80-SPOKE FRONT WHEEL KIT - Harley
Contents
1. Service Parts Table for Wheel Kit 41203 05 Kit Installation Kit Item Description Quantity Part Number 2006 2007 FXDWG 43848 08 A Bearing 2 9247 Front 21 x2 15 inch B Sleeve bearing spacer 43633 06 Fitment C Screws 10 3655A Discard the following components which are provided with this installation kit but are not required for this fitment Spacer axle 43517 00 Sleeve bearing spacer 43755 04 Sleeve bearing spacer 43641 01 Screws TORX 10 3762M Washers 10 6966M Valve stem 43157 83A Valve stem 43206 01 2007 FX Softail 43851 08 A Bearing 2 9276 Wheel spacer 41504 07 Front 21x2 15 inch B Sleeve bearing spacer 41349 07 is included to replace the Fitment tapered spacer for 2007 C Screws 10 3655A and later FXSTD E Spacer axle FXSTD only 41504 07 i Tne ent Sioe of the wheel F Shim bearing install under primary left 43315 07 is the primary bearing side ce side bearing for this fitment Discard the following components which are provided with this installation kit but are not required for this fitment Shim bearing 43903 08 Sleeve bearing spacer 41900 08 Spacer axle 41695 07 Valve stem 43157 83A Valve stem 43206 01 J04023 7 of72. assemble the spoke nipples 5 See Figure 6 Insert the first inner row spoke into the hub Angle the spoke counterclockwise crossing four outer row spokes Loosely assemble the spoke nipples is02622 COT 5A R_LO CL GS I EN OO K JA AoA CLZ Figure 6 Install Inner Spokes 21 inch wheel shown 6 Install the inner row spokes into every fourth remaining hole above the rim centerline Loosely assemble the spoke nipples 7 See Figure 7 Turn rim over so brake disc side faces down Place any outer row spoke into hub Angle spoke counterclockwise and insert into rim hole angled to accept it Loosely assemble the spoke nipple J04023 is02621 SARS eR T TS SRN A KA fi AS Sa N f S78 Figure 7 Install Outer Spokes 21 inch wheel shown 8 Insert the remaining outer row spokes angled counter clockwise into hub and rim Loosely assemble the spoke nipples 9 Insert inner row spoke into hub and angle spoke clock wise crossing over 4 outer row spokes Place spoke into appropriate rim hole Loosely assemble the spoke nipples 10 See Figure 8 Install remaining inner row spokes Loosely assemble the spoke nipples 1 k Tighten spoke nipples to 19 35 in Ibs 2 2 4 Nm is02623 Ye 0 N Figure 8 Remaining Inner Spoke Installation 21 inch wheel shown TRUING LACED WHEELS The rim must be trued bot
3. strip 43939 89 43147 40 3 je Rim 41253 05 43087 04 4 je Hub 41255 05 41133 04 5 Spoke and nipple kit contains 20 inner spokes 20 41337 05 41899 05 outer spokes and 40 nipples 6 Hub plate 1 44614 03 44614 03 Table 4 Service Parts Table for Wheel Kit 42958 07 Kit Installation Kit Item Description Quantity Part Number 42958 07 1 Wheel Not Sold Separately 1A Machined groove Not Sold Separately 6 Hub plate 44614 03 Items requiring separate purchase J04023 5 of 7 Table 4 Service Parts Table for Wheel Kit 42958 07 Kit Installation Kit 2000 2006 FLST FLSTC FLSTF and FLSTN Not 2006 FLSTFSE2 For FLSTC and FLSTN Models Wheel spacer 43617 00A is included to replace the moon style hub cap 43833 07 Front 16x3 Fitment Item Description Quantity Part Number A Bearing 2 9267 B Sleeve bearing spacer 43608 00 C Screws 10 3655A E Spacer axle FLSTC and FLSTN only 43617 00A Discard the following components which are provided with this installation kit but are not required for this fitment Sleeve bearing spacer 43536 00 Sleeve bearing spacer 43613 00 Valve stem 43157 83A Valve stem 43206 01 Spacer axle 43313 98 Spacer axle 40910 00A 2007 and later FLSTC and 43851 08 A Bearing 2 9276 FLSTN Front 16x3 Fitment B Sleeve bearing spacer 41349 07 e For FLSTC and FLSTN Models
4. 693 m TTT Figure 3 Spoke length Table 1 Spoke Lengths Spoke Length A Outer spoke 21 inch wheel 7 83 inch 199 mm Inner spoke 21 inch wheel 8 35 inch 212 mm Outer spoke 16 inch wheel 5 19 inch 132 mm Inner spoke 16 inch wheel 5 59 142 mm 3 Machined directional groove Figure 2 Spoke and Directional Groove Location on Hub See Figure 3 and Table 1 Measure distance A outer to determine outer and inner spoke lengths Separate outer and inner spokes in preparation for installation to hub and rim J04023 1 See Figure 4 Place the hub on table with machined groove side up Insert a spoke in each hole of the outer row as shown Angle the spokes clockwise 2 For Kits 42958 07 Center the rim over the hub assembly with the valve stem hole facing up See Figure 5 For Kit 41203 05 The rim size should face up 3 See Figure 4 Using any outer row spoke insert the first spoke into the rim hole to the left of the valve stem hole on the upper half of the rim centerline Loosely assemble the spoke nipple is02618 Figure 4 Install Outer Spokes on Hub 2of7 is02619 Cape ESS AP ES ORES ses SR 1 Outer spoke location on rim 2 Valve stem hole location on kits 42958 07 Figure 5 Install Outer Spokes 21 inch wheel shown 4 Install the rest of outer row spokes in every fourth hole Loosely
5. Wheel spacer C Screws 10 3655A 41695 07 is included to E Spacer axle FLSTN and FLSTC only 41695 07 replace themoonsstyle hub F Shim bearing install under primary left 43315 07 cap side bearing Discard the following components which are provided with this installation kit but are not required for this fitment Shim bearing 43903 08 Sleeve bearing spacer 41900 08 Spacer axle 41504 07 Valve stem 43157 83A Valve stem 43206 01 Table 5 Service Parts Table for Wheel Kit 41203 05 Kit Installation Kit Item Description Quantity Part Number 41203 05 1 Wheel Not Sold Separately 1A Machined groove Not Sold Separately 6 Hub plate 44614 03 Items requiring separate purchase 2000 2006 FX Softail except 43833 07 A Bearing 2 9267 Ecole and 2000 2005 Front poet inch B Sleeve bearing spacer 43536 00 For FXSTS Models Install C Screws 10 3655A spacer 43313 98 on the E Spacer axle FXSTD only 40910 00A ees RA G ISpacer axle FXSTS only 43313 98 spacer and fork Wheel spacer 40910 00A Discard the following components which are provided with this installation kit but are not required for this fitment is e to T Sleeve bearing spacer 43608 00 tapered spacer on ase p Sleeve bearing spacer 43613 00 Valve stem 43157 83A Valve stem 43206 01 Spacer axle 43617 00A J04023 6 of 7 Table 5
6. cMOTOR HARLEY DAVIDSON WY J04023 INSTRUCTIONS REV 2007 09 19 80 SPOKE FRONT WHEEL KIT GENERAL Kit Number 41203 05 42958 07 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only NOTE Accessory hub caps are not compatible with this wheel Additional Parts Required This kit includes the custom wheel only Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley Davidson dealer e Wheel Bearing Remover and Installer HD 44060 e Wheel Installation Kit See Service Parts Tables for part number The following Harley Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning e Harley Bright Chrome Cleaner 94683 99 e Harley Glaze Polish and Sealant 99701 84 e Harley Wheel and Spoke Brush 43078 99 e Harley Davidson Wheel and Tire Cleaner 94658 98 IWIN NIN 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 m
7. de is the left side 3 Assemble wheel installation kit components and brake disc s to wheel using the appropriate service parts table Refer to FRONT WHEEL in Service Manual 4 For FLSTC and FLSTN Models Install wheel kit and right side wheel spacer provided in installation kit Refer to FRONT WHEEL in Service Manual For FXSTD Models Install the right side axle spacer provided in the installation kit in place of the stock tapered axle spacer For FXSTS Models Install the left side axle spacer pro vided in the installation kit between the stock axle spacer and fork For all other models Install previously removed wheel spacers Refer to FRONT WHEEL in Service Manual 5 Install front wheel 1 stock axle and stock axle nut Refer to FRONT WHEEL in Service Manual 1 of 7 WHEEL LACING PROCEDURE NOTE If only the rim is to be replaced tape the spokes together to hold the position on hub and remove spokes from rim Install taped hub spoke assembly to the new rim and tighten spokes Then remove the tape and true wheels The nipple fitting of the spoke uses a standard T 30 TORX bit for removal and installation is02615 KTS OD ISS SC a N Figure 1 Spoke Wheel Components 21 inch wheel shown The 80 spoke wheel uses two lengths of spokes installed in the inner and outer rows on the hub See Figure 2 is02617 1 Inner spoke row 2 Outer spoke row is02
8. h laterally and radially If new bear ings were installed wheels may be trued with only the bearings and center spacer installed See Figure 9 and Table 2 for the proper offset dimensions for your wheel 3 of 7 1S02624 pase 1 Cast in marking or groove side of hub Table 2 Wheel Offset Dimensions Kit Number A B 41203 05 1 69 inch 1 48 inch 42 8 mm 37 7 mm 42958 07 1 17 inch 0 93 inch 29 6 mm 23 6 mm J04023 Figure 9 Offset Dimension See TRUING LACED WHEELS the Service Manual for your model motorcycle MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to ensure that they keep their original shine and luster 1 Clean heavily soiled wheel surfaces using Harley Davidson Wheel and Tire Cleaner applied with the Harley Wheel and Spoke Brush 2 Thoroughly clean chrome with a good quality chrome cleaner such as Harley Bright Chrome Cleaner 3 After cleaning and polishing seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant 4 of 7 SERVICE PARTS is05004 Figure 10 Service Parts 80 Spoke Front Wheel 21 inch wheel shown Table 3 Service Parts Table Item Description Quantity Kit Number Kit Number 41203 05 42958 07 1 Wheel assembly consists of items 2 3 4 5 Not Sold Separately Not Sold Separately 2 je Rim
9. odel motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See the Service Parts section for kit contents INSTALLATION 1 Remove existing front wheel assembly Save axle axle nut brake disc and wheel spacers for kit installation Refer to FRONT WHEEL in Service Manual J04023 For FLSTC and FLSTN Models Discard moon style hub cap For FXSTD Models Discard tapered spacer 2 Install valve stem assembly on wheel Refer to TIRES in Service Manual CAUTION Do not re use brake disc screws Re using disc screws can result in torque loss and damage to rotor and or brake assembly 00319b NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER INSTALLER e Kits 41203 05 Should be installed so that the machined groove and cast in markings on the hub are on the right side of the motorcycle e Kit 42958 07 Should be installed so that the machined groove valve stem and cast in markings on the hub are on the left side of the motorcycle Kits 41203 05 For 2007 FXST FXSTB FXSTC Models The primary bearing side is the left side For 2006 and earlier FXST FXSTS FXSTB FXSTC FXSTD and 2007 and earlier FXDWG Models The primary bearing side is the right side For FXSTS Models Install the brake disc on the right side For all other models Install the brake disc on the left side Kit 42958 07 The primary bearing si
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