 94467 94T 3 Screw 2 94468 94T 4 Bushings 4 67621 94 5 15 16 inch chrome flat washers 4 94066 90T 6 Left retainer wire bracket 58514 96 7 Right retainer wire bracket 58515 96 8 Mounting clamps 2 58351 96 9 Cable ties 6 10006
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