XL FRAME SERVICE KIT
Contents
1. cMOTOR HARLEY DAVIDSON WU J04486 INSTRUCTIONS REV 2008 08 13 XL FRAME SERVICE KIT GENERAL Kit Numbers 48878 06 49274 06 Models These kits are designed to replace the frame for 2007 Sportsters Additional Parts Required AWARNING 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 NOTES This instruction sheet references Service Manual information for your motorcycle A Service Manual for your model and year motorcycle is required for this installation and is available from a Harley Davidson Dealer In addition a 2007 Sportster Service Manual is required for proper installation of the wiring harness on the new 2007 frame We recommend that this kit be installed by a factory trained technician at an authorized Harley Davidson Dealer We recommend that this kit be installed by a factory trained technician at an authorized Harley Davidson Dealer Kit Contents See Figure 2 and Table 1 INSTALLATION NOTE Prior to installing the new frame verify that the VIN number matches the original frame VIN number See Figure 2 After completing the installation of this frame kit the original frame head stock2. that contains the Vehicle Identi fication Number VIN along with a minimum of 12 0 inches of the front down tubes A and 12 0 inches of the backbone B from the headstock MUST be returned to your local Harley Davidson dealer There may be situations that require the entire frame to be returned but only when instructed by Tech nical Services If the entire frame is returned without prior Harley Davidson authorization the dealer will not receive credit for the freight costs for the entire frame Your new frame will have the correct VIN number stamped on the headstock Refer to your model and year service manual for procedures to remove all components from your frame Then refer to the service manual and install all of the removed components onto the frame included in this kit replacing the left and right side harness clips jiffy stand and bumper with the parts included in this kit is05120 1 Cable strap 3 2 Double sided adhesive tape T y INU KU 3 Connector 4 Black wire Figure 1 Harness Installation J04486 1of2 See Figure 1 Secure the wire harness as follows Sportster service manual Verify that the connector 3 is oriented as shown with the Secure the harness in place using three cable straps 1 black wire at the top Secure in place with the double sided located in the positions shown SERVICE PARTS adhesive tape 2 from the kit e Install the left and right harness cl
3. ips according to the 2007 is02949b Figure 2 Service Parts for Sportster Frame Kit Table 1 Service Parts Table Item Description Quantity Part Number 1 Weldment frame PNTD Not Sold Separately 2 Cup bearing 2 48315 60 3 Jiffy stand 883 883R 1200R 50116 05 Jiffy stand 883C 883L 1200C 1200L 50185 04B 4 Bumper 62122 89A 5 Cable strap 5 10039 6 Wire harness clip left side 73203 04A 7 Wire harness clip right side 73204 04A 8 Double sided adhesive tape 66249 01 Items Mentioned in Text A Down tube 12 in 80 cm B Backbone 12 in 30 cm J04486 2 of 2
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