Chrome Fork Cover Kit

J031992006-11-22

GENERAL

Kit Number

66440-05, 66441-05

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 available from a Harley-Davidson Dealer.

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)

WARNING

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

Kit Contents

Table 1. Kit Contents

Description (Quantity)	Part Number
Chrome Fork Side Cover Kit 66441-05
Rear triple clamp cover, left hand	67888-91A
Rear triple clamp cover, right hand	67887-91A
Smooth Chrome Fork Cover Kit 66440-05
Rear, triple clamp Cover, left hand	67888-91A
Rear, triple clamp Cover, right hand	67887-91A
Chrome front panel	Not sold separately

INSTALLATION of Kit 66441-05

1	Passing lamp mounting hole location
2	Rear triple clamp cover, left hand
3	Rear triple clamp cover, right hand

Figure 1. Chrome Fork Side Cover Kit

1	Chrome front cover
2	Headlight wiring access hole
3	Rear triple clamp cover, right hand
4	Rear triple clamp cover, left hand
5	Passing lamp mounting hole

Figure 2. Smooth Chrome Fork Cover

1.	Remove the windshield (if equipped) according to the procedure in the applicable Service Manual.
2.	See Figure 1. If so equipped, remove the passing lamp switch from the left hand side triple clamp cover mounting hole (1).
	WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
3.	For Kit 66441-05, start with one side and remove the screws fastening the trim strip and rear triple clamp cover (2). Insert the new rear triple clamp cover and the original trim strip and install fasteners. Repeat procedure for other side.

INSTALLATION of Kit 66440-05

1.	Kit 66440-05, Loosen the fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of the Service Manual.
2.	Disconnect the headlight connector from the main harness.
3.	Start with one side and remove the screws fastening the trim strip and rear triple clamp cover. Remove trim strip and rear triple clamp cover. Repeat procedure for other side.
4.	Remove the nut, washers, lockwashers and bolt holding the headlight housing to the tripletree. Retain all hardware for future use. Remove headlight housing.
5.	Remove front panel.
6.	See Figure 2. From kit, place front panel (1) into position.
7.	Install headlight using the bolt, washer, lockwasher and nut removed earlier. Tighten fastener. Refer to your service manual for torque specifications and headlight alignment procedures.
8.	Insert headlight wiring through hole (2) in front panel and connect wiring to main electrical harness.
	WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
9.	Install fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of your Service Manual.
10.	Start with the left side and install the chrome rear triple clamp cover (4), and trim strip using screws removed earlier. Tighten fasteners.
11.	Install the headlight switch thru switch hole (5) removed earlier.
12.	Install the chrome right side rear triple clamp cover (3) and trim strip and tighten fasteners.
	WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
13.	Connect the battery cables, positive (+) cable first.
14.	If required, adjust the headlight according to the procedure in the applicable Service Manual.