FL TOURING CVO-STYLE REAR FENDER KITS - Harley
Contents
1. 1 See the service manual to install the main fuse 5 of 8 SERVICE PARTS is07238c 59500245 59500246 59500470 59500469 59500245 59500470 59500246 59500469 Ip IH 59500245 59500470 Figure 5 Service Parts FL Touring CVO Style Rear Fender Kits J05914 6 of 8 SERVICE PARTS Table 1 Service Parts Item Description Quantity Part Number 1 Fender rear Prime paint no center tail lamp opening for kit 59500246 60463 09A Fender rear Prime paint with center tail lamp opening for kit 59500245 60472 09A 2 Boss fender mounting 4 59786 01 3 Washer fender mounting 4 59788 01 4 Hex nut 1 2 13 4 7880 5 Screw pan head TORX self tapping 5 16 18 x one inch 25 4 mm long 4 3684 6 Cushion saddlebag support 2 11100068 7 Clip 6 for kits 59500246 and 59500469 69200313 Clip 2 for kits 59500245 and 59500470 8 Spacer rubber adhesive backed 1 75 x 0 75 x 0 06 in 44 5 x 19 0 x 1 6 mm 11891 9 Fascia rear fender unpainted for kits 59500246 and 59500245 59500107 10 Stud plate 2 59500018 11 Fascia support bracket 2 67900185 12 Large flange nut 1 4 20 7 7499 13 LED stop tail turn signal lamp assembly Red with Smoke lens 2 for kits 59500246 and 59500469 67800201 LED turn2. signal lamp assembly Amber right for kits 59500245 and 59500470 67800203 LED turn signal lamp assembly Amber left for kits 59500245 and 59500470 67800204 14 Screw pan head TORX black 10 x 0 5 inch 12 7 mm long 6 3152 15 Bracket license plate 60915 09A 16 Cover license light unpainted for kits 59500246 and 59500245 60934 10 17 Screw 1 4 20 x 0 75 in 19 mm 4 940 18 Light license plate 60920 09 19 Socket housing 2 way black 74112 98BK 20 Secondary lock 74152 98 21 Gasket upper license plate 57637 09 22 Stud plate 59840 09 23 Connector cover 60916 09 24 Foam pad adhesive backed license plate bracket 2 11100008 25 Bracket reflector for kits 59500246 and 59500469 60922 09 Bracket reflector for kits 59500245 and 59500470 67900182 26 Reflector for kits 59500246 and 59500469 2 88 x 0 875 in 73 x 22 mm 59359 06 Reflector for kits 59500245 and 59500470 2 72 x 1 24 in 69 x 32 mm 59259 90 27 Pad rubber adhesive backed 1 18 x 0 75 x 0 06 in 30 0 x 19 0 x 1 6 mm 6549 28 Clip adhesive backed 2 10102 29 Harness rear lighting for kits 59500246 and 59500469 69200720 Harness rear lighting for kits 59500245 and 59500470 69200719 30 Antenna bracket rear 76555 09 31 Antenna base assembly includes items 32 33 76335 87 32 e Lock washer 7129 33 e Nut 2 76259 86 34 Spacer antenna front 12400091 35 Spacer antenna rear 12400092 36 Screw button head TORX 5 16 18 x 1 62 in 41 3
3. the kit onto the larger threads of the antenna base 31 under the hex nut 33 Insert the antenna base through the hole in the antenna mounting bracket Install the second hex nut 33 onto the threads of the antenna base Place a wrench on the upper nut and tighten the lower nut to 6 ft lbs 8 Nm Plug the antenna cable connector into the antenna base Tighten the knurled nut to secure the connector to the antenna base Allow slack in the cable at the antenna base to avoid kinking or binding at the connection Fasten the antenna cable to the fender support bar with a cable strap Use a second cable strap to tie the antenna cable FLHX models the excess rear fascia lamp wires to the frame rail near the suspension air lines underneath the painted cover DO NOT tie the cable to the air lines Thread the antenna mast assembly securely onto the antenna base 31 FENDER INSTALLATION NOTES The help of an assistant aids in the placement of the fender onto the motorcycle Protect the lower edges of the fascia beneath the tail lamps with tape to prevent the mufflers damaging the paint during fender installation J05914 1 Carefully roll forward the new fender into position between the rear frame rails 2 See Figure 5 Get four 5 16 18 x one in 25 4 mm long fender mounting screws 5 from the kit Loosely install a screw through the rear frame rail into the rearmost fender mounting boss on each side 3 Align the fro
4. GHT Remove the blue film from the lens faces before the lamps are installed in the fascia 6 Install a rear fascia lamp 6 into the correct side opening in the fascia from behind Fasten with three black 10 TORX screws 7 Alternately tighten each screw to 14 18 in Ibs 1 6 2 1 Nm Repeat for the remaining fascia lamp Antenna Relocation on FLHX and FLHTRX Models 1 See Figure 5 Disconnect the antenna cable from the antenna base assembly 2 Unscrew the antenna mast from the antenna base 40f8 10 11 12 Remove the lower locknut Remove the antenna base from the mounting bracket Remove the two screws and lockwashers retaining the antenna mounting bracket Remove and discard any cable straps securing the antenna cable to the fender support and saddlebag rear support brackets Get the new antenna bracket 30 spacers 34 and 35 screws 36 flat washers 37 and antenna base assembly 31 Position the antenna bracket near the fender supports as shown in Figure 5 and fasten the bracket to the fender supports a Assemble the thin washer 37 to the screw threads b Install screws through antenna bracket from rear c Slide the spacers onto the threads that are extending through the bracket Note the spacer lengths Refer ence Figure 5 d Align and fasten this bracket and fastener assembly to the fender support and tighten to 15 20 ft lbs 20 3 27 1 Nm Install tooth lockwasher 32 from
5. MOTOR HARLEY DAVIDSON WY J05914 INSTRUCTIONS REV 2015 07 15 FL TOURING CVO STYLE REAR FENDER KITS GENERAL Kit Numbers 59500245 59500246 59500469 59500470 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Installation Requirements A wallpaper seam roller is required for proper installation of the lighting harness in this kit The help of an assistant aids in the removal and placement of the fender 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 refers to service manual information A service manual for this year model motorcycle is required for this installation One is available from a Harley Davidson dealer Kit Contents See Figure 5 and Table 1 J05914 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled PREPARATION IWIN NIN To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b NOTE Vehicles WITH security siren With security fo
6. b present turn ignition switch ON Disarm security system IMMEDI ATELY remove the main fuse per the service manual Vehicles WITHOUT security siren See the service manual to remove the main fuse 1 Remove the saddlebags per the service manual 2 Remove the left and right side covers per the service manual unless already done 3 Remove seat Retain the seat and all mounting hardware 4 Remove the license plate if installed Set aside for later installation The license plate bracket and reflector can remain on the fender 5 See the service manual to remove and save the following items if present Tour Pak luggage rack or Tour Pak support e Rider backrest e Passenger backrest e Grab rail reinforcement plate and fasteners 6 Release the air pressure in the rear suspension per the service manual Disconnect the right side shock absorber hose at one end 1 of 8 Please dispose of materials responsibly FENDER REMOVAL NOTE The help of an assistant aids in the removal of the fender 1 See the service manual to remove the rear fender from the vehicle with the following exception a The tail lamp assembly turn signal bar rear fender tip lamp rear lighting harness and when present the rear fascia and rear fascia lamp can remain on the fender is07163a Original equipment rear fender Stud plate Nut 2 Washer 2 Saddlebag to fender support bracket Screw 2 Locknut 2 Sc
7. e the liner from the adhesive backing of the reflector Install to the bracket as shown NOTE International models using reflector bracket 60921 09 see Figure 3 Remove the liner from the adhesive backing of the 3 of 8 1 18 x 0 75 x 0 06 in 30 0 x 19 0 x 1 6 mm rubber pad 18 Position the pad to the back of the reflector bracket 7 just above the hole as shown Press firmly into place 4 Hold the gasket 6 in place Feed the lamp wires 3 through the license bracket 1 reflector bracket 7 and the hole 10 in the fender 9 5 Hold the stud plate 11 in place on the underside of the fender Secure the license plate bracket 1 to the stud plate with screws 13 Tighten the screws securely 6 Insert the license lamp wires into the two way socket housing 14 per the service manual Secure with the secondary lock 15 Plug the two way pin housing on the rear harness into the license lamp socket 45B 7 Install the license lamp connector cover 16 Secure with a flange nut 17 Tighten the nut to 30 45 in Ibs 3 4 5 1 Nm 8 Secure the wire harness with the clip on the inside of the fender Center Stop Tail Lamp Installation For Models So Equipped Install the new center stop tail lamp per service manual instructions Rear Fascia Installation 1 See Figure 1 Install a new fender mounting boss 11 from the inside through one of the four holes in the sides of the fender Place a washer 10 on
8. mm long Grade 8 2 3148 37 Flat washer 2 6702 J05914 7 0f8 Table 1 Service Parts Item Description Quantity Part Number Items used in ki ts 59500245 and 59500470 only 38 Light assembly tail lamp includes items 39 44 68142 04 39 e Lens tail lamp includes item 40 68558 03 40 E CAR Screw tail lamp 2 68026 99 41 Bulb and socket assembly tail lamp includes item 42 44 69187 03A 42 b sinr Bulb tail lamp wedge mount 68167 04 43 HE Socket housing four way 73154 96BK 44 Hin Socket terminal 16 20 AWG 3 73191 96 45 Tail lamp base assembly includes items 46 47 68066 99A 46 ER Tail lamp base chrome 68296 99A 47 NEN Circuit board and cover 68830 99A 48 Screw socket head 1 4 20 x 5 8 in 16 mm long 3022A 49 J nut 7964 J05914 8 of 8
9. nt mounting holes Loosely install the remaining screws through the frame rails into the forward fender mounting boss on each side 4 Get the two 5 16 18 x one in 25 4 mm long fender mounting screws and flanged locknuts saved earlier Install the screws from the front through the saddlebag support lower rear mounting holes and the saddlebag to fender support bracket Loosely install the flanged locknuts onto the screw threads 5 Route the harness leg with the gray four way connector between the front of the fender and the left side fender support Plug the connector 18 into the left side fascia lamp NOTE FLHX Models The electrical caddy must be loosened to allow the harness connector to fit through 6 Route the harness leg with the black four way connector between the front of the fender and the right side fender support Plug the connector 19 into the right side fascia lamp 7 Alternately tighten the four fender mounting screws to 15 20 ft lbs 20 3 27 1 Nm 8 Install the rear shock absorber air hose to the air valve assembly on the left side 9 See Figure 1 Install the saddlebag supports 12 10 Loosely install the passenger grab strap 11 See Figure 5 Use a clip 7 from the kit to fasten a harness leg to the clip slot on the underside of each saddlebag support COMPLETION NOTE To prevent possible damage to the sound system verify that the ignition switch is OFF before installing the main fuse
10. rew 4 Nut 4 10 Fender mounting washer 4 11 Fender inner mounting boss 4 12 Saddlebag support OPHONAARYNS Figure 1 Remove Rear Fender Items 2 See Figure 1 Remove the following items from the OE fender 1 and set aside for later installation to the new fender a The stud plate 2 two nuts 3 and two washers 4 at the front of the fender and b the saddlebag to fender support bracket 5 two screws 6 and two locknuts 7 at the rear of the fender c The saddlebag supports 12 FENDER ASSEMBLY NOTE Finish paint the rear fender fascia and license plate light cover before assembly J05914 is07190 Rear fender Stud plate Nut 2 Washer 2 Rear harness Black two way pin housing Black six way socket housing Version with center tail lamp Wire hole in front of fender Conduit end 2 5 in 64 mm from hole Conduit 1 5 in 38 mm minimum from fender centerline Se OG NO OV ND a O Figure 2 Install Rear Fender Harness Harness Installation NOTES e Ambient temperature must be at least 60 F 16 TC for proper adhesion of the harness conduit to the fender e Allow AT LEAST 24 hours after applying the harness before exposing the area to strong water spray or extreme weather e The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature 1 See Figure 2 Clean the fender 1 underside along the ha
11. rness mounting path as shown with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water Allow to dry completely Do not use solvents or harsh chemicals that damage painted surfaces 2 Get the stud plate 2 removed from the OE fender Posi tion the plate to the inside front of the fender with the channel positioned nearest the wire hole Loosely assemble the plate to the fender with the OE nuts 3 and washers 4 Do not fully tighten NOTE The two branches of the rear lighting harness without adhesive conduit remain outside the fender 20f8 3 Install the rear harness 5 to the underside of the fender a Feed the main body of the harness with adhesive conduit from the outside through the hole 9 in the front of the fender b Lay the harness along the length of the fender Posi tion the forward end of the adhesive conduit about 2 1 2 in 64 mm from the wire entry hole Lay the con duit a minimum of 1 1 2 in 38 mm from the center line of the fender Mark the position of the conduit on the fender c Beginning at the rear pull the tab on the harness conduit to expose the adhesive while pressing the conduit into place along the length of the fender Use a wallpaper seam roller to press the conduit securely in place At the front capture the wire harness under the stud plate channel d Tighten the stud plate nuts to 60 96 in Ibs 6 8 10 9 N m NOTE e Proceed with assembly and ins
12. tallation of the fender but do NOT pull or reposition the adhesive conduit Allow the adhesive 72 hours to cure fully License plate bracket License lamp License lamp wires License lamp cover Screw 1 4 20 x 0 75 in 19 mm long 2 Upper license plate gasket Reflector bracket Reflector Rear fender 1 2 3 4 5 6 7 8 9 10 Wire hole in rear fender is07188 11 Stud plate 12 Foam tape pad 2 13 Screw 1 4 20 x 0 75 in 19 mm long 2 14 Two way socket housing 15 Secondary lock 16 License lamp connector cover 17 Flange nut 1 4 20 18 Rubber pad 19 Remove this tab if present Figure 3 License Plate Lamp and Bracket Installation License Lamp Installation NOTE Some license lamps have a tab see Figure 3 inset Item 19 that prevents installation Remove the tab before proceeding 1 See Figure 3 Assemble the license lamp 2 and cover 4 to the license plate bracket 1 Tighten the screws 5 to 57 69 in Ibs 6 4 7 8 Nm Get the stud plate 11 and two foam tape pads 12 from the kit Remove the liner from the adhesive backing on one side of one pad Carefully position the pad to a flange J05914 of the stud plate on the side opposite the nuts Press firmly into place Repeat with the second pad on the remaining flange Remove the liner from the exposed side of the pads 3 Get the correct reflector 8 and bracket 7 from the kit Remov
13. to the threads of the boss and fasten with a nut 9 Tighten the nut to 15 20 ft los 20 3 27 1 Nm Repeat for the remaining three holes 2 See Figure 4 Remove the liner from the adhesive backing of the 1 75 x 0 75 x 0 06 in 44 5 x 19 0 x 1 6 mm rubber pad 2 Position the pad to the center of the fascia 1 just below the slot as shown Press firmly into place 3 Position the fascia under the rear edge of the fender Align the three holes on each side of the fascia with the mating holes in the fender Insert the three studs of a stud plate 3 from beneath the fender through the fender holes and fascia on one side J05914 is07189 Rear fascia Rubber pad Stud plate 2 Fascia support bracket 2 Flange nut 1 4 20 6 Rear lamp assembly left shown Screw 10 x 0 5 in 12 7 mm long 6 1 2 3 4 5 6 7 Figure 4 Rear Fascia Installation 4 Install a fascia support bracket stiffener plate 4 over the studs Loosely install three flange nuts 5 onto the stud threads 5 Loosely fasten the other side of the fascia with the remaining stud plate support bracket and flange nuts Alternately tighten each flange nut to 30 45 in Ibs 3 4 5 1 Nm NOTE e U S models only The fascia mounted LED lamps are identical International models The fascia mounted LED lamps are side specific The label on the back of the left side lamp is marked LEFT The right side lamp is marked RI
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