CHROME BUMPER AND FIN KIT
J005812006-09-12
GENERAL
Kit Number
91235-97B
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 and Tools Required
Proper installation of this kit also requires the following:
Loctite® 243 (blue) (99642-97)
Drill motor
1/16 inch drill bit
17/64 inch drill bit
Installation
Figure 1. Installed Chrome Bumper and Fin Kit
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.
| 1. | Lift motorcycle off ground and remove rear wheel according Service Manual instructions. | |
| 2. | See Figure 2. Attach fender plates to pre-assembled kit as follows: a. Place fender plates (11) on outboard surface of bumper and align holes in fender plates with holes in the rear fender bumper brackets. b. Insert screws (2) as shown in Figure 2 and fasten with washers (5) and nylon locknuts (8). c. Tighten locknuts to 13.5 N·m (10 ft-lbs). |
| 3. | See Figure 2. Assemble center strap (19) to rear bumper (10) using the helical spring washer (7) and 1/4-20 x 1/3 inch hex cap screw (1). Tighten screw to 13.5 N·m (10 ft-lbs). | |
| 4. | Drill holes for center strap as follows: a. Using a high quality masking tape, mask the lower three inches of the middle of the rear fender for the purpose of drawing a centerline on the fender. b. Use a machinist's square to locate the vertical centerline of the fender by measuring in from each side of the fender flats. Mark centerline on masking tape applied in Step 4a. c. Measure up one inch from lower edge of fender along the center line, mark location on the tape and prick punch. d. Carefully drill mounting hole in marked location. Start with a 1/16 inch drill bit and finish with a 17/64 inch drill bit. | |
| 5. | Drill holes for fender plates and stanchions as follows: a. Using a high quality masking tape, mask fender where fender plates (11) and stanchions (18) will meet fender when kit is installed. b. Hang assembled kit from rear fender by placing center strap inside fender and aligning hole in center strap with hole drilled in Step 4d. c. Insert 1/4-20 x 3/4 inch screw (20) through outside of fender and use washer (5) and locknut on inside of center strap (8). Tighten locknut to 13.5 N·m (10 ft-lbs). d. Have an assistant hold the assembled kit so that the fender plate's (11) lower contour is parallel to the fender contour with approximately a 3/16 inch offset. The upper straight edge of the fender plates should be parallel to the ground and fins. e. Carefully drill mounting holes in marked locations. Start with a 1/16 inch drill and finish with a 17/64 inch drill bit. | |
| 6. | Apply a drop of Loctite® 243 (blue) to 1/4-20 x 7/8 inch hex cap screws (3). | |
| 7. | Place a nylon washer (6) in the recess of each stanchion. | |
| 8. | Line up stanchions to fit over holes drilled in Step 5e. Place washers (5) on screws (3). Insert screws through fender and stanchions and thread into bumper rails. Tighten screws to 13.5 N·m (10 ft-lbs). | |
| 9. | Align fender plate holes with holes drilled in Step 5e. Insert screw (21) through hole and use washer (5) and nylon locknut (8) on inside of fender. Tighten locknut to 13.5 N·m (10 ft-lbs). | |
| 10. | Reinstall rear wheel according to Service Manual instructions. |
Figure 2. Service Parts: Chrome Bumper and Fin Kit
Table 1. Service Parts: Chrome Bumper and Fin Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Screw, hex cap, 1/4-20 x 1/2 in. | 3728 | 12 | Rail, bumper (2) | 91238-97 | |
2 | Screw, button head, 1/4-20 x 5/8 in. (2) | 924 | 13 | Ball (2) | 91239-97 | |
3 | Screw, hex cap, 1/4-20 x 7/8 in. (2) | 3802W | 14 | Fin (4) | 91240-97 | |
4 | Washer, plain 5/16 in. narrow (2) | 6702 | 15 | Spacer, top | 91241-97 | |
5 | Washer, plain 1/4 in. narrow (7) | 6703 | 16 | Spacer, center (6) | 91242-97 | |
6 | Washer, nylon, 1/4 in. (2) | 7017 | 17 | Spacer, bottom (2) | 91243-97 | |
7 | Lock washer, helical spring, 1/4 in. | 7036 | 18 | Stanchion (2) | 91224-97 | |
8 | Locknut, nylon 1/4-20 (5) | 7671 | 19 | Strap, center | 91245-97 | |
9 | Locknut, nylon 6/16-18 (2) | 7710W | 20 | Screw, button head, 1/4-20 x 3/4 in. | 94386-92T | |
10 | Bumper, rear fender | 91236-97 | 21 | Screw, button head, 1/4-20 x 1/2 in. (2) | 94407-94T | |
11 | Plate, fender (2) | 91237-97 |