SPORTSTER SIDE COVER TRIM KIT
J034602004-10-06
GENERAL
Kit Number
66264-04
Models
This kit fits all 2004 and later XL (Sportster®) model motorcycles.
Kit Contents
1Side cover trim (right)
2Side cover trim (left)
3Install with long edge upward
Figure 1. Side Cover Trim Kit
There are no Service Parts available with this kit.
INSTALLATION
1. Refer to the Owner's Manual and follow the instructions given to remove the seat. Retain all seat mounting hardware.
1Side cover mounting clips (2)
2Mounting tab on battery tray
Figure 2. Left Side Cover Removed
2. See Figure 2. Grasp the left-hand side cover at the upper corners and gently pull it away from the plastic mounting clips (1) on the frame. Lift the cover up slightly so the mounting grommet clears the tab (2) on the battery tray. Remove the cover from the vehicle and set it aside.
3. Remove the right-hand side cover by gently pulling the bottom lip off of the tab on the oil tank.
4. To ensure surface cleanliness, clean the side covers with a mixture of 50% to 70% isopropyl alcohol and 30% to 50% distilled water. Allow to dry thoroughly.
1Line up holes
Figure 3. Right-Side Template Placement
1Line up slots
Figure 4. Left-Side Template Placement
5. See Figure 3 and Figure 4. Select a template from the kit and position it to the correct side cover. Line up the holes or slots in the template with the matching holes or slots in the side cover.
NOTE
DO NOT tape the bottom edges of the template legs to the side cover.
6. Tape the template in position on the side cover, avoiding tape on the bottom edges of the template legs.
NOTE
The trim strip installs to the side cover with the long edge up.
7. Repeat Steps 5 and 6 for the opposite side.
1Line up front of trim strip with edge of side cover
2Line up top of trim strip with bottom of template
Figure 5. Right-Side Trim Strip Installation
8. Select the correct-side trim strip. Test-fit the trim to the side cover, lining up the forward edge of the strip with the leading edge of the side cover, and lining up the top edge with the bottom legs of the template (see Figure 5 and Figure 6 ).
9. Peel the liner from the adhesive backing of the strip. Position the trim strip over the side cover without touching the adhesive to the cover surface. Line up the top of the trim strip with the bottom edge of the template legs, and the front edge of the trim strip with the front edge of the cover.
10. Starting at the front, press the trim strip firmly against the side cover along its entire length, and hold pressure for 30 seconds. After releasing pressure, avoid direct contact with the trim for about 20 minutes.
11. Repeat Steps 8 through 10 for the opposite side.
12. Remove the templates from the side covers, carefully peeling the tape from the cover surface. Remove any tape residue with the same isopropyl alcohol/ distilled water mixture used to clean the covers earlier.
1Line up front of trim strip with edge of side cover
2Line up top of trim strip with bottom of template
Figure 6. Left-Side Trim Strip Installation
13. See Figure 2. Place the grommet at the bottom of the left-hand side cover onto the tab (2) on the battery tray. Line up the top of the cover with the two mounting clips (1), aligning with the front clip first. Press the top of the side cover into the clips until snug.
14. Carefully place the top of the right-hand side cover over the oil filler cap, lining up the two holes in the cover with the buttons on the top of the oil tank. Pivot the bottom of the cover inward until the bottom lip snaps into the tab on the oil tank.
15. Refer to the Owner's Manual and follow the instructions given to install the seat.
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)
16. Allow AT LEAST 24 hours after applying the trim strips before exposing the areas to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperatures.
SERVICE PARTS
Figure 7. Sporster Side Cover Trim
Table 1. Service Parts: Sportster Side Cover Trim
Item
Description (Quantity)
Part Number
1
Trim, side cover (right side)
Not Sold Separately
2
Trim, side cover (left side)
Not Sold Separately
3
Template, side cover (right)
Not Sold Separately
4
Template, side cover (left)
Not Sold Separately
Items not included in kit:
A
Side covers (2)
B
Clip, left side cover (2)
C
Grommet, left side cover mounting