V-Rod Muffler End Caps
J027592005-02-15
GENERAL
Kit Number
65000-04
Models
This end cap kit fits all V-Rod models with P&A Slipfit or original equipment mufflers.
A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
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)
| 1. | Disconnect the battery cables, Negative (-) cable first. | |||||||||
| 2. | Clean back end surface of muffler prior to starting installation. | |||||||||
| 3. | See Figure 1. Apply round adhesive disks (1) to three bosses (2) on bottom of endcaps (3). NOTE Endcaps have a "U" or "L" stamped on them to identify which muffler they fit. | |||||||||
| 4. | See Figure 2. Position endcap on muffler and firmly press into place to secure endcaps with adhesive disks being careful not to let the endcaps move around. Repeat for other muffler. | |||||||||
| 5. | Insert transfer punch into each hole in endcap and use a hammer to mark pilot holes on each endcap. Repeat for other muffler. | |||||||||
| 6. | Remove endcaps and remove adhesive disks from endcaps. | |||||||||
| 7. | Drill pilot holes (3) in each muffler using a 1/16 inch drill bit. | |||||||||
| 8. | Finish drill holes using a #11 (.192-.196 inch) drill bit. NOTE Use a pop rivet gun that has a nose piece capable of fitting into endcap rivet recesses. Ensure all rivets can be inserted completely as rivets are difficult to set. Before setting, reaming of holes in end cap or muffler may be required for best fit. Use several small steps in setting. Do not ream holes too big as rivets may not hold properly. | 
Figure 1. Apply Adhesive Disks to Endcap Bosses 
Figure 2. End Cap Position on Muffler | ||||||||
| 9. | Insert rivets into holes in endcaps and rivet endcaps into place. | |||||||||
| 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) | ||||||||||
| 10. | Connect battery cables, Positive (+) cable first. | |||||||||
| 11. | Remove any fingerprints from endcaps resulting from installation process before starting vehicle. |
SERVICE PARTS
Figure 3. Service Parts: V-Rod Muffler End Cap Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | End cap, lower | Not sold | 4 | Disks, adhesive (6) | Not sold | |
2 | End cap, upper | Not sold | 5 | Rivets, (8) | 65040-04 | |
3 | Punch, transfer | Not sold | ||||