0/0
ENGINE GUARD KITS
J015432011-08-12
GENERAL
Kit Number
49004-00A, 49037-05A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 4 and Table 1.
INSTALLATION
WARNING
If Equipped: Front and/or rear guards are not intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022d)
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. Hold the engine guard (1) in place, lining up the hole in the top center mounting flange of the guard with the hole in the cross brace located between the front downtubes just below the steering head.
3. Install a flat washer (3) onto the screw threads and insert the screw (4) through the holes from the front. Install the second flat washer over the screw threads and thread the hex nut (2) onto the screw. Tighten finger-tight.
1ABS brake line
2Down tube
3Engine guard
4Clutch cable clip
5Clutch cable
6Brake line clip
Figure 1. Brake Line and Clutch Cable Routing
4. See Figure 3. On the right side of the motorcycle, attach the engine guard (1) to the footboard mounting bracket (2) with a screw (6), washer (5) and locknut (4) from the kit. Tighten finger-tight.
5. Repeat Step 4 for left side footboard mounting bracket (3). Tighten the screw to 44 N·m (33 ft-lbs).
6. Tighten the right side screw to 44 N·m (33 ft-lbs).
7. Tighten the top screw to 25.7 N·m (19 ft-lbs).
1Engine guard
2Hex nut (behind cross brace)
3Washer (2)
4Screw
Figure 2. Engine Guard Mounting Flange (Top Center)
1Engine guard
2Footboard mounting bracket, right side
3Footboard mounting bracket, left side
4Locknut
5Washer
6Screw
Figure 3. Engine Guard Lower Mounting (Right Side View)
SERVICE PARTS
Figure 4. Service Parts for Engine Guard Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Engine guard
Not Sold Separately
2
Hex nut, 5/16-18 in.
7748W
3
Plain washer, 5/16 in. I.D. (2)
6702
4
Screw, pan head, TORX, 5/16-18 X 7/8 in.
3655A
5
Locknut, 3/8-16 in. (2)
7778
6
Plain washer, 3/8 in. I.D (2)
6812
7
Screw, pan head, TORX, 3/8-16 X 1-1/4 in.
4188