w w w.hdonline s h o p .d e - HARLEY
Contents
1. MOTOR HARLEY DAVIDSON U J04729 INSTRUCTIONS REV 2008 06 27 FL ADJUSTABLE RIDER BACKREST MOUNTING HARDWARE KIT GENERAL Kit Number 52593 09 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 WARNING 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 model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 17 and Table 1 INSTALLATION 1997 THROUGH 2007 MODELS 1 Remove existing seat and grabstrap following the instructions in the service manual Models equipped with a grab handle must leave the grab handle in place Remove the nuts only Save all hardware for installation 2 Remove left side cover following instructions in the service manual 3 See Figure 1 1999 and Later Models Remove the flange nuts 2 in location indicated if applicable Leave the nylon retaining washers 1 in place 1997 1998 Models Remove bolts J047292. is01437 Nylon retaining washer 2 Flange nut 2 Adjustable handle bracket attachment point Adjustable handle cable access hole D N gt Figure 1 Remove Flange Nuts Bracket Location 4 See Figure 2 Install the adjustment handle bracket 1 with the appropriate hardware 2000 2007 Models See Figure 17 Use the screw 5 and flange nut 13 1997 1999 Models See Figure 17 Use the self tapping screw 11 5 Vehicles Equipped with Cruise Control See Figure 17 Install the cruise control cable through the wire clip 7 Install screw 5 or 11 through wire clip On 2000 2007 models install flange nut 13 6 See Figure 7 Verify the cable end 1 is secure in the bracket 2 before routing the backrest cable NOTE Over tightening the adjustment handle screws may cause damage to the adjustment handle 7 See Figure 3 Feed cable on handle through the adjust ment handle bracket 1 and install the backrest adjustment handle 2 in the bracket as shown with the provided flat head screws 3 Item 5 or 11 Figure 17 Tighten screws securely Feed the cable underneath the frame and up under the seat 8 Proceed to FINAL INSTALLATION ALL MODELS 1 of 7 1 Adjustment handle bracket generic shown 2 Backrest adjustment handle 3 Screw 2 Figure 3 Installed Backrest Adjustment Handle is01440 4 3 z ti r 1 Speed nut location Figure 4 Install Speed Nut
3. INSTALLATION 2008 MODELS Models without the Mid Frame Air Deflector Accessory 1 Remove existing seat and grabstrap according to service manual instructions Models equipped with a grab handle must leave the grab handle installed Remove the mounting nuts only Save all hardware for installation J04729 2 Remove the left side cover following the instructions in the service manual 3 See Figure 1 Remove the flange nuts 2 Leave the nylon retaining washers 1 in place 4 California models with the evaporator canister tube Pull plastic hose clip out of the hole in the frame plate at the location where the adjustment handle bracket is going to mount Discard plastic hose clip NOTE The following step s will provide a threaded backrest adjust ment handle bracket mounting hole in the 2008 frame The special self clinching nut included in the kit is inserted into the upper left hex shaped hole in the frame plate where the backrest mounts and secured in place by deforming the nut with a screw Care must be taken to verify the nut is fully engaged in the hex hole when tightening the screw to clinch the nut into the frame plate 5 See Figure 17 Obtain self clinching nut 15 and screw 16 from kit Install hex head screw into flanged end of the self clinching nut until head of the screw just makes contact with the top of the nut NOTE If necessary clean any paint from the hex hole to fully engage the self cli
4. mounting bracket 2 as shown Carefully secure the cable to the shaft of the gas spring 4 with the provided cable strap 3 4 of 7 WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 5 Install seat and grabstrap if equipped with the previously removed hardware 1 Backrest cable is04819 Release cable Backrest bracket Cable strap Gas spring shaft PRTI Figure 10 Attach Cable to Backrest Bracket J04729 BACKREST INSTALLATION ALL MODELS 1 See Figure 11 Press on lever located on backrest bracket as shown Insert backrest and press gently until it snaps into place WARNING After installing backrest pull upward to be sure it is locked in position While riding a loose backrest can shift causing loss of control which could result in death or serious injury 00386a is05616 Figure 11 Installing Backrest 5of7 OPERATION AWARNING After installing backrest pull upward to be sure it is locked in position While riding a loose backrest can shift causing loss of control which could result in death or serious injury 00386a 1 The adjustment handle is used to move the backrest pad into the forward and rearward positions is04959 2 See Figure 12 and Figure 13 To adjust the backrest
5. pad forward or rearward push the handle Leaning back against the backrest pad will help adjust it rearward Keeping your weight off of the backrest pad while pushing on the handle will cause the backrest to come to its full forward position Releasing the handle will lock the back rest into place 3 See Figure 14 and Figure 15 To adjust the backrest pad up and down pull the knob on rear of pad in approximate location shown Move the backrest up or down into the desired position then release when the pad is in the desired position is04956 4 See Figure 16 The backrest pad may be pushed forward against seat as shown to ease in getting off and on the motorcycle without activating the release handle is04957 Figure 15 Backrest in Fully Down Position is04960 is04958 Figure 16 Backrest Pushed Fully Forward Figure 13 Backrest in Full Rearward Position J04729 6 of 7 SERVICE PARTS is05628 D Figure 17 Service Parts Adjustable Rider Backrest Mounting Hardware Kit Table 1 Service Parts Table Adjustable Rider Backrest Item Description Quantity Part Number 1 Backrest bracket 52482 01A 2 Pivot bracket 52342 09 3 Washer 2 6223 4 Hex flange screw 2 1997 1998 models Not Sold Separately 5 Hex flange screw 1 4 20 x 5 8 inch 2 3921 6 Speed nut 8108 7 Wire clip Not Sold Separately 8 Backres
6. See Figure 7 Verify the cable end 1 is secure in the bracket 2 before routing the backrest cable 14 See Figure 8 Route the backrest cable through the large opening in the adjustment handle bracket then through the large oval slot 2 in the frame cross member plate 3 and down through the lower drain hole 1 located at the 2 of 7 bottom corner of the frame cross member plate where the cross member plate meets the rear frame 15 See Figure 9 Route cable 1 between the battery com partment and the fuse electrical box It may be necessary to loosen electrical box to fit the cable between the frame and the electrical box Continue routing the cable 1 up from the rear of the electrical box to between the frame and the rear fender and finally up to the top of the rear fender and to the backrest bracket is04764 1 Left deflector partially removed for clarity 2 7 8 inch long button head screw lockwasher and 1 inch OD flat washer 3 3 4 inch long button head screw lockwasher and 5 8 inch OD flat washer 4 Evaporator canister hose mounting hole Cali fornia models only 5 Frame cross member plate 6 Bottom frame opening drain hole for cable routing 7 Large oval slot Figure 5 2008 Models Fastener Locations View of Frame Rearward of Rear Cylinder Engine Removed for Clarity Models with the Mid Frame Air Deflector Accessory 1 Remove existing seat and grabstrap according to service manual ins
7. etween the frame and the electrical box Continue routing the cable 1 up from the rear of the electrical box to between the frame and the rear fender and finally up to the top of the rear fender and to the backrest bracket NOTE Over tightening the adjustment handle screws may cause damage to the adjustment handle 17 See Figure 3 Install the backrest adjustment handle 2 in the adjustment handle bracket 1 as shown with the provided flat head screws 3 Item 5 Figure 17 Tighten screws securely 1 Backrest bracket 2 Flange nuts 3 Electrical connector Figure 6 Attach Backrest Bracket with Flange Nuts and Screw J04729 is04765 M 1 Cable end 2 Adjustment handle bracket Figure 7 Seat Adjustment Cable Position View from Under Installed Handle FINAL INSTALLATION ALL MODELS 1 See Figure 4 Install soeed nut 1 in location shown 2 1999 and Later Models See Figure 17 Install backrest bracket 1 as shown using the flange nuts 13 washers 3 and screw 5 1997 1998 Models Use hex screws 4 and washers 3 3 See Figure 6 Slide the electrical connector 3 to the side so that the bracket does not interfere with it is04768 1 Lower drain hole under frame cross member plate 2 Large oval slot 3 Frame cross member plate Figure 8 Route Backrest Cable Through Frame 2008 Models Shown 4 See Figure 10 Attach the release cable 1 to the backrest
8. fore routing the backrest cable NOTE Over tightening the adjustment handle screws may cause damage to the adjustment handle 10 While holding the left side Mid Frame Air Deflector and the adjustment handle bracket with adjustment handle and cable in their as mounted orientation and so air deflector will end up captured between the adjustment handle bracket and the frame cross member align the deflector upper mounting hole 2nd hole from top of deflector with large slot in adjustment handle bracket Align bottom mounting hole in air deflector with bottom hole in adjust ment handle bracket 11 See Figure 5 Place air deflector and adjustment handle bracket into position while feeding backrest cable through large oval slot 7 in frame cross member plate 5 and down through bottom frame opening 6 in the compart ment behind the frame cross member plate NOTES With adjustment handle already installed in bracket it may be desirable to access the bracket mounting hardware from the right side of the vehicle Do not use Loctite on the fasteners used to secure the mid frame air deflector to the frame If Loctite contacts the air deflector damage will occur 12 Using hardware from Mid Frame Air Deflector Kit install 7 8 inch long button head screw with lock washer and 1 inch OD flat washer through slot in adjustment handle bracket and through upper mounting hole 2nd from top of air deflector Install screw into upper self clinch
9. ing nut installed as part of air deflector kit or as part of adjustable backrest kit Tighten screw snugly but do not fully tighten 13 Install 3 4 inch long button head screw with lockwasher and 5 8 inch OD flat washer from air deflector kit through lower hole in adjustment handle bracket and through lower mounting hole of air deflector Install screw into lower self clinching nut in frame cross member plate installed as part of air deflector kit While holding bracket and air deflector aligned and with hook bent tab of adjustment handle bracket tight against upper edge of large oval slot in frame tighten screw to 25 35 in Ibs 2 8 3 9 Nm 14 While holding bracket and air deflector aligned and with hook bent tab of adjustment handle bracket tight against 3 of 7 upper edge of large oval slot in frame cross member plate tighten upper screw to 25 35 in Ibs 2 8 3 9 Nm 15 California models with the evaporator canister tube See Figure 17 Obtain the adhesive backed clip 17 from kit Clean the flat area of the adjustment handle bracket approximately in the location where the stock plastic hose clip was removed using isopropyl alcohol Attach the clip to the bracket and route the evaporator tube through the clip Fold clip down to capture the tube securely 16 See Figure 9 Finish routing cable 1 between the battery compartment and the fuse electrical box It may be neces sary to loosen electrical box to fit the cable b
10. nching nut in the hole 6 Install the self clinching nut and screw into the upper hex hole in the frame plate where the backrest bracket mounts Engage hex shoulder of nut into the hex hole in frame 7 Turn screw with a 7 16 wrench while holding the self clinching nut firmly in place The back of the self clinching nut behind the frame plate will deform to clinch itself into the frame plate 8 Tighten screw to 60 65 in lbs 6 8 7 4 Nm approximately 2 1 2 turns 9 Remove screw 16 and discard 10 Hold shim 18 with hole in shim aligned with slot in bracket 10 and aligned with self clinching nut in frame plate and so shim gets sandwiched between the bracket and the frame plate Install adjustment handle bracket 10 and shim with flange screw 5 through bracket and shim and into the self clinching nut Make sure the hook bent tab of the bracket engages the edge of the large oval hole in the frame When aligned tighten flange screw to 45 55 in Ibs 5 1 6 2 Nm 11 California models with the evaporator canister tube See Figure 17 Obtain the adhesive backed clip 17 from kit Clean the flat area of the adjustment handle bracket approximately in the location where the stock plastic hose clip was removed using isopropyl alcohol Attach the clip to the bracket and route the evaporator tube through the clip Fold clip down to capture the tube securely 12 See Figure 17 Obtain actuator handle and cable 9 from kit 13
11. t pad Sold As Separate Kit Actuator Handle Kit includes Items 9 19 52367 09 9 Actuator handle and cable Not sold separately 10 Actuator handle bracket Not Sold Separately 11 Self tapping screw 5 16 18 x 3 4 inch 4328 12 Cable strap Not Sold Separately 13 Flange nut 1 4 20 2000 2008 models 8021 14 Flathead screw 10 24 2933 15 Nut self clinching 1 4 20 2008 models 8194 16 Hex head cap screw 1 4 20 x 1 0 inch 2008 models 2551W 17 Adhesive clip 10103 18 Handle bracket shim 2008 models Not Sold Separately 19 Nut w lockwasher 10 20 keps 2 7838 J04729 7 of 7
12. tructions Models equipped with a grab handle must leave the grab handle installed Remove the mounting nuts only Save all hardware for installation 2 Remove left side cover following instructions in the service manual 3 See Figure 1 Remove the flange nuts 2 in location indi cated if applicable Leave the nylon retaining washers 1 in place 4 California models with the evaporator canister tube Pull plastic hose clip out of the hole in the frame plate at the location where the adjustment handle bracket is going to mount Discard plastic hose clip NOTE If installing the Mid Frame Air Deflector Accessory Kit also follow Step 5 then skip to Step 7 If the Mid Frame Air Deflector Accessory has already been installed skip to Step 6 J04729 5 Follow the instructions included with the Mid Frame Air Deflector Kit to install the four self clinching special nuts 6 See Figure 5 Remove the left air deflector 1 and hard ware 2 and 3 7 See Figure 17 Obtain actuator handle bracket 10 from kit NOTE The air deflector mounting hardware should be used reused to mount the adjustment handle bracket 8 See Figure 17 Insert cable part of Item 9 through Opening in adjustment handle bracket 10 as shown Install adjustment handle part of Item 9 into bracket 10 using the two screws 5 Tighten screws securely but do not over tighten 9 See Figure 7 Verify the cable end 1 is secure in the bracket 2 be
Download Pdf Manuals
Related Search