WINDSHIELD INSTALLATIONS ON XR1200
J038912007-11-30
GENERAL
Kit Number
57260-08, 57262-08
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).
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)
INSTALLATION
| 1. | Remove windshield sub-assembly from packaging and place face down on a clean, soft surface with mount brackets facing upwards. | |
| 2. | See Figure 1 and Table 1. Unpack hardware kit (6) and assemble the two hardware stacks, shoulder bolt (7), two Belleville washers (8) and cup washer spacer (9). The Belleville washer cupped sides must face each other. | |
| WARNING The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce windshield's ability to break away in a collision, which could result in death or serious injury. (00422b) | ||
| 3. | Thread shoulder bolt into quick clamp (5) loosely and sandwich the windshield bracket (3 or 4)with the Belleville washers at the bracket lower notch with clamps to the outside and finger-snug shoulder bolt. Repeat for other bracket. | |
| 4. | Orient the quick-clamp roughly perpendicular to the w/s mount bracket. Align second quick-clamp with the first. Minor adjustments with be made when attaching clamps to fork tubes. Tighten shoulder bolts to 6.8–8.5 N·m (60–75 in-lbs). | |
| 5. | Assemble the two upper handlebar mount clips (17) and posts (16) using screws (18) and tighten to 3.4–4 N·m (30–35 in-lbs). | |
| 6. | Attach clip assembly posts to socket assemblies. | |
| 7. | Approach vehicle with windshield from the front and with quick-clamps in the open position and handlebar clips kept above handlebars. Align lower quick-clamps with fork tubes roughly 1/4 inch (6 mm) below the upper triple tree on both sides and clamp quick-clamps to tubes. | |
| 8. | With handlebar snap clips still above the handlebars, position the windshield forward or rearward, against the resistance of the Belleville washers, so that the handlebar clips align with the handlebar depth. Ensure the quick-clamps remain perpendicular to the fork-tubes when handlebar clips are aligned. | |
| 9. | Snap the handlebar clips over handlebars in two places to secure the windshield. | |
| 10. | Make sure that lower fork quick-clamps are securely attached. |
Removal and Re-installation
- To remove the windshield from the motorcycle reverse Steps 7, 8, 9 and 10.
Storage, Care and Cleaning
NOTICE
Polycarbonate windshields/wind deflectors require proper attention and care to maintain. Failure to maintain polycarbonate properly can result in damage to the windshield/wind deflector. (00483e)
- Clean the windshield when necessary. Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier.
- If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant.
- Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windscreen/windshield. Doing so will damage the surface.
- Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield.
- Do not clean polycarbonate (Lexan) in hot sun or high temperature.
- Sunlight reflections off of the inside curvature of a windscreen/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 windscreen/windshield to avoid reflections.
- When storing windshield, place in a location where windshield clamps will receive the greatest protection. Keep from locations where the windshield may be bumped or dropped. Do not stack anything on top of assembly.
- Prior to re-installation after any storage period, inspect clamps and hardware for fastener preload and cleanliness. Each clamp should have a pair of rubber gaskets in the clamp saddle that mates to the fork slider, and should cycle open and closed freely.
- Periodically check the torque of the fasteners and re-tighten if necessary.
SERVICE PARTS
Figure 1. Service Parts: Windshield for XR1200
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Windshield, super-sport (with grommets) | 57263-08 |
2 | Windshield, wind deflector (with grommets) | 57265-08 |
3 | Bracket, mount, left | Not Sold Separately |
4 | Bracket, mount, right | Not Sold Separately |
5 | Quick-clamp (2) | 57287-07 |
6 | Kit, Quick clamp hardware, includes items 7 through 9, (2) | 58790-04 |
7 |
| Not Sold Separately |
8 |
| Not Sold Separately |
9 |
| Not Sold Separately |
10 | Grommet, upper windshield mount (4) | Not Sold Separately |
11 | Cap, upper windshield mount (4) | Not Sold Separately |
12 | Socket head cap screw, M5 x 0.8 x 16mm (4) | 3080M |
13 | Acorn nut, M5 x 0.8 (4) | 7154M |
14 | Button head cap screw M5 x 0.8 x 8mm (2) | 3106M |
15 | Socket assembly, upper windshield mount (2) | 57791-08 |
16 | Post, upper windshield mount (2) | 57351-07 |
17 | Clip, handlebar mount (2) | 57790-08 |
18 | Socket head cap screw, M6 x 1.0 x 20mm (2) | 4252M |