INSTRUCTIONS - Harley
Contents
1. 18 Fasten the shock absorber air pump to the rear air suspension adjustment valve Pressurize the rear air suspension system to check for air leaks Adjust air pressure for rider comfort and to accommodate changing load conditions Do not exceed 50 psi 241kPa 19 Install the saddlebags 20 Reconnect negative cable to battery PINNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a The following are recommended Starting points adjust to suit load conditions riding style and comfort desired NOTE Less initial pressure does not necessarily result in a softer ride Recommended Pressures Kit 54631 02B Shock Loading Recommended Pressures PSI kPa Single rider under 160 Ibs 0 5 0 34 4 Single rider 160 200 Ibs 0 10 0 68 8 Single rider over 200 Ibs 5 10 34 4 68 8 Two up 180 Ib rider and 120 150 Ib passenger 20 30 137 6 206 4 Two up 180 Ib rider and 160 Ib passenger 25 35 172 240 8 Two up and Fully loaded Bags 40 50 275 2 344 Maximum Pressure 50 344 MOTOR Service Parts Part No 54631 02B Date 8 03 Low Profile Suspension Kit i02359a Part No 54661 02A Item Description 1 Low Profile Shock Absorber oe N J02179 2of22. shock absorbers 1of2 9 Remove the upper mounting bolts and washers from the shock absorbers 10 Apply teflon tape or thread sealant to the air hose fittings removed in step 7 11 Replace the plugs in the new shock absorbers with the air hose fittings removed in step 7 Tighten the fittings until they are snug in the shock absorbers 12 Install the plugs removed from new shocks in Step 11 into old shocks to prevent oil loss 13 Install the washers removed in step 9 onto the upper shock bolts and push the bolts through the shock upper bushings Apply two or three drops of Loctite 243 blue to the exposed threads of the upper shock mounting bolt 14 Fasten the top of the new shocks to the frame Tighten the upper shock bolts to 33 35 ft lbs 45 47 Nm 15 Install the washers removed in step 8 onto the lower shock bolts and push the bolts through the shock lower bushings Apply two or three drops of Loctite 243 blue to the exposed threads of the lower shock mount ing bolt 16 Fasten the bottom of the new shocks to the swingarm Tighten the lower shock bolts to 35 40 ft lbs 47 54 Nm 17 Fasten the air hoses removed in step 6 to the air hose fittings on the new shocks CAUTION Do not exceed maximum air pressure of 50 psi for low profile rear suspension Air components fill rapidly Therefore use low air line pressure Failure to do so may result in possible damage to components 00165a
3. 03A to the rear air suspension adjustment valve on the motorcycle See the Touring model s owner s manual for valve location Add 3 5 psi to clear the line but do NOT exceed 50 psi 5 Using the pressure relief valve located below the gauge on the pump release the air pressure from the rear sus pension AcauTIon Failure to relieve air pressure from the rear suspension could cause injury during shock absorber removal J02179 INSTRUCTIONS REV 8 28 03 kit Number 54631 02B LOW PROFILE REAR TOURING SUSPENSION KIT ea ee Figure 1 Rear Shock Absorber Air hose b i02360 Plastic collar 2P Air hose fitting a Figure 2 Air Hose Removal and Installation WARNING Use caution when bleeding air from the suspension Moisture combined with lubricant may leak on to the rear wheel tire and or brake components and adversely affect traction which could result in death or serious injury 00084a 6 See Figure 1 and Figure 2 Remove the air hoses from the shock absorber air hose fittings NOTE Press the plastic collar down on the air hose fitting to remove and install the air hose 7 Remove the air hose fittings from the shock absorbers Save the fittings for installation on the new shocks NOTE Air suspension shock absorbers are oil filled and must be kept upright at all times to prevent oil leakage 8 Remove the lower mounting bolts and washers from the
4. MOTOR HARLEY DAVIDSON WY J02179 General This kit fits 1997 and later Touring model motorcycles This kit requires the separate purchase of air pump part number 54630 03A This part is available for purchase from any Harley Davidson Dealer Awarnine Installation of any accessory suspension components may affect cornering clearance This could distract the rider causing loss of control and could result in death or serious injury WARNING The rider s safety depends on the correct installation of this kit Follow the procedures listed in this Instruction Sheet and applicable Service Manual If any procedures are not within your capabilities or you do not have the correct tools have your Harley Davidson Dealer per form the installation Improper installation could result in death or serious injury NOTE A Service Manual for your vehicle is available from any Harley Davidson dealer Installation 1 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first 2 Raise the rear end of the motorcycle so that the rear wheel is just off the ground Support the motorcycle with suitable blocking under the frame NOTE Retain the original fasteners for installation of new shocks 3 Remove the saddlebags from the motorcycle See the Touring model s Owner s Manual for saddlebag removal 4 Fasten the air pump part number 54630
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