ENGINE GUARD KITS
J015382011-08-19
GENERAL
Kit Number
49024-02, 49078-04, 49200-07A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
NOTE
These kits will not fit models equipped with Oil Cooler Part Number 26136-05.
Kit Contents
See Figure 6 and Table 1.
WARNING
Front and/or rear guard(s) can provide limited leg and cosmetic vehicle protection under unique circumstances. (Fall over while stopped, very slow speed slide.) It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022b)
INSTALLATION
FXSTD models only:
  • See Figure 5. Remove the clutch cable (2) from the clamp (1) on the downtube.
  • Position the engine guard between the front of the downtubes and behind the clutch cable.
All Models
1.
See Figure 1. Check the position of the clutch cable clip (4). The clip should extend outboard. If it does not, rotate the clip 180 degrees as follows:
a.
Open clutch cable clip (4) on left downtube (2) and remove the clutch cable (5) from the clip.
b.
Loosen the screw holding the clutch cable clip.
c.
Rotate the clip 180 degrees.
d.
Tighten the clutch cable clip screw.
e.
Install clutch cable back into the clutch cable clip.
NOTE
See Figure 1. When installing engine guard on models with ABS brakes, route the brake line (1) outboard of the frame tube and behind the engine guard (3) as shown. Rotate the brake line retaining clips (6) as shown to allow proper brake line routing.
2.
See Figure 2 and Figure 3. Align the top center mounting plate with the frame cross brace, located between the front downtubes.
1ABS brake line
2Down tube
3Engine guard
4Clutch cable clip
5Clutch cable
6Brake line clip
Figure 1. Brake Line and Clutch Cable Routing
Figure 2. Engine Guard Installed
3.
Fasten the mounting plate to the cross brace with screw (3), washer (2), and hex nut (1) as shown. Do not tighten.
4.
See Figure 6. Install the left side engine guard (1) with a screw (7), washer (6), and locknut (5). Do not tighten.
1Hex nut (behind frame cross brace)
2Washer (2)
3Screw
Figure 3. Engine Guard Mounting Plate (Top Center)
1Locknut (2)
2Washer (2)
3Screw (2)
Figure 4. Engine Guard Lower Mounting (Right Side View)
5.
See Figure 4. Repeat Step 4 for the right side.
6.
Tighten the right side screw to 44 N·m (33 ft-lbs). Repeat for the left side.
7.
Tighten the engine guard top center mounting hardware to 25 N·m (19 ft-lbs).
8.
FXSTD models only: See Figure 5. Remove and discard stock clamp (1). Fasten the clutch cable (2) to the downtube and engine guard with the two cable straps (3) from the kit.
1Clamp
2Clutch cable
3Cable strap
Figure 5. FXSTD Clutch Cable and Cable Strap
SERVICE PARTS
Figure 6. Service Parts: Engine Guard
Table 1. Service Parts: Engine Guard
Item
Description (Quantity)
Part Number
1
Engine guard
Not Sold Separately
2
Hex nut, 5/16 inch
7748W
3
Washer, 5/16 inch (2)
6702
4
Screw, pan head
3655A
5
Locknut, nylon, 3/8-16 (2)
7778
6
Washer, 3/8 inch (2)
6812
7
Screw, buttonhead (2)
4188
Screw, buttonhead (2) (Kit 49078-04 only)
4459
8
Cable strap (2), (FXSTD only) (not shown)
10081