VRSC DETACHABLE WINDSHIELD AND DOCKING HARDWARE KITS
J015202006-01-13
GENERAL
Kit Number
57105-02, 58360-01, 58680-04, 57895-04
Models
These kits fit 2002 and later VRSC (V-Rod) Model Motorcycles.
Table 1. Models
Kits | Contents |
|---|---|
57105-02 | Clear, detachable windshield |
58680-04 | Clear, detachable windshield with "Skull and Wings" emblem |
57895-04 | Clear, detachable windshield assembly with flames. |
Installation of any of the above windshield kits will also require a Docking Hardware Kit (Harley-Davidson Part Number 58360-01), available separately from any Harley-Davidson dealer.
NOTICE
Do not use windshield bags with flamed windshields. Damage to graphics will occur. (00393f)
Additional Parts Required
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 available from a Harley-Davidson Dealer.
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect 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)
- Remove the 40 amp Maxi-Fuse or disconnect the battery cables, negative cable first.
Assemble and Install Docking Hardware
NOTE
After assembling the docking hardware, there will be two top and two bottom clamps. These clamps differ in that the upper clamps have a Mounting Pin and the lower have a Turn Signal Standoff attached to them.
| 1 | Mounting pin |
| 2 | Clamp |
| 3 | Clamp washer |
| 4 | Clamp locknut |
| 5 | Bushing |
| 6 | Chrome washer |
Figure 1. Assemble Upper Docking Hardware
| 1. | See Figure 1. Assemble the docking (mounting) hardware as follows: a. See Figure 1. Install a Rubber Bushing (5), a Chrome Washer (6) and a Mounting Pin (1) into boss on each of two of the clamps (2) Tighten mounting pins finger tight. These will be the upper clamps. Temporarily remove the washers and locknuts from the clamps and save for Step 6. b. See Figure 2. Install a Rubber Bushing (5), a Chrome Washer (6 ) and a Chrome Turns Signal Standoff (4) (with flats toward clamp) into boss on each of the two clamps (1). Tighten the Turn Signal Standoffs finger tight. These will be the lower clamps. Temporarily remove the washers and locknuts from the clamps and save for Step 5. | 
Figure 2. Assemble Lower Docking Hardware | ||||||||||||
NOTICE Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b) | ||||||||||||||
| 2. | While facing the headlamp from behind (looking toward front of motorcycle), reach behind the headlamp bucket and twist the headlamp bulb approximately 45 degrees counterclockwise, then gently pull straight out of the headlamp. Repeat for the remaining bulb. Use cable straps and tie bulbs out of the way. | 
Figure 3. Headlamp and Handlebar Top Cover Hardware | ||||||||||||
| 3. | See Figure 3. Remove the two mounting screws securing the headlamp bracket to the upper triple clamp and remove headlamp assembly. Save hardware. NOTE After installation, adjust the distance between upper and lower clamps by sliding the upper clamps either up or down on fork tube. Leave lower clamp in place. Do not slide lower clamp downward or clamp screw may make contact and damage motorcycle cosmetics. | 
Figure 4. Install Lower Clamps (Right Fork Shown) 
Figure 5. Install Upper and Lower Clamps | ||||||||||||
| 4. | See Figure 4 and Figure 5. Install the lower clamps onto the fork tubes (oriented as shown) using washers and locknuts (removed in Step 2a ). Adjust so that when measured at rear of fork tube, the lower clamps are at least 1-1/4 inches (32 mm) from the lower triple clamp. Tighten locknuts to 10 ft-lbs (14 Nm). | |||||||||||||
| 5. | See Figure 5. Install upper clamps onto the fork tubes (oriented as shown) using washers and locknuts (removed in Step 2b). Make sure clamps are even and tighten locknuts just enough to hold clamps in place. | |||||||||||||
| 6. | While making sure left and right sides remain even, slide upper clamps (up or down) on fork tube until 5-1/8 (130 mm) inches exist between upper and lower clamps (when measured center to center as shown). |
Relocate Turn Signals
| 7. | On 2004 and later models, remove the left side frame panel. See Figure 3. On all models perform the following steps to remove the handlebar cover. a. To removing the cover, remove the two screws securing the handlebar top cover and instrument housing bezel to the handlebar bottom cover. b. From headlamp bracket end of cover, gently tilt the handlebar top cover and bezel up and back to separate from bezel hook, then remove. NOTE A bezel hook holds bottom of bezel and top cover to the bottom handlebar cover and can be damaged if forced during removal or installation. If damaged, the cover must be replaced. It is not necessary to remove the instrument bezel from the top cover. | 
Figure 6. Remove Handlebar Bottom Cover | ||||||||||
| 8. | See Figure 6. For 2002-2003 models, remove two screws securing the handlebar bottom cover to the handlebars and gently separate bottom cover from cluster. For 2004 models remove the left side frame panel. Save hardware. | |||||||||||
| 9. | Gently pull wiring with instrument cluster away from the handlebars. | 
Figure 7. Remove Connector and Turn Signal Wiring (2002-2003 models) | ||||||||||
| 10. | See Figure 7(2002-2003 models). Locate turn signal connector [31B] and disconnect from socket [31A]. Note left and right turn signal wire locations. Follow instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation) and remove left and right front turn signal Socket Terminals from connector. | 
Figure 8. Remove Turn Signal Connector 31 (2004 models) | ||||||||||
| 11. | See Figure 8(2004 models). Locate turn signal connector [31B] and disconnect from socket [31A]. Note left and right turn signal wire locations. Follow instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation) and remove left and right front turn signal Socket Terminals from connector. | 
Figure 9. Remove Turn Signal Assemblies | ||||||||||
| 12. | See Figure 9 and perform Steps (a) through (d) for each turn signal. a. At turn signal mount under handlebar, loosen jamnut. Hold retainer and loosen ball stud clamp. Unthread ball stud and remove turn signal. b. Unthread and discard retainer, but save lockwasher. Unthread remaining hardware from turn signal housing and discard. c. Carefully pull turn signal wiring through cable strap attached to handlebar and remove assembly. d. See Figure 14. Obtain Acorn Nut (6) from kit. Use lockwasher saved in Step b, and install acorn nut to secure mirror. Tighten securely. | 
Figure 10. Turn Signal Wire Routing | ||||||||||
| 13. | See Figure 14 and Figure 10. Obtain two hex jamnuts (7) from kit and thread one onto each standoff attached to lower windshield mounting clamp. | |||||||||||
| 14. | Thread turn signal completely onto standoff. Make sure turn signal is aligned and facing forward then tighten jamnut up against signal to secure in place. Repeat this Step for the other turn signal. | |||||||||||
| 15. | See Figure 10. Route turn signal wiring along standoff. Using Cable Strap (1) from kit, secure wiring to standoff at approximately midpoint along standoff. Continue to route wiring behind fork leg and, using another Cable Strap (1), secure wiring by installing cable strap through lower clamp assembly and around wiring. | 
Figure 11. Turn Signal Wire Routing | ||||||||||
| 16. | See Figure 11. For 2002-2003 models, route wiring over to instrument cluster harness, then route upward. Continue routing along with instrument cluster harness through upper triple tree and between left and right handlebar control harnesses. For 2004 models, route wires to the left side frame panel (up the backside of the fork tubes). At area just above triple tree, pass wiring under electrical bracket to turn signal connector socket. Repeat this Step for opposite turn signal wiring. | |||||||||||
| 17. | Following instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation), install socket terminals to turn signal connector. Make sure left and right terminals are correctly located, then plug connector into socket. | |||||||||||
| 18. | Using Cable Strap (1) from kit, secure turn signal wiring to instrument cluster harness. | |||||||||||
| 19. | See Figure 6. For 2002-2003 models align the handlebar bottom cover over instrument cluster and secure cover to handlebar using two screws removed in Step 9. For 2004 models align install left side frame panel using screw. Tighten securely. | 
Figure 12. Mount Headlamp Visor | ||||||||||
| 20. | See Figure 15 and Figure 12. Obtain Headlamp Visor (4) from kit. Remove the two screws securing the headlamp to the headlamp mounting bracket. | |||||||||||
| 21. | Install headlamp visor over the headlamp (oriented as shown in Figure 12 ) and secure headlamp with visor to headlamp bracket using two screws. | |||||||||||
| 22. | See Figure 3. Using two mounting screws saved in Step 4, align and install headlamp bracket to upper triple clamp. Tighten screws to 11–18 N·m (8–13 ft-lbs). NOTE The low beam headlamp bulb (labeled H11) mounts in the top hole in the rear of the headlamp assembly. The high beam bulb (labeled H9) mounts in the bottom hole. | |||||||||||
NOTICE Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b) | ||||||||||||
| 23. | Gently install each of the headlamp bulbs to back of headlamp and twist approximately 45 degrees clockwise to secure. NOTE See Figure 3. A bezel hook holds bottom of bezel and top cover to the bottom handlebar cover and can be damaged if forced during removal or installation. If damaged, the cover must be replaced. | |||||||||||
| 24. | See Figure 3. Orient instrument bezel and handlebar top cover, and fit bezel hook over tab on handlebar bottom cover. Gently press handlebar top cover and instrument housing bezel down until bezel hook snaps into tab. | |||||||||||
| 25. | Using two screws saved in Step 8A, align and install handlebar top cover to handlebar bottom cover. Tighten screws to 1.3–1.9 N·m (12–16 in-lbs). |
Install Windshield
| 1 | Retainer |
| 2 | Upper mounting bracket "jaws" |
| 3 | Lower mounting bracket "jaws" |
Figure 13. Mount Windshield
| 26. | See Figure 15 and Figure 13. Perform the following and install windshield. DD a. Hook the two lower windshield mounting bracket "jaws" into the grooves of the lower bushing. b. Hook the two upper windshield mounting bracket "jaws" into the grooves of the upper bushing. c. Slide windshield down until all of the "jaws" of the brackets fit firmly into the bushings. d. If not previously tightened, tighten the turn signal standoff to 20.3 N·m (15 ft-lbs). e. Tighten the upper docking hardware mounting pins to 20.3 N·m (15 ft-lbs). f. Fasten the retainer spring by placing over the mounting pins. | |
| 27. | With the windshield in place, tighten the upper docking hardware clamp locknuts to 14 N·m (10 ft-lbs). Be sure that the clamps do not rotate during tightening (the mounting bushings must be parallel to the windshield brackets. NOTE Inspect windshield for proper adjustment in relation to the headlight opening. If necessary, adjust the mounting clamps for proper headlamp to windshield relationship. | |
| 28. | Follow instructions in applicable Service Manual and adjust headlamp for proper visibility. | |
| 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) | ||
| 29. | Install 40 amp Maxi-Fuse or connect battery cables, positive cable first. | |
| 30. | Check turn signals for proper operation. | |
| 31. | See Windshield Care Instructions. |
NOTE
Check windshield for proper alignment with headlight opening. If necessary, adjust the mounting clamps for proper headlamp to windshield alignment.
WARNINGImproper installation of accessories or loading of cargo can affect motorcycle stability and handling, which could result in death or serious injury. (00455b)
WARNINGFailure to provide adequate clearance between stationary and moving parts can cause loss of control, which could result in death or serious injury. (00378a)
NOTE
Inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed.
NOTE
Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of components.
CARE AND CLEANING
NOTE
Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections.
NOTICE
Harley-Davidson windshields are made of Lexan. Lexan is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. Failure to maintain Lexan properly can result in damage to the windshield. (00230b)
NOTICE
Use only Harley-Davidson recommended products on Harley-Davidson windshields. Do not use harsh chemicals or rain sheeting products, which can cause windshield surface damage, such as dulling or hazing. (00231c)
NOTICE
Do not use benzine, paint thinner, gasoline or any other type of harsh cleaner on the windshield. Doing so will damage the windshield surface. (00232c)
Do not clean Lexan® polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result.
NOTE
Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier.
Harley-Davidson Windshield Water Repellent Treatment Part Number 99841-01 is approved for use on Harley-Davidson Lexan® windshields.
SERVICE PARTS
Figure 14. Service Parts: Windshield Docking Hardware Kit
Table 2. Service Parts: Windshield Docking Hardware Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Strap, cable (8) | 10006 | 5 | Bushing, rubber (4) | 67621-94 | |
2 | Pin, windshield mounting (2) | 58172-96 | 6 | Nut, acorn (2) | 7736 | |
3 | Clamp, mounting (4) with washers (4), nuts (4) | 58369-01 | 7 | Nut, hex jam (2) | 7912 | |
4 | Standoff, turn signal (2) | 58556-97 | 8 | Washer, chrome flat, 5/16 inch long (4) | 94066-90T |
Figure 15. Service Parts: Windshield Kit
Table 3. Service Parts: Windshield Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Bracket, mounting (left) | 57028-01 | 11 | Windshield, clear replacement | 57897-04 | |
2 | Bracket, mounting (right) | 57029-01 | 11 | Windshield, clear replacement | 57106-02 | |
3 | Washer, flat chrome (10) | 6352 | Windshield, clear with flames replacement | 57897-04 | ||
4 | Visor, headlamp | 69200-01 | 12 | Washer, chrome (2) | 6703 | |
5 | Nut, acorn (2) | 94004-90T | 13 | Bushing, plastic (4) | 58272-95 | |
6 | Nut, acorn (8) | 94007-90T | 14 | Washer, rubber (12) | 57064-97 | |
7 | Screw, button head, chrome (2) | 94426-95 | 15 | Brace, center with "Bar and Shield" emblem | 57871-02 | |
8 | Screw, button head, chrome w/lock patch (8) | 94639-99 | Brace, center with "Skull with Wings" emblem (not shown) | 58561-04 | ||
9 | Retainer Spring, (right) | 58580-96A | 16 | Emblem only "Bar and Shield" (not shown) | 99352-82Z | |
10 | Retainer Spring, (left) | 58579-96A | Emblem only "Skull with Wings" (not shown) | 91723-02 |