SHOCK ABSORBER TOWER COVERS
J009182005-06-10
GENERAL
Kit Number
54341-96, 54616-96, and 54618-96
Models
Table 1. Models
Kits | Models |
|---|---|
54341-96 (Upper, chrome) | Fits 1991 and later Dyna models (except FXDX, FXDXT, '06 FXDC, '06 FXDWG, '06 FXDL, and models with profile low suspension shocks). |
54616-96 (Upper, chrome) | Fits 1990 to 2003 Sportster models (except XL 1200 Sport and models with profile low suspension shocks). |
54618-96 (Lower, chrome) | Fits 1990 to 2003 Sportster models (except XL 1200 Sport and models with profile low suspension shocks). |
Kit Contents
Table 2. Kit Contents
Description (Quantity) | Part Number |
|---|---|
Shock tower cover, right | Not Sold Separately |
Shock tower cover, left | Not Sold Separately |
Set screw (4) | Not Sold Separately |
Wrench | Not Sold Separately |
INSTALLATION
NOTE
Parts are only required to be removed when installing upper shock tower covers. Shock tower covers are specially shaped to fit in place over the ends of the shocks without interfering with shock or chassis components.
The instructions for installing upper shock tower covers is the same for both left and right sides.
Upper shock tower covers
1990-1999 Sportster Models
- See Figure 1. Remove acorn nut (1), outer washer (2), and original equipment shock cover (3). Discard outer washer and original equipment shock cover. Save inner washer (4), and leave bushing (5), nut (6), and bolt (7) assembled.
- Apply two to three drops of Loctite® Threadlocker 243 Blue (99642-97) to threads of bolt and reinstall acorn nut. Tighten acorn nut to 21-35 ft-lbs (28-47 Nm).
- Slide shock tower cover from kit over end of shock absorber. Using wrench supplied with kit, tighten two set screws to secure shock cover in place.
| 1 | Acorn nut |
| 2 | Outer washer |
| 3 | Shock cover |
| 4 | Inner washer |
| 5 | Bushing |
| 6 | Nut |
| 7 | Bolt |
Figure 1. Shock Covers 1990-1999 Sportster Models
2000-2003 Sportster Models
- See Figure 2. Remove bolt (1), outer washer (2), and original equipment shock cover (3). Discard outer washer and original equipment shock cover. Save inner washer (4), and leave bushing (5) assembled.
- Apply two to three drops of Loctite® Threadlocker 243 Blue (99642-97) to threads of bolt. Reinstall bolt and tighten to 21-35 ft-lbs (28-47 Nm).
- Slide shock tower cover from kit over end of shock absorber. Using wrench supplied with kit, tighten two set screws to secure shock cover in place.
1991-2005 Dyna Models
- See Figure 3. Remove acorn nut (1), outer washer (2), and original equipment shock cover (3). Discard outer washer and original equipment shock cover. Leave inner washers (4), lockwasher (6), and stud nut (7) assembled.
- Apply two to three drops of Loctite® Threadlocker 243 Blue (99642-97) to threads of stud and reinstall acorn nut. Tighten acorn nut to 21-35 ft-lbs (28-47 Nm).
- Slide shock tower cover from kit over end of shock absorber. Using wrench supplied with kit, tighten two set screws to secure shock cover in place.
| 1 | Bolt |
| 2 | Outer washer |
| 3 | Shock cover |
| 4 | Inner washer |
| 5 | Bushing |
Figure 2. Shock Covers 2000-2003 Sportster Models
| 1 | Acorn nut |
| 2 | Outer washer |
| 3 | Shock cover |
| 4 | Inner washer (2) |
| 5 | Stud |
| 6 | Lockwasher |
| 7 | Stud nut |
Figure 3. Shock Covers 1991-2005 Dyna Models
2006 FXD35, FXD, and FXDB Dyna Models
NOTE
Place the vehicle on a center stand with the rear wheel raised off the ground to remove the bolt.
- See Figure 4. Remove bolt (1), outer washer (2), and original equipment shock cover (3). Discard outer washer and original equipment shock cover. Save inner washer (4) and leave sleeve (5) assembled.
- Apply two to three drops of Loctite® Threadlocker 271 Red (99671-97) to threads of bolt. Reinstall bolt and tighten to 75-85 ft-lbs (101.6-115.2 Nm).
- Slide shock tower cover from kit over end of shock absorber. Using wrench supplied with kit, tighten two set screws to secure shock cover in place.
| 1 | Bolt |
| 2 | Outer washer |
| 3 | Shock cover |
| 4 | Inner washer |
| 5 | Sleeve |
Figure 4. Shock Covers 2006 FXD35, FXD, and FXDB Dyna Models
Lower shock tower covers (all models)
NOTE
The lower shock tower covers require no disassembly.
- Slide shock tower cover from kit over end of shock absorber. Using wrench supplied with kit, tighten two set screws to secure shock cover in place.
- After riding for several miles, check to make sure that the set screws are tight.