Road Zeppelin Air Adjustable Seat Kit Instruction - Harley
Contents
1. one must be installed in order to install the seat a See Figure 9 Get the retention nut kit 7 and cable strap 12 from the kit b Remove the plastic plug from the rear hole location in the fender by pushing up from under the fender c See Figure 2 Use the cable strap 3 as an aid to install the seat retention nut 1 and washer 2 from the retention nut kit Place the nut over the cable strap so the wide end of the nut rests on the eye of the strap Thread the cable strap up under the fender and through the fender hole Pull up on the cable strap to hold the seat retention nut snug against the underside of the fender d Position the seat nut rib in the fender hole notch Slide the retention washer into the exposed retention nut slot from the rear to lock the nut in place Remove cable strap Grab Strap Installation 1 See Figure 9 Get the grab strap 3 hex nut 8 and fender washer 9 from the kit 2 Determine the correct hole choice for the grab strap from Figure 3 and Table 1 Loop the strap so the seam is on the inside and the chosen holes are aligned J05814 3 See Figure 4 Install the grab strap holes over the forward fender stud 1 so the stud protrudes inside the loop 4 Place the fender washer over the stud threads Thread the hex nut onto the stud finger tight 5 Pivot the outboard ends of the grab strap around the stud so the strap ends cross each other at about 90 degrees pointing rearw2. fender 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 Tighten the mounting bracket screw securely to the fender to 60 90 in Ibs 6 8 10 2 Nm If removed install the saddlebags to the motorcycle per the instructions in the service manual Secure with the original bail head studs and flat washers 2013 earlier models Tighten the forward saddlebag mounting bolts to 10 12 ft lbs 13 6 16 3 Nm ALL models Adjust backrest pads and wiring as neces sary Read and understand the Pressure Adjustment and Care and Maintenance sections on Page 1 before riding with your new seat for the first time 2 Angle the front of the seat into place so the front slot engages the tongue of the frame SERVICE PARTS Table 2 Service Parts Kit ltem Description Quantity Part Number KIT 52000145 1 Seat Not sold separately Sportster 2 Kit Rear Seat Tab Mounting 51699 09 KIT 520001 47 3 Grabstrap Sportster and Dyna models 52400100 Dyna 5 Screw Hex Hd 1 4 20 x 1 0 in 3574 6 Nut Plastic 1 4 20 Dyna models only 7891 7 Kit Seat Nut 59768 97 8 Nut KEPS 1 4 20 in Dyna models only 7792 9 Washer fender 1 4 in 6036 10 Washer Nylon Step 7487 12 Cable Strap 10039 KITS 52000148 1 Seat Not sold separat
3. FX B 1 5 25 5 in 64 8 cm 52000149 Softail B 2 4 22 5 in 57 2 cm FLSTC SC 52000150 Softail B 3 4 21 5 in 54 6 cm FLSTN 52000152 Touring B 2 5 24 5 in 62 2 cm 30f9 INSTALLATION DYNA MODELS NOTE Avoid scratching painted surfaces with tools or metal seat tabs during installation Preparation and Removal 1 Remove seat per the service manual Save the mounting screw for installation of the new seat 2 See Figure 4 Remove the OE grab strap 2 if present by removing the nut and washer 1 from the forward fender location Save the hardware for later installation Discard the strap 3 If small rubber cushions are attached to the rear fender peel up at a corner to remove Remove any residue left behind 4 Ifthe motorcycle is not equipped with a grab strap mount stud at the forward strap mount hole location 1 one must be installed in order to install the seat a See Figure 9 Get the flange screw 5 and plastic retention nut 6 from the kit b See Figure 4 Install the flange screw from the underside of the fender through the grab strap mounting hole 1 in the fender Secure the screw with the retention nut NOTE 2010 Later FXDWG Models Check underneath the fender to verify that the flange screw head is clear of the wire guide and is installed against the fender 5 ALL Dyna Models If the motorcycle is not equipped with a seat retention nut at the rear seat mount hole location 3
4. MOTOR HARLEY DAVIDSON Qu J05814 INSTRUCTIONS REV 2013 11 27 ROAD ZEPPELIN AIR ADJUSTABLE SEAT KITS GENERAL Kit Numbers 52000145 52000147 52000148 52000149 52000150 52000152 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 WARNING Do not install these seat kits on motorcycles that are not equipped with an appropriate grab strap and passenger footpegs If footpegs and grab strap are not installed passenger could fall from moving motorcycle or grab onto operator causing loss of control and death or serious injury 000410b Models WITHOUT passenger footpegs require their installa tion See the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only for the correct passenger footpegs and mounts FXSTC Softail Custom models with original equipment OE upright and king or queen seat require separate pur chase of e A Seat Nut Kit Part No 59768 97 A seat mounting screw Part No 2952A e If desired a passenger backrest compatible with the OE upright WARNING The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have a Harley Dav idson dealer perform the installation Improper installation of this kit c
5. Pry up the bezel enough to grip Pull up the bezel away from the rubber trim strip Starting at either end peel the rubber trim strip away from the fender Clean the trim strip area with a 50 50 mixture of isop ropyl alcohol and distilled water Allow to dry com pletely Grab Strap Installation 1 See Figure 9 Get the grab strap 4 from the kit 70f9 See Figure 3 and Table 1 for the correct hole choice 5 and 2 for the grab strap a Place hole 5 from the figure over the grab strap fender stud on the high side of the vehicle with the grab strap seam facing up b Thread a flange nut 11 from the kit over the stud Snug finger tight c Loop the strap so hole 2 can be placed over the remaining fender stud d Thread the second flange nut 11 over the stud Snug finger tight e Hold the grab strap straight out perpendicular to the vehicle fender Tighten the flange nut on that side to 60 90 in Ibs 6 8 10 2 Nm f Hold the grab strap straight out in the opposite direc tion Tighten the second flange nut to 60 90 in lbs 6 8 10 2 Nm Seat Installation 1 From the front insert the rear of the new seat through the grab strap loop until the seat front slot can engage the fuel tank seat mount tongue Push the seat forward Rotate the rear of the seat down ward until the seat contacts the frame Install the seat mounting screw removed earlier Fasten the seat mounting bracket to the top of the rear
6. acket to the top of the rear fender Tighten the mounting bracket screw securely to the fender to 60 90 in Ibs 6 8 10 2 Nm FX models a From the front insert the rear of the new seat through the grab strap loop until the seat front tongue engages the fuel tank seat mount b Angle the front of the new seat into place so the front tongue engages the slot in the frame c Push the seat forward Rotate the rear of the seat downward until the seat contacts the frame d Install the seat mounting screw removed earlier Fasten the seat mounting bracket to the top of the rear fender e Tighten the mounting bracket screw securely to the fender to 60 90 in Ibs 6 8 10 2 Nm 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 2 ALL Softail models Read and understand the Pressure Adjustment and Care and Maintenance sections on Page 1 before riding with your new seat for the first time 6 of 9 INSTALLATION TOURING MODELS Preparation and Removal NOTE Avoid scratching painted surfaces with tools or metal seat tabs during installation 1 Remove seat per the service manual Save the mounting screw for installation of the new seat 2 Remove the left and right saddlebags per the service manual Save all hardware for installation NOTE Record the orien
7. ard 6 Tighten the grab strap hex nut to 60 90 in lbs 6 8 10 2 Nm Seat Installation 1 From the front insert the rear of the new seat through the grab strap loop until the seat front tongue engages the fuel tank seat mount 2 Angle the front of the seat into place so the front tongue engages the slot between the fuel tank bracket and frame 3 Push the seat forward Rotate the rear of the seat down ward until the seat contacts the frame 4 Install the seat mounting screw removed earlier Fasten the seat mounting bracket to the top of the rear fender IWIN NIN 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 Tighten the mounting bracket screw securely to the fender to 60 90 in Ibs 6 8 10 2 Nm 6 Read and understand the Pressure Adjustment and Care and Maintenance sections on Page 1 before riding with your new Seat for the first time is07789 Grab strap mount fastener Grab strap Rear seat mount location Stock seat bumpers remove PON Figure 4 Dyna Model Rear Fender Configuration 40f9 INSTALLATION SOFTAIL MODELS NOTE Avoid scratching painted surfaces with tools or metal seat tabs during installation Preparation and Removal 1 Remove seat per the service manual FL Softail models Save the rearmost pillion mounting screw
8. d of the nut rests on the eye of the strap Thread the cable strap up under the fender and through the fender hole Pull up on the cable strap to hold the seat retention nut snug against the underside of the fender d Position the seat nut rib in the fender hole notch Slide the retention washer into the exposed retention nut slot from the rear to lock the nut in place Remove cable strap Grab Strap Installation 1 See Figure 9 Get the grab strap 4 and flange nuts 11 from the kit 2 Determine the correct hole choice for the grab strap from Figure 3 and Table 1 FL models a Place the larger hole location number from the figure hole 4 or 5 over the grab strap fender stud on the high side of the vehicle with the grab strap seam facing up b Thread a flange nut 11 onto the stud finger tight c Hold the grab strap straight out perpendicular to the vehicle fender Tighten the flange nut to 60 90 in Ibs 6 8 10 2 Nm d The other end of the grab strap is installed after the seat is in position FX models a Loop the strap so the seam is on the inside and the chosen holes are aligned b Get the hex screw and fender washer saved earlier Insert the screw through the washer and into the aligned grab strap holes from the inside of the loop c See Figure 6 At the grab strap hole location 1 thread the hex screw into the retention nut finger tight d Orient the outboard ends of the grab strap on either sid
9. e of the hex screw so the strap ends oppose each other pointing outward e Tighten the grab strap hex screw to 60 90 in Ibs 6 8 10 2 Nm 5 of 9 Seat Installation A 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 1 FL models a J05814 Angle the front of the new seat into place so the front tongue engages the slot in the frame Place the seat in final position Slightly push up the seat on the fender toward the high side of the vehicle Wrap the grab strap over the waist of the seat Determine the correct hole choice for the free end of the grab strap from the smaller number side in Figure 3 and Table 1 A hole from the larger number side was chosen for the end already installed Wrap the grab strap around the seat aligning the correct second hole with the remaining grab strap fender stud The remainder of the close fitting grab strap installa tion is done in tight quarters under the partially installed seat Thread a flange nut onto the fender stud finger tight Pull the grab strap straight out perpendicular to the vehicle fender Tighten the flange nut to 60 90 in Ibs 6 8 10 2 Nm Push the seat forward Rotate the rear downward until the seat contacts the frame Install the seat mounting screw removed earlier Fasten the seat mounting br
10. ely Brent 2 and 2 Kit Rear Seat Tab Mounting 51699 09 Softail Grabstrap Softail and Touring 52400101 11 Nut Hex Flange 5 16 18 in 2 7499 KIT 52000152 Seat Not sold separately Touring 2 Kit Rear Seat Tab Mounting 51699 09 4 Grabstrap Softail and Touring 52400101 Items on seat identified see Inset A __ Seat cover fabric B Independent air cell bladder systems C Rider bulb pump for inflation D Rider release valve for deflation E Passenger bulb pump for inflation F Passenger release valve for deflation J05814 8 of 9 SERVICE PARTS is07796a Figure 9 Service Parts Road Zeppelin Air Adjustable Seat Kits J05814 9 of 9
11. er Proceed to the INSTALLATION section for the specific model INSTALLATION SPORTSTER MODELS NOTE Avoid scratching painted surfaces with tools or metal seat tabs during installation Preparation and Removal 1 Remove seat per the service manual Save the mounting screw for installation of the new seat See Figure 1 If there is NO seat retention nut at the forward seat mount location 2 install the seat retention nut from the Seat Nut Kit Figure 9 Item 7 a Remove the plastic plug if present from the forward hole location in the fender by pushing up from under the fender Save the plug b See Figure 2 Get the cable strap 3 from the kit as an aid to install the seat retention nut 1 and washer 2 Place the nut over the cable strap so the wide end of the nut rests on the eye of the strap Thread the cable strap up under the fender and through the fender hole Pull up on the cable strap to hold the seat retention nut snug against the underside of the fender c Position the seat nut rib in the fender hole notch Slide the retention washer into the exposed retention nut slot from the rear to lock the nut in place Remove cable strap is07788 1 Seat mount nut 2 Air seat grab strap mount location 3 Mid seat mount hole location not used shown with plug 4 Air seat rear tab mount location Figure 1 Sportster Rear Fender Configuration J05814 See Figure 1 Chopped fender Sport
12. for installation of the new seat Discard the two for ward rider seat mounting mushroom nuts FXSTC models Discard all OE seat mounting hardware FXSTC models require separate purchase of a Seat Nut Kit Part No 59768 97 and a seat mounting screw Part No 2952A ALL other FX Softail models Save the rearmost pillion mounting screw for installation of the new seat is07790 1 Grab strap mounting location 2 Rear seat mount location Figure 5 FL Softail Model Fender Configuration is07791 1 Grab strap mounting location 2 Rear seat mount location Figure 6 FX Softail Model Fender Configuration 2 FL Softail models See Figure 5 Remove the OE grab strap from the studs 1 protruding through the fender Discard the strap J05814 FX Softail models See Figure 6 Remove the hex cap screw and fender washer 1 Remove the grab strap Save the hardware for later installation Discard the grab strap 3 FXSTC models require installation of a Seat Nut Kit Part No 59768 97 purchased separately at the rear seat mounting hole location 2 a Get the Seat Nut Kit Get a cable strap from this kit b Remove the plastic plug from the rear hole location in the fender by pushing up from under the fender c See Figure 2 Use the cable strap 3 as an aid to install the seat retention nut 1 and washer 2 from the retention nut kit Place the nut over the cable strap so the wide en
13. g loss of control which could result in death or serious injury 00070b 4 Pull up on the center of the seat to verify that it is locked into place There will be a small amount of play but the seat should be held firmly in place by the post on the underside If the seat is not firmly in place repeat previous steps until the seat is locked into place See the owner s or service manual for further seat placement instruction Install the seat mounting screw removed earlier Fasten the seat mounting bracket to the top of the rear fender Chopped fender models like XL883L 883N 1200N 1200V 1200X Place guide washer over rear seat mounting hole in fender before installing seat screw ALL Sportster models Tighten the mounting bracket screw securely to the fender to 60 90 in Ibs 6 8 10 2 Nm Read and understand the Pressure Adjustment and Care and Maintenance sections on Page 1 before riding with your new seat for the first time J05814 is01955a 1 Retention nut 2 Retention washer 3 Cable strap installation aid Figure 2 Install Retention Nut Figure 3 Grab Strap Holes Table 1 Grab Strap Hole Selection Kits Models Strap Hole Length Location 52000145 Sportster A 1 3 29 5 in 74 9 cm 52000147 Dyna A 1 4 30 5 in 77 5 cm 52000148 Softail B 3 4 21 5 in 54 6 cm FLSTF B 52000148 Softail
14. nto the vacant fender hole Grab Strap Installation 1 6 See Figure 9 Get the grab strap 3 hex screw 5 and fender washer 9 from the kit Determine the correct hole choice for the grab strap from Figure 3 and Table 1 Loop the strap so the seam is on the inside and the chosen holes are aligned Place the fender washer onto the screw threads Insert the screw through the aligned grab strap holes from the inside of the loop outward See Figure 1 At the forward hole location 2 thread the hex screw into the retention nut finger tight Pivot the outboard ends of the grab strap around the hex screw so the strap ends cross each other at about 90 degrees with the strap ends facing rearward Tighten the screw to 60 90 in Ibs 6 8 10 2 Nm Seat Installation 1 From the front insert the rear of the new seat through the grab strap loop until the seat front tongue engages the fuel tank seat mount Angle the front of the seat into place so the front tongue engages the slot at the rear of the fuel tank mounting loc ation 2of9 Push the seat forward Rotate the rear of the seat down ward until the seat contacts the frame Flex the seat slightly in the middle Slide the seat towards the rear so that the bracket on the underside engages with the center seat post on the frame WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causin
15. ould result in death or serious injury 00308a NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is available from a Harley Davidson dealer Kit Contents See Figure 9 and Table 2 J05814 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled IMPORTANT READ BEFORE RIDING Pressure Adjustment 1 Before sitting on the seat inflate the seat to the point of bulging the seating surface Inflation takes 30 pumps or more with the bulb pump 2 While seated adjust the air pressure first by deflating with the vent valve until seated pressure feels distributed throughout the seating surface Experiment to find the most comfortable inflation state 3 If too much air pressure is released inflate the seat again with the bulb pump while either on or off the seat 4 Periodically check to see if there is adequate pressure in the seat Shift your weight or lean your body not the motorcycle from side to side The air within the seat transfers from cell to cell beneath you to redistribute the pressure NOTES e Avoid adjusting this seat while in motion Get as close as possible to ideal seating pressure while stationary to avoid distraction while riding e Proper adjustment can only be made while the rider is seated on the cushion in normal riding position For optimum comfort find the balance between air p
16. res sure and foam support from the seat Adjust the seat according to rider and passenger size weight riding pos ition and time in the saddle e Do not over inflate This seat works most effectively with a moderate amount of air Over inflation results in a floating unstable feeling and does not effectively distribute the seated pressure loads Care and Maintenance e When mounting or dismounting the vehicle avoid dragging a boot or other potentially damaging object across the seat surface Boot edges buckles and conchos can snag and scar the seat material This damage is NOT a warrantable condition e To clean the seat material treat as furniture upholstery Vacuum regularly to remove dust and debris embedded in the fabric Use water and mild detergent NOT laundry detergent to remove minor blemishes Commercial spot removers can also be used with light wiping or blotting DO NOT brush clean as that can damage or snag the fabric The seat materials are resistant to contact with all common chemicals used in and around the vehicle However flush 1 of 9 Please dispose of materials responsibly with water and clean up as soon as chemical contact occurs Seat fabric surfaces are treated with a water resistant coating but use a seat cover when vehicle is stored out doors Do not direct any high pressure water toward seat sur faces When washing vehicle with a pressure washer remove the seat or use a seat cov
17. ster models like 883L 883N 1200N 1200V 1200X have a threaded hole at the rear seat mount location 4 and require a nylon step washer Figure 9 Item 10 to protect the fender when the seat is installed Remove the screw in the rearmost fender hole and discard Full fender Sportster models If the motorcycle is not equipped with a seat retention nut at the rear seat mount hole location 4 one must be installed in order to install the seat a If the retention nut from the Seat Nut Kit Figure 9 Item 7 is available install that nut If the retention nut from the Seat Nut Kit was installed earlier remove the mid fender location Figure 1 Item 3 retention nut already installed on the vehicle b Remove the plastic plug from the rear hole location in the fender by pushing up from under the fender Save the plug c See Figure 2 Get the cable strap 3 from the kit as an aid to install the seat retention nut 1 and washer 2 Place the nut over the cable strap so the wide end of the nut rests on the eye of the strap Thread the cable strap up under the fender and through the fender hole Pull up on the cable strap to hold the seat retention nut snug against the underside of the fender d Position the seat nut rib in the fender hole notch Slide the retention washer into the exposed retention nut slot from the rear to lock the nut in place Remove cable strap e If desired install the plastic plug removed earlier i
18. tation of the saddlebag mounting brackets before removing the bracket fasteners 3 2013 earlier models Remove the grab strap a b See Figure 7 Remove the left side screw 1 and washer 2 Remove the bracket 4 and passenger grab strap 3 Repeat for the right side saddlebag mounting bracket 2014 later models Remove the grab strap a See Figure 8 Remove the grab strap screws 4 washers 5 and grab strap 3 from the vehicle Dis card hardware and grab strap b Grab strap mount brackets 6 can be left on the vehicle or removed IF removed install the mount bracket fastener removed earlier per the service manual is05863a NS 2 N IN A u 1 Stock screw 2 Stock washer 3 Grab strap 4 Saddlebag mounting bracket Figure 7 Remove and Install Grab Strap J05814 So or OD OE seat Rear seat mount fastener OE grab strap Grab strap screw Grab strap flat washer Grab strap mount bracket Grab strap mounting stud 2 Figure 8 2014 Later Touring OE Seat and Grab Strap 4 Remove the two flanged nuts from the studs 7 near the front of the rear fender Keep assemblies separate until installation 5 Models with fender trim strips Remove the trim strips from the rear fender a Cover the tip of a regular screwdriver with tape to protect chrome and painted surfaces Insert the tip of the screwdriver between the chrome bezel and the rubber trim strip
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