FRONT FORK SLIDER COVER KIT
J005412007-09-28
GENERAL
Kit Number
45953-91B
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).
Additional Parts Required
Separate purchase and installation of an adapter wire (H-D Part No. 69505-89) is required when installing this kit on 1987 and 1988 models of the FLT vehicle family.
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
See Table 1.
INSTALLATION
Marker Lamp Wiring Harness 1987 - 1993 Models
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
| 1. | 1987 - 1988 models: Proceed to step 2. 1989 - 1993 models: Proceed to step 4. | |||||||||||||||||||||||||
| 2. | 1987-88 models only. Gain access to circuit breakers by removing instrument panel (on FLT and FLHS) or headlamp (on FLHT models); refer to appropriate Service Manual, if required. Locate the 15-amp ?Lights? circuit breaker. This circuit will have one black wire and | |||||||||||||||||||||||||
| 3. | 1987-88 models only. See Figure 2. Obtain adapter wire (1) (H-D Part No. 69505-89, purchased separately). Leaving the existing wires in position, connect ring terminal end (8) of adapter wire (1) onto silver terminal of ?lights? circuit breaker. Route socket connector (2) of adapter wire downward to area above left side of front fork lower bracket. Proceed to step 5. | |||||||||||||||||||||||||
| 4. | 1989-93 models only. See Figure 3. Disconnect socket (2) and pin (6) connectors of front fender tip lamp wire (1 and 12). Front fender tip lamp wire is color-coded blue/white. Connector assembly (2 and 6) is located above left side of front fork lower bracket (7). | |||||||||||||||||||||||||
| 5. | All models, 1987-1993. See Figure 6. Cut 3-pin connectors (1 and 2) off of main wire and ground wire, as close as possible to base of connector. Cut off middle joining wire (3) that connects two main wires together as close to main wire as possible. | 
Figure 1. Modifying Wiring Harness, 1987-1993 (All Models) | ||||||||||||||||||||||||
| 6. | See Figure 1. Obtain single pin connectors from kit. Strip 1/4 in. insulation off of bare wire ends on the main wires and ground wire. crimp a pin connector (10 and one end of ground wire (2) (cut in above step); on longer of two wires on harness. Crimp socket connector (3) and remaining end of ground wire (20 onto shorter harness wire. slide the socket housing (5) over socket (3) until it clicks in place. Gently tug wire to make sure it is seated securely. Do the same procedure for the pin housing (4) over the pin (1). | |||||||||||||||||||||||||
| 7. | Seal all remaining bare wire ends. | 
Figure 2. Marker Lamp Wiring, 1987-1993 Models | ||||||||||||||||||||||||
| 8. | See Figures 2 and 3. Obtain slider cover marker lamp wiring harness (3). In middle of harness, locate pin (4) and socket (5) connectors, each of which holds two wires. Perform the following procedures, as applicable: See Figure 3. connect pin connector (4) to socket connector (2). On 1989 - 1993 models only. See Figure 4. Connect socket connector (5) to pin connector (6). On 1987 - 1988 models only. Socket connector (5) will remain disconnected. For corrosion resistance, you may wish to apply silicone sealant in each end of socket connector (5). | |||||||||||||||||||||||||
| 9. | See Figure 3. Route shorter lead (8) of wiring harness over front upper left side of front fork lower bracket (7), and then downward, along left front brake hose. This wire will be the electrical supply for left slider cover marker lamps. | |||||||||||||||||||||||||
| 10. | Remove paper backing from adhesive-backed retaining clip (10). Press clip onto front vertical surface of front fork baffle (11); baffle is attached to rear side of front fork lower bracket (7). | 
Figure 3. Marker Lamp Wiring Harness Connected to Front Fender Tip Lamp Wire, 1987 - 1993 Models | ||||||||||||||||||||||||
| 11. | Insert longer lead (9) of wiring harness into retaining clip (10). Route longer wire lead over front upper right side of front fork lower bracket (7) and the downward along right front brake hose. This wire will be the electrical supply for right slider cover marker lamps. |
| 1 | 3-place socket connector |
| 2 | 3-place pin connector |
| 3 | Circuit breaker holder |
Figure 4. Connector Location, 1994-1996 FLTC-U Models
| 1 | 3-place front fender tip lamp connector |
| 2 | Directional and spot lamp connector |
| 3 | Left spot lamp |
Figure 5. Connector Location, 1994-1995 FLHTC and FLCTC-Ultra Models
Installation - 1994 and Later Models
| 1. | For 1994 - 1996 FLTC-U models only. See Figure 4. disconnect 3-place socket (1) and 3-place pin connector (2) located along left front fork on bottom of circuit breaker holder (3). Front fender tip lamp wires are black, blue and blue/white. For 1994 and 1995 FLHTC and FLHTC-Ultra models only. See Figure 5. Remove headlamp. Disconnect 3- place connector, located inside of left side of headlamp housing. Front fender tip lamp wires are black, blue and blue/white, and are located behind directional and spot lamp wire connector. | |||||||||||||
| 2. | For 1996, 1997 and Later FLHTC and FLHTC-Ultra models only. Refer to applicable Service Manual Connector Tables, following Wiring Diagrams, to find location of Front Fender Tip Light connector. Remove outer fairing. Disconnect 3-place connector on 1996 models or 2-place connector on 1997 models. Front fender tip lamp wires are black and blue. | |||||||||||||
| 3. | See Figure 6. Obtain wiring harness from kit. In middle of harness, locate 3-place pin (1) and socket (2) connectors or 2-place pin (5) and socket (6) connectors. Connect appropriate pin housing (1 or 5) to socket housing from Step 1. Connect socket housing (2 or 6) to pin housing from Step 1. Plug unused connector halves together. | 
Figure 6. 1994 and Later Wiring Harness, All Models | ||||||||||||
| 4. | Route shorter lead of wiring harness over front upper left side of front fork lower bracket (See Figure 3, Item 7), and then downward, along left front brake hose. This wire will be the electrical supply for left slider cover marker lamps. | |||||||||||||
| 5. | Remove paper backing from adhesive-backed retaining clip (See Figure 3, Item 10). Press clip onto front vertical surface of front fork baffle; baffle is attached to rear side of front fork lower bracket (See Figure 3, Item 11). | |||||||||||||
| 6. | Insert longer lead of wiring harness into retaining clip. Route longer wire lead over front upper right side of front fork lower bracket and then downward along right front brake hose. This wire will be the electrical supply for right slider cover marker lamps. |
| 1 | Brake rotor cover |
| 2 | Rotor cover lower mounting bracket |
| 3 | Front fork slider |
| 4 | Mounting studs |
| 5 | Slider cover lower mounting bracket |
| 6 | Hex locknut |
| 7 | Button head screw and washer |
| 8 | Rotor cover upper mounting bracket |
| 9 | Slider cover upper mounting bracket |
Figure 7. Slider Cover Mounting Brackets, Left Side View
Installation - All Years and Models
| 1. | See Figure 7. Remove and discard two hex locknuts and flat washers which secure left brake rotor cover (1) to left rotor cover lower mounting bracket (2). Lower mounting cover is located at bottom of front fork left slider (3). NOTE Due to limited length of studs on both left rotor cover lower mounting bracket and front fork right slider, install only the locknuts supplies in this kit. They are designed to ?lock? with a minimum of thread engagement. Do not reinstall the original washers or nuts. The thread-locking ability of the locknuts supplied in this kit greatly decreases after the first installation and removal. Any reinstallation of these locknuts requires the application of LOCTITE Threadlocker 242 (blue) to the locknut threads. New locknuts, H-D Part No. 7740, identical to those in the kit, may be used. NOTE If your motorcycle does not have spacers between the lower mounting bracket (2) and the left rotor cover (1) mounting tab, proceed to Step 2. If your motorcycle does have spacers between the lower mounting bracket (2) and the left rotor cover (1) lower mounting tab, do not perform Step 2. Instead, remove and discard these spacers. (It will be necessary to remove the caliper and rotor covers to perform this procedure.) In place of the spacers, install a slider cover lower mounting bracket (5), with its stamped dot surface facing forward, between the lower mounting bracket and the rotor cover. The positioning of this slider cover lower mounting bracket is different than that specified in Step 2. Secure components by installing two new 5/16-18 hex locknuts (6) on mounting bracket studs (4). tighten locknuts to 6.8–14.9 N·m (5–11 ft-lbs) . | |
| 2. | Front side of each slider cover lower mounting bracket (5) has a dot stamped in its metal surface. Install one of these lower mounting brackets, with its stamped dot surface facing forward, over mounting studs (4) and against lower mounting tab of rotor cover. Secure bracket by installing two new 5/16-18 hex locknuts (6) on studs. Tighten locknuts to 6.8–14.9 N·m (5–11 ft-lbs). | |
| 3. | Remove and discard two hex nuts, lockwashers, and flat washers which secure tight rotor cover against front fork axle cap (axle cap is located at bottom of front fork right slider). Leave right rotor cover in position on mounting studs of front fork right slider. NOTE If your motorcycle does not have spacers between the axle cap of the front fork right slider and the lower mounting tab of the right brake rotor cover, proceed to Step 4. If your motorcycle does have spacers between the axle cap of the front fork right slider and the lower mounting tab of the right brake rotor cover, do not perform Step 4. Instead, remove and discard these spacers. (It will be necessary to remove the caliper and rotor covers to perform this procedure.) In place of the spacers, install a slider cover lower mounting bracket, with its stamped dot surface facing forward, between the axle cap and the rotor cover. (The positioning of this slider cover lower mounting bracket is different than that specified in Step 4.) Secure components by installing two new 5/16-18 hex locknuts (6) on mounting bracket studs. Tighten locknuts to 6.8–14.9 N·m (5–11 ft-lbs). Proceed to next section.) | |
| 4. | Install other slider cover lower mounting bracket, with its stamped dot surface facing forward, over mounting studs and against lower mounting tab of rotor cover. Secure bracket by installing two new 5/16-18 hex locknuts (6) on studs. Tighten locknuts to 6.8–14.9 N·m (5–11 ft-lbs). |
SLIDER COVER UPPER MOUNTING BRACKETS
| 1. | See Figure 7. Remove button head screw (with wave washer) (7) which secures top of left brake rotor cover (1) to rotor cover upper mounting bracket (8). | |
| 2. | Place the slotted hole end of one slider cover upper mounting bracket (9) over the open mounting hole at top of rotor cover. Install original button head screw (with wave washer) through holes in slider cover upper mounting bracket and rotor cover, and finger tighten into threaded hole of rotor cover upper mounting bracket. NOTE Each slider cover upper mounting bracket has a slotted mounting hole at one end in order to allow for fore and aft adjustment of the top of the slider cover. | |
| 3. | Pivot the threaded hole end of slider cover upper mounting bracket forward to that it is parallel with front surface of front fork slider (3). Hold bracket in this position and tighten button screw to 2.5 N·m (22 in-lbs). NOTE If your motorcycle is not equipped with a bumper on the front fender, install one of the kit?s spacer washers between the rotor cover upper mounting bracket (8) and the fender. This spacer washer will reposition, in the inboard direction, the tops of both the rotor cover and the front fork slider cover. Without the spacer washer in this situation, you may observe a large gap between the slider cover and the outboard side of the fork slider. | |
| 4. | Repeat Steps 1-3 for right side of vehicle. |
FRONT FORK SLIDER COVER
NOTE
If your motorcycle is equipped with chrome axle nut covers (H-D) Part No. 43899-86 or 43899-86A), these covers must be removed before installing front fork slider covers.
| 1. | Remove the three button head screws (one upper and two lower) and wave washers which secure left brake caliper cover (3). Remove caliper cover. | |
| 2. | Position front fork left slider cover assembly over its upper and lower mounting brackets (Figure 7, Item 4 and 5). Check clearance between top of slider cover and front fork slider; there should be an equal space at front and rear. If space is not equal, perform the following steps: a. Remove slider cover. b. Loosen upper mounting screw (Figure 7, Item 7). c. Reposition slider cover upper mounting bracket as required at its slotted mounting hole. d. Tighten upper mounting screw to 2.5 N·m (22 in-lbs). NOTE To avoid possible cross-threading of slider cover fasteners, loosely install all three button head screws (with wave washers) before tightening screws to specified torque. | |
| 3. | Secure cover at its three mounting points (front upper, front lower and rear lower) using #10-32 x 3/8 in. button head screws with #10 wave washers. Tighten screws to 2.5 N·m (22 in-lbs) . | |
| 4. | See Figure 8. Route left slider cover marker lamp supply wire (1) beneath mounting tab of left caliper cover upper mounting bracket (2), forward above caliper upper mounting bolt (3), and down toward pin connector (4) of left slider cover marker lamp wire (5). Connect socket connector (6) of supply wire to pin connector (4). | |
| 5. | Install left caliper cover using the original fasteners. Tighten Screws to 2.5 N·m (22 in-lbs). | |
| 6. | Taking into account the travel range of the front suspension, secure left side wiring harness lead to left front brake hose (6), and to other vehicle components above the brake hose, using cable straps as required. | |
| 7. | Repeat Steps 1 - 6 for right side of vehicle. | |
| 8. | Connect battery cables to battery (positive cable first). Turn ignition switch to "lights" or "on" positions in order to test slider cover marker lamps and front fender top lamp. NOTE Verify that rotor covers and mounting brackets/fasteners are not contacting either of the brake rotors. Adequate clearance must be maintained. Operating a motorcycle in which either actual contact of inadequate clearance exists may result in a front wheel lock-up, causing personal injury and/or damage to the vehicle. Make adjustments as required before riding the vehicle. |
| 1 | Marker lamp supply wire |
| 2 | Brake caliper cover upper mounting bracket |
| 3 | Brake caliper upper mounting bolt |
| 4 | Pin connector |
| 5 | Slider cover marker lamp wire |
| 6 | Socket connector |
| 7 | Front brake hose |
| 8 | Front fork slider cover |
Figure 8. Slider Cover Marker Lamp Wire Routing-Left View
SERVICE PARTS
Table 1. Service Parts Table
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 45953-91B Fork Slider Cover Kit | 1 | Mounting bracket, top (2) | 45959-91 |
2 | Mounting bracket, lower (2) | 45958-91 | |
3 | Cover assembly, right fork slider | 45955-91 | |
4 | Cover assembly, left fork slider | 45954-91 | |
5 | Cable strap, small (8) | Not Sold Separately | |
6 | Cable strap, large (2) | 10006 | |
7 | Socket wiring assembly (2) (includes items 8 and 9) | 69300-91 | |
8 |
| 72039-71A | |
9 |
| 72043-71A | |
Kit 45960-91A Hardware Kit | 1 | Hex lock nut (4) | 7740 |
2 | Wiring harness | 70240-91B | |
3 | Cable clamp, adhesive back | Not Sold Separately | |
4 | Washer, wave (6) | 6065 | |
5 | Spacer (2) | Not Sold Separately | |
6 | Hex socket buttonhead screw (6) | 2719 |