INSTRUCTIONS - Harley
Contents
1. Part No 58164 96 Date 10 04 SMOTORZ a Service Parts Windshield Docking Hardware Kit sp58034 3a Item Description Part No Description Part No Hardware kit 58164 96 Flatwasher chrome 5 94066 90T 1 Wireform 58558 97 use with wireform item 1 2 Mounting clamp 4 58124 96 Turn signal relocation kit 3 Bushings 4 67621 94 not shown 72389 96 4 Buttonhead screw 2 Sockethead screw 5 16 24 x 5 8 long 94468 94T 5 16 18 x 1 25 long 3210 Mushroom fastener 2 58172 96 Cable straps 4 not shown 10006 NOTE Wireform location and throttle cable routing for buckhorn style pullback handlebars Wireform location and throttle cable routing for handlebar styles other than buckhorn style pullbacks Upper windshield mounting Lower windshield mounting J01449 6 of 62. D See Service Parts Illustration Mount attaching brackets 6 to outside face of brackets 14 15 using shoulder bolt 18 washer 20 and locknut 21 Leave assembly snug to allow for adjustment later 7 Place wellnuts 16 into fairing 3 and attach headlight cover 7 with washers 4 and screws 2 8 Remove the backing to the adhesive backed pads 23 and attach them in the locations shown Two pads are placed on the upper corner of the fairing in the windshield recess and two pads are placed on the inner surface of the windshield in the bottom corners 9 Attach windshield 1 to fairing using the 4 gaskets 19 along with screws 2 washers 4 and nuts 22 The windshield can be positioned in two different locations The upper position allows air to pass through fairing creating a more open feel when riding To change positions remove screws and rotate the gaskets 19 to plug the unused holes and reinstall the windshield and screws Installing Quarter Fairing NOTE Cover gas tank and front fender before beginning installation to prevent scratching 1 See Figure 4 Relocate clutch cable 1 to the inside of the handlebars 2 as shown in illustration as follows a See Figure 5 Slide rubber boot 1 off cable adjuster 2 Adjuster is located approximately halfway along clutch cable by the front frame downtube b Holding cable adjuster with 1 2 inch wrench loosen jam nut 3 using a 9 16 inch wrench Back
3. is raised slightly off the ground 2 Remove fork tube pinch screw from right side of lower bracket 3 Cut wires connected to right directional light about 2 in away from directional light body 4 Remove fork tube pinch screw from right side of upper fork bracket This is the screw that secures the right directional light 5 Install right directional light on right side of lower fork bracket using pinch screw removed in step 4 Install pinch screw removed in step 2 into right side of upper bracket Tighten both pinch screws to 30 35 ft lbs 6 Repeat steps 1 through 5 to relocate left directional light INSTRUCTIONS REV 10 11 2004 Kit Numbers 57070 98 primed kit DETACHABLE QUARTER FAIRING AND DOCKING HARDWARE KIT NOTE Fork tubes may slide downward within fork brackets If this occurs front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures 7 Connect the right directional light as follows Strip approx 5 16 in of insulation from the wires cut in step 3 8 Crimp solderless connectors from kit on two wires coming from motorcycle 9 Split one end of the 2 conductor polarized wire from kit back about 2 in and strip 5 16 in of insulation from wire ends 10 Slide a piece of shrink tubing from kit over each of the wire ends stripped in step 9 and crimp the wires into the terminals installed in step 8 Make sure you connect the sil
4. gun or hair dryer 13 Cut 8 in of 5 16 in ID conduit from conduit supplied with kit 14 Slide 8 in length of conduit onto three wires connected in step11 and over existing conduit 15 Cut three spliced on wires to the lengths required for connection to the wires connected to the directional light Make certain to leave enough slack to allow routing harness along fork tube 16 Slide heat shrink tubes over the three wire ends 17 Strip 5 16 in of insulation from remaining wire ends and connect like colored wires at directional light with connectors from kit 18 Slide heat shrink tubing over connectors and activate shrink tubing with heat gun or hair dryer 19 Slide 5 16 in conduit installed in step 14 over all new connections and as close to directional light as possible 20 Install a cable strap on the 5 16 in conduit next to directional light to secure conduit in position J01449 i07000 Gasket Adhesive application area Figure 1 Inner view of fairing 21 Position harness along fork tube and secure with cable straps 22 Repeat steps 9 through 21 to connect left directional light 23 Continue at ASSEMBLING FAIRING Assembling Fairing 1 See Figure 1 Attach gasket 1 to the edge of the fairing at the headlamp opening as shown Place the gap in the gasket at the top of the headlamp opening then trim the gasket to the proper length so that the ends meet WARNING Please observe t
5. jam nut away from cable adjuster Move adjuster toward jam nut to introduce a large amount of freeplay at the hand lever J01449 oe ww ree Pedy w 6 ale H i ps w 9 3 1 Large hooked end of spring 2 Small hooked end 3 Bushings Figure 3 Rear view of installed spring 1 Clutch cable 2 Handlebars Figure 4 New Clutch Cable Routing i06938 Rubber boot Cable adjuster Jam nut Cable end Figure 5 Clutch cable adjustment c Remove small snap ring from pivot pin groove at bottom of clutch lever bracket Remove pivot pin and clutch hand lever from bracket d Reroute clutch cable to the inside of the handlebars as shown in Figure 4 and reconnect clutch cable to clutch lever by reversing step c 3 of 6 e See Figure 6 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 as necessary to obtain 1 16 to 1 8 inch 1 6 3 2 mm free play 1 between end of cable ferrule and clutch lever bracket f 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 i00716 a 1 16 1 8 inch 1 6 3 2 mm 1 Free play Figure 6 Clutch Cable Adjustment 2 See Figure 7 and Service Parts Illustration on page 6 For handlebar styles other than buckhorn pullbacks use wireform 1 it
6. SMOTOR HARLEY DAVIDSON WN J01449 General This kit is for installation on 1988 and later XL FXR and FXD model motorcycles with 39 mm front forks This kit does not fit XL Custom or FXLR model motorcycles This kit must be installed with Docking Hardware Kit Part Number 58164 96 This kit must be purchased separately from your Harley Davidson Dealer See Service Parts Illustration on page 5 for a list of kit contents NOTE A Service Manual for your vehicle is available from your Harley Davidson Dealer Installation The rider s safety depends upon the correct installation of this kit Use the appropriate service manual proce dures 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 If your motorcycle has directional lights mounted on the upper fork bracket they must be relocated to the bottom fork bracket Some models have front directional lights equipped with three wires the third black wire is a ground wire Check to determine how many wires are connected to the front directional lights and follow the following procedure that applies If directional lights are not mounted on the upper fork bracket proceed to ASSEMBLING FAIRING Relocating Two Wire Directional Lights 1 Support motorcycle on a center stand such that front wheel
7. airing in place tighten upper clamp nuts to 10 ft lbs 14 Nm Be sure the clamp does not rotate during tightening the mounting bushing must be parallel to the fairing brackets J01449 101138 1 Wireform 2 Chrome washer Figure 7 Throttle Cable Attachment on all handlebars except buckhorn style i00712 1 Sockethead screw item 8 on sheet 6 Or stock if XL Custom or FXLR models 2 Stock washer Retain for re use 3 Washer See item 6 on page 6 4 Wireform See item 1 page 6 Figure 8 Throttle Cable Attachment on Buckhorn style pullback handlebars 6 Align fairing with headlight and tighten nuts 21 on the adjustable brackets 6 14 15 When tight verify function of detachable feature by grabbing the fairing and pulling forward and upward to remove If brackets or clamps slide or rotate during removal realign and retighten all fasteners NOTE Inspect fairing for proper adjustment in relation to the headlamp opening If necessary adjust the mounting clamps up or down for proper headlamp to fairing relationship 7 If front signal lights were relocated test operation of turn signals and running lights If operation is not correct verify that the wire splices were made properly Awarnine Inspect fairing upon completion of installation Be sure fair ing mounting does not restrict full left or full right move ment of front fork assembly Restricted movement could affect handl
8. em 1 on Service Parts sheet 6 included in hardware kit part number 58164 96 to secure throttle cables to upper mounting clamp as shown Place chrome washer 2 from hardware kit item 6 on Service Parts sheet 6 between wireform and mounting clamp nut See Service Parts Illustration on page 6 For buckhorn style pullback handlebars use wireform 1 included in kit to secure throttle cables to upper fork triple clamp as shown Use sockethead screw 8 and washer 6 contained in hardware kit and place washer under wireform WARNING After securing throttle cable with wireform check that throt tle control opens and closes smoothly when handlebars are turned fully to left and right fork stops A sticking throttle could result in loss of control of the vehicle and possible personal injury 3 See Service Parts Illustration Assemble mounting hardware for lower fairing mounting as shown Locate assemblies approximately 1 2 inch from lower fork triple clamp with clamp nuts facing rear of motorcycle Tighten clamp nuts to 10 ft lbs 14 Nm Be sure the clamp does not rotate during tightening the mounting bushing must be parallel to the fairing brackets Tighten buttonhead screws 4 to 15 ft lbs 20 Nm 4 Hook the two lower quarter fairing assembly jaws into the grooves of the lower bushings then slide the upper clamp assemblies into place until the upper bushings firmly fit into the upper fairing jaws 5 With quarter f
9. his warning when applying the adhesive in this kit EYE IRRITANT BONDS SKIN IN SECONDS CON TAINS 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 immediate ly 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 2 Carefully apply one to two drops of adhesive at areas indicated 2 and to the gasket ends Glue the ends together With the gasket installed on the fairing carefully lift the inside edge of the gasket and apply one drop of adhesive to the gasket and non painted surface of the fairing as shown 3 Attach left and right mounting brackets 14 15 to quarter fairing 3 with self tapping screws 10 4 See Figures 2 3 and Service Parts Illustration Attach springs 1 to brackets 2 as shown 2 of 6 i06999 1 Spring 2 Bracket Figure 2 Installed spring 5 See Figure 3 Feed the large hooked end of spring 1 through the slot in the bracket Slide the spring until coiled portion aligns with the 1 4 hole in bracket Compress ends of spring together and feed the small hooked end 2 through the same slot that the large hooked end went through Insert bushings 3 into coiled ends of spring as shown Line up the spring and bushings with the 1 4 hole and fasten with screw 4 washer 5 and acorn nut 6 as shown
10. ing resulting in personal injury If restriction does occur adjust fairing as needed until proper clearance is obtained 4 of 6 WARNING Check mounting hardware periodically Never ride with loose mounts A loose mounting causes extra stress on all other mounts as well as the fairing itself and could result in premature failure of components allowing the fairing to detach and startle rider This could cause loss of control and personal injury 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 CAUTION Do not clean Lexan polycarbonate in hot sun or high tem perature Powdered abrasive or alkaline cleanser will dam age the windshield Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result CANY e Service Parts CAUTION 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 CAUTION Do not use harsh chemicals including rain sheeting prod ucts on Harley Davidson wi
11. ing lengths from the directional light Blue wire 1 1 4 in from directional light Violet wire 2 1 4 in from directional light Black wire 3 1 4 in from directional light NOTE The wires are cut at different lengths to stagger the butt connectors and prevent a large bulge in the harness 5 Strip 5 16 in of insulation from the cut ends of the three wires cut in step 4 6 Remove fork tube pinch screw from right side of upper fork bracket This is the screw that secures the right directional light 7 Install right directional light on right side of lower fork bracket using pinch screw removed in step 6 Install pinch screw removed in step 2 into right side of upper bracket Tighten both pinch screws to 30 35 ft lbs 8 Repeat steps 1 through 7 to relocate left directional light NOTE Fork tubes may slide downward within fork brackets If this occurs front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures 9 Connect right directional as follows Crimp solderless connectors from kit on three wires coming from motorcycle 10 Cut a 6 in length of wire from the black blue and violet wires in the kit 11 Strip 5 16 in of insulation from one end on each of the 6 in wire lengths connect like colored wires and crimp into connectors installed in step 9 12 Slide shrink tubing from kit over crimped terminals Activate shrink tubing with heat
12. ndshields They can cause dulling or hazing If you want to use a windshield protec tant on your windshield try Harley Glaze Polish and Sealant 00231a CAUTION Do not use benzine paint thinner gasoline or any other type of harsh cleaner on the windshield Doing so will dam age the windshield surface 00232a e Do not use benzine paint thinner gasoline lubricants including Armorall or other cleaning agents on the rub ber bushings They will damage the bushing surfaces NOTE Covering the windshield with a clean wet cloth for approximately 15 minutes before washing will make dried bug removal easier Date 10 04 Part No 57070 98 Detachable Quarter Fairing Kits sp57070 99 Item Description 1 Windshield 57074 98 Buttonhead screws 7 982 Quarter Fairing primed 57077 98 Washers 7 6276 Nylon bushings 4 58272 95 bracket 2 57073 98 Headlight cover 57075 98 LT wireform not shown 58579 96A RT wireform 58580 96A Screw tapping 6 5209 Acorn nuts 1 4 20 2 94004 90T ASeEMNONAWD J01449 Part No 6703 94426 95 57071 98 57072 98 5210 52428 99 5403B 57076 98 6424 7981 7979 57078 99 5 of 6 Item Description 12 Flatwashers 2 13 Buttonhead screws 2 14 Bracket left not shown 15 Bracket right 16 Well nut 3 17 Gasket edge 18 Bolt 1 4 20 carriage 4 19 Gasket trim 4 20 Washer 4 21 Nut flange 1 4 20 22 Nut keps 6 32 4 23 Pads adhesive backed 4
13. ver and copper colored wires to like colored wires NOTE Polarized wire is used in this application to ensure correct wiring One wire is silver one is copper colored Wire colors of spliced wire must match wire color of original directional wire leads 11 Cut polarized wires to the length required for connection to the wires at the relocated directional light Make certain you leave enough slack in wires to allow routing the harness along the fork tube 12 Split remaining end of the 2 conductor polarized wire from kit back about 2 in and strip 5 16 in of insulation from wire ends 13 Slide heat shrink tubes over the two wire end 14 Strip 5 16 in of insulation from wires connected to directional light and connect like colored wires at directional light with connectors from kit 15 Slide heat shrink tubing over connectors installed in steps 10 and 14 Activate shrink tubing with heat gun or hair dryer 16 Position harness along fork tube and secure with cable straps 17 Repeat steps 7 through 16 for left directional light 18 Continue at ASSEMBLING FAIRING Relocating Three Wire Directional Lights 1 Support motorcycle on a center stand such that front wheel is raised slightly off the ground 2 Remove fork tube pinch screw from right side of lower bracket 3 Carefully cut off 4 in of conduit covering the wires connected to right directional light 1 of 6 4 Cut the directional light wires at the follow
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