CHROME CALIPER/ROTOR COVER KIT
J015422007-10-03
GENERAL
Kit Number
42230-00
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of additional parts or accessories is required for proper installation of this Caliper/Rotor Cover Kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
WARNINGRider 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.
Kit Contents
Table 1. Kit Contents
Qty. | Description | Part Number |
|---|---|---|
1 | Cover service kit, right hand (includes the following items) | 42221-00 |
1 |
| Not sold separately |
1 |
| Not sold separately |
1 | Cover service kit, left hand (includes the following items) | 42220-00 |
1 |
| Not sold separately |
1 |
| Not sold separately |
1 | Mounting bracket, rotor/caliper cover (right hand) | Not sold separately |
1 | Mounting bracket, rotor/caliper cover (left hand) | Not sold separately |
2 | Mounting bracket, rotor cover, top | 43072-89A |
14 | Screw, hex socket button head, #10-32 x 3/8 inch | 2719 |
14 | Wave washer, #10 | 6065 |
2 | Lock nut, flanged, 5/16-18 | 7531 |
1 | Mounting bracket, rotor cover, lower (right hand) | Not sold separately |
1 | Mounting bracket, rotor cover, lower (left hand) (includes the following items) | Not sold separately |
1 |
| Not sold separately |
1 |
| Not sold separately |
1 |
| Not sold separately |
1 |
| Not sold separately |
1 |
| Not sold separately |
INSTALLATION
NOTE
If this kit is being installed at the same time as Lighted Fork
Slider Cover Kit 46732-00, follow the instructions in that kit for proper installation sequence.
If the Lighted Fork Slider Cover Kit is not being installed, proceed as follows.
Preparation
Models WITH Maxi® Fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse.
Models WITHOUT Maxi® Fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
Left Side Installation
| 1. | See Figure 1. Assemble the wedge spacer halves (Items 1 and 2) to the left-hand lower caliper mounting bracket (3) with the 1/4-28 hex head screw (4) and washer (5) as shown. | 
Figure 1. Assemble Left Lower Mounting Bracket | ||||||||||||||
| 2. | See Figure 2. Install the left-hand lower caliper mounting bracket (1) to the left-side fork slider by sliding the wedge spacer into the hole in the bottom of the fork slider. Tighten finger-tight so the rotor cover can be positioned later. | 
Figure 2. Install Left Lower Mounting Bracket to Slider 
Figure 3. Install Left Rotor/Caliper Mounting Bracket | ||||||||||||||
| 3. | See Figure 3. Install the left-hand rotor/caliper mounting bracket by removing the 12-point bolts that attach the caliper to the fork slider. Align the bracket over the holes as shown. Replace the bolts in the correct position (longer bolt on top). Tighten the bolts to 38–52 N·m (28–38 ft-lbs). | |||||||||||||||
| 4. | See Figure 4. Bend back the locking plate tabs on the left forward fender mounting bolt. Remove the bolt. | 
Figure 4. Bend Back Locking Tabs (Left Side Shown) 
Figure 5. Top Bracket Orientation (Left Side) | ||||||||||||||
| 5. | See Figure 5. Insert one of the rotor cover top mounting brackets (1) from the kit between the locking tab and fender. The bracket must be oriented so the small hole is toward the bottom and furthest from the tire. If the motorcycle IS NOT equipped with fender rails
(bumpers), obtain a spacer washer from the kit. If the motorcycle IS equipped with fender rails, the spacer washer is not used. See Figure 6. Insert the fender mounting bolt (1) Finger-tighten only at this time. a. through the locking tab (2), b. through the rotor cover top mounting bracket (3), c. through the spacer (4, if WITHOUT fender rails), d. through the fender (5), and e. into the threaded hole in the fork slider (6) as shown. | 
Figure 6. Install Rotor Cover Top Bracket (Left Side Shown) 
Figure 7. Slide Rotor Cover Into Position (Left Side Shown) | ||||||||||||||
| 6. | See Figure 7. From the bottom of the fork slider, slide the left-hand rotor cover up between the fork slider and rotor, over the lower and top mounting brackets. | |||||||||||||||
| 7. | See Figure 8. Using four of the hex socket button head screws and wave washers from the kit, assemble the left-hand rotor cover to the lower mounting bracket (1), rotor/caliper mounting bracket (2) and top bracket (3). Finger-tighten only. | 
Figure 8. Install Screws To Rotor Cover (Left Side) 
Figure 9. Adjust Rotor Cover (Left Side Shown) | ||||||||||||||
| 8. | Slide the lower mounting bracket in or out on its mounting screw as necessary to adjust the cover to the proper position. The edge of the rotor cover lip should align with the inside surface of the brake rotor (see Figure 9 ). Tighten the lower mounting bracket screw to 14–20 N·m (10–15 ft-lbs). NOTE When tightening the top rotor cover mounting screw, use a ball end wrench to avoid contacting the fork slider with the wrench. | |||||||||||||||
| 9. | Align the rotor cover so the space between the rotor cover and brake rotor is even all around, and the space between the rotor cover and fork slider is even. Tighten the four rotor cover mounting screws (see Figure 8 ) to 3 N·m (22 in-lbs). | |||||||||||||||
| 10. | Tighten the mounting bolt (Refer to Figure 6 ) securing the left-side rotor top mounting bracket and front fender to the fork slider to 19–24 N·m (14–18 ft-lbs). | |||||||||||||||
| 11. | Bend the locking plate tabs (Refer to Figure 4 ) against the side of the bolt head to lock the bolt into position. | |||||||||||||||
| 12. | See Figure 10. Install the left-hand caliper cover (1) with three hex socket button head screws and wave washers from the kit, as shown at locations (2). Tighten the screws to 2.5 N·m (22 in-lbs). | 
Figure 10. Install Left-Hand Caliper Cover |
Right Side Installation
| 13. | See Figure 11. Install the right-hand rotor cover lower mounting bracket (1) to the back side of the right-hand rotor cover as shown with two hex socket button head screws and wave washers (2) from the kit. Finger-tighten only. | 
Figure 11. Install Right Lower Mounting Bracket to Cover 
Figure 12. Install Right Rotor/Caliper Mounting Bracket | ||||||||||||||
| 14. | See Figure 12. Install the right-hand rotor/caliper mounting bracket by removing the 12-point bolts that attach the caliper to the fork slider. Align the bracket over the holes as shown. Replace the bolts in the correct position (longer bolt on top). Tighten the bolts to 38–52 N·m (28–38 ft-lbs). | |||||||||||||||
| 15. | Bend back the locking plate tabs on the right forward fender mounting bolt as was done in Step 5 for the left side. (Refer to Figure 4 ). Remove the bolt. | 
Figure 13. Top Bracket Orientation (Right Side) | ||||||||||||||
| 16. | Insert the remaining rotor cover top mounting bracket with the large hole between the locking tab and fender. The bracket must be oriented so the small hole is toward the bottom and furthest from the tire, as shown in Figure 13. If the motorcycle IS NOT equipped with fender rails
(bumpers), obtain a spacer washer from the kit. If the motorcycle IS equipped with fender rails, the spacer washer is not used. Reference Figure 6 , the left-side installation. Insert the fender mounting bolt (1) in the same sequence: Finger-tighten only at this time. a. through the locking tab (2), b. through the rotor cover top mounting bracket (3), c. through the spacer (4, if WITHOUT fender rails), d. through the fender (5), and e. into the threaded hole in the fork slider (6) as shown. | |||||||||||||||
| 17. | See Figure 14. Remove and discard the two nuts, lock washers, and flat washers that secure the axle cap (1) to the right-side fork slider. NOTE The axle cap may fall away from the fork slider when the hardware is removed. Make sure the axle cap is installed with the stamped word "OUT" oriented furthest away from the wheel (facing outward). | 
Figure 14. Remove Axle Cap Hardware (Right Side) | ||||||||||||||
| 18. | Reference Figure 7 , the left-side installation. From the bottom of the fork slider, slide the right-hand rotor cover up between the fork slider and rotor, over the caliper mounting bracket, and the top mounting bracket. | |||||||||||||||
| 19. | See Figure 15. Fasten the rotor cover lower mounting bracket (1) onto the right fork slider studs, against the axle cap (2) with the two flanged lock nuts (3, seen reflected in the cover) from the kit. Tighten the flanged lock nuts evenly to 12–18 N·m (9–13 ft-lbs). | 
Figure 15. Install Rotor Cover to Fork Slider Studs 
Figure 16. Install Screws to Rotor Cover (Right Side) | ||||||||||||||
| 20. | See Figure 16. Using two hex socket button head screws and wave washers from the kit, fasten the right-hand rotor cover to the rotor/caliper mounting bracket (1) and top bracket (2). Finger-tighten only. NOTE When tightening the top rotor cover mounting screw, use a ball end wrench to avoid contacting the fork slider with the wrench. | |||||||||||||||
| 21. | Align the rotor cover so the space between the rotor cover and brake rotor is even all around (reference Figure 9 , the left-side installation), and the space between the rotor cover and fork slider is even. Tighten all four rotor cover mounting screws (see Figure 16 , items 1, 2 and 3) to 2.5 N·m (22 in-lbs). | |||||||||||||||
| 22. | Tighten the mounting bolt (4, hidden behind the fender bracket) securing the right-side rotor top mounting bracket and front fender to the fork slider to 19–24 N·m (14–18 ft-lbs). | |||||||||||||||
| 23. | Bend the locking plate tabs (Refer to Figure 4 , the left-side installation) against the side of the bolt head to lock the bolt into position. | |||||||||||||||
| 24. | See Figure 17. Install the right-hand caliper cover (1) with three hex socket button head screws and wave washers from the kit, as shown at locations (2). Tighten the screws to 3 N·m (22 in-lbs). | 
Figure 17. Install Right Side Caliper Cover | ||||||||||||||
| 25. | Verify that the Ignition/Light Key Switch is turned to the OFF position. Models WITH Maxi Fuse: Refer to the Service Manual and follow the instructions given to re-install the Maxi® Fuse. Models WITHOUT Maxi Fuse: Apply a light coat of petroleum jelly or corrosion retardant material to the negative battery terminal. Refer to the Service Manual and follow the instructions given to re-attach the negative battery cable. Refer to the Service Manual, and follow instructions to install the seat. |
WARNINGAfter 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)
WARNINGAfter repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)