TOURING LOW PROFILE REAR SUSPENSION KIT
J047542018-10-12
GENERAL
Kit Number
54635-09
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
WARNING
Rider and passenger safety depend 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. (00333b)
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.
Additional Parts Required
This kit requires the separate purchase of air pump part number 54630-03A. This part is available for purchase from any Harley-Davidson Dealer.
Kit Contents
See Figure 4 and Table 2.
INSTALLATION
1. Remove seat. See service manual.
WARNING
Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311b)
WARNING
Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b)
2. Disconnect the battery cables, negative cable first or remove the main fuse if equipped.
3. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame.
NOTE
Retain the original fasteners for installation of new shocks.
4. Remove the saddlebags from the motorcycle. See the Touring model's Owner's Manual for saddlebag removal.
5. Fasten the air pump, part number 54630-03A to the rear air suspension adjustment valve on the motorcycle. See the Touring model's owner's manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi.
6. Using the pressure relief valve located below the gauge on the pump, release the air pressure from the rear suspension.
WARNING
Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a)
7. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air hose fittings.
NOTE
Press the plastic collar down on the air hose fitting to remove and install the air hose.
NOTE
Air suspension shock absorbers are oil filled and must be kept upright at all times to prevent oil leakage.
1Air hose fitting
Figure 1. Rear Shock Absorber
1Air hose
2Air hose fitting
3Plastic collar
Figure 2. Air Hose Removal and Installation
1Bolt
2Spring washer
3Flat washer
Figure 3. Removing Rear Shock Absorber
8. See Figure 3. Remove the lower mounting bolts (1), spring washers (2) and flat washers (3) from the shock absorbers.
9. Remove the upper mounting bolts and washers from the shock absorbers.
10. Install the washers removed in step 9 onto the upper shock bolts and push the bolts through the shock upper bushings.
11. Apply two or three drops of threadlocker to the exposed threads of the lower shock mounting bolt.LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
12. Fasten the top of the new shocks to the frame. Secure the upper shock bolts. Tighten.
Torque: 47–54.2 N·m (35–40 ft-lbs)
13. Install the washers removed in step 8 onto the lower shock bolts and push the bolts through the shock lower bushings.
14. Apply two or three drops of threadlocker to the exposed threads of the lower shock mounting bolt.LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
15. Fasten the bottom of the new shocks to the swingarm. Secure the lower shock bolts. Tighten.
Torque: 47–54 N·m (35–40 ft-lbs)
16. Fasten the air hoses, removed in step 6, to the air hose fittings on the new shocks.
NOTICE
Wipe all fingerprints off of exhaust system components after installation and before starting engine. Oil from hands can leave permanent marks on exhaust system finish. (00346a)
NOTICE
Do not exceed maximum air pressure for suspension. Air components fill rapidly. Therefore, use low air line pressure. Failure to do so can result in possible damage to components. (00165b)
17. Fasten the shock absorber air pump to the rear air suspension adjustment valve. Pressurize the rear air suspension system to check for air leaks. Adjust air pressure for rider comfort and to accommodate changing load conditions. Do not exceed 50 psi (241 kPa).
18. Install the saddlebags.
19. Reconnect battery cables to battery, positive (+) cable first or main fuse if removed.
20. Install seat. After installing seat, pull up on the seat to verify that it is secure. See service manual.
Table 1. Touring Suspension Recommended Air Pressure
SHOCK LOAD
TOTAL WEIGHT
PRESSURE
LB.
KG
PSI
kPa
Solo Rider
up to 150
up to 68
0
0
150-200
68-91
0-10
0-69
200-250
91-113
10-20
69-138
250-300
113-136
20-30
138-206
over 300
over 136
30-50
206-345
Solo rider with capacity luggage of 40 lbs (18 kg)
up to 150
up to 68
10-20
69-138
150-200
68-91
20-30
138-206
200-250
91-113
30-40
206-276
250-300
113-136
40-50
276-345
over 300
over 136
50
345
Rider plus passenger
All
All
40-50
276-345
Maximum GVWR
All
All
50
345
If P&A Tour-Pak is installed, add 5-10 psi (34-69 kPa) to shock.
Do not exceed 50 psi (345 kPa) rear shock pressure.
SERVICE PARTS
Figure 4. Service Parts: Low Profile Rear Suspension Kit
Table 2. Service Parts
Item
Description (Quantity)
Part Number
1
Low profile rear shock absorbers (2)
54662-09