1. | Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level. | |
![]() To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
2. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. Remove any of the following items if attached to the rear fender, and set aside for later assembly: |
1 | Housing |
2 | Lens |
3 | Bulb |
4 | Gasket |
5 | Reflector |
6 | Bulb socket |
7 | Spring |
8 | Non-threaded hole |
9 | Threaded hole |
10 | Black wire |
11 | Violet wire |
12 | Blue wire |
13 | Protective tubing |
14 | Support |
15 | Screw |
16 | Washer |
1. | Assemble the Side-Mount License Plate Bracket as necessary per the instructions in that kit. | |||||||||||||||
2. | Snap a wire channel (5) onto each new rear fender mounting bracket (4) in the orientation shown in Figure 6. | |||||||||||||||
3. | Get the two new 5/16-18 hex screws (3) from the kit, and the original flat washers (A) removed earlier. Place a washer onto the threads of each screw. NOTE Refer to the service manual for instructions on re-using of fasteners with threadlocking agents. | |||||||||||||||
4. | Get the forward mounting hardware (B) and (C) removed from the original fender. Thoroughly remove all existing threadlocking agent from fastener threads. Apply a few drops of Loctite 243 - Blue to the clean threads of the screws (B). | |||||||||||||||
5. | With an assistant holding the new, painted chopped rear fender (1) in place between the fender supports, and the license bracket between the fender and fender support on the left side, insert the original TORX® screws (B), from the outside, through the forward holes in the fender support covers, fender supports, spacers (C) and fender. Thread the screws into the front holes of the rear fender mounting brackets, but do not fully tighten at this time. | |||||||||||||||
6. | From under the fender, insert the hex screws (with washers) through the rear holes of the fender mounting brackets, the fender, fender supports and support covers. | |||||||||||||||
7. | Get the two new lamp supports (2) from the kit, and the stop/tail/turn signal (STT) lamps assembled earlier. Carefully route the lamp wires through the lamp supports and into the holes in the fender support covers, just forward of the fender mounting screws. | |||||||||||||||
8. | Thread the screws into the threaded holes in the lamp housings, but do not fully tighten. | |||||||||||||||
9. | Tighten the TORX screws at the front of the fender to 16.3–24.4 N·m (12–18 ft-lbs). NOTE Take care to avoid pinching the lamp wires when tightening the screws. | |||||||||||||||
10. | Tighten the hex screws at the rear of the fender to 16.3–21.7 N·m (12–16 ft-lbs). | |||||||||||||||
11. | See Figure 2. Route the STT lamp wire harnesses (1) up and forward through the wire channels (2) on the fender mounting brackets as shown. NOTE Apply a few drops of Loctite 243 - Blue to the clean threads of each screw before installation. | |||||||||||||||
12. | Assemble the P-clip wire retainers (3) to the harnesses in the orientation shown with the #8-32 machine screws (4), nuts (5) and washers (6) from the kit. |
Figure 2. Rear Lamp Harness Routing | ||||||||||||||
13. | Insert the new rubber grommet (7) into the hole in the front of the fender. Route the wire harnesses through the grommet and into the area under the seat. |
1 | Reflector (right side shown) |
2 | Fender support cover |
3 | Fender forward mounting hole |
4 | About 1/8-inch (3.3 mm) above support cover |
5 | About 1-1/2 inches (38 mm) to rear of hole |
1. | Clean the outer surface of the fender in the area that will be covered by the seat with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly. | |||||||||||||||||||||||
2. | See Figure 4. Lay a strip of masking tape (1) down the center of the fender, starting about 25 mm (1 in) in back of the rearmost seat mounting hole (2) and ending about 75 mm (3 in) in front of the forward seat mounting hole (3). | |||||||||||||||||||||||
3. | Pierce a hole through the tape into the center of each seat mounting hole. Draw a line (4) on the tape, down the center of the fender, from end to end of the tape. |
Figure 4. Rear Fender Pad Placement, Two-Up Seat | ||||||||||||||||||||||
4. | Measure forward (5) about 86 mm (3⅜ in) from the rearmost seat mounting hole, and mark the tape from side to side. Lay a 130 mm (5 in) long strip of masking tape (6) crosswise on the fender, with the forward edge of the tape on the line. Draw a line (7) on the tape about 25 mm (1 in) from the centerline on each side, toward the forward edge of the tape. | |||||||||||||||||||||||
5. | Measure forward (8) about 6 mm (¼ in) from the forward seat mounting hole, and mark the tape from side to side. Lay a 130 mm (5 in) long strip of masking tape (9) crosswise on the fender, with the rearward edge of the tape on the line. Draw a line on the tape about 25 mm (1 in) from the centerline on each side, toward the rearward edge of the tape. NOTE The square-cut and rounded-edge fender cushions can be used in any position. | |||||||||||||||||||||||
6. | Remove the liner from the adhesive back of one new fender cushion. Carefully position the cushion to the fender at one of the shaded positions (10) as shown, and press firmly into place. Hold the cushion in position with steady pressure for a few seconds. Repeat with the remaining three fender cushions at the shaded positions. | |||||||||||||||||||||||
7. | Remove the masking tape, and clean any tape residue from the fender. NOTE Allow AT LEAST 24 hours after applying the cushions before exposing the area to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature. |
1. | Clean the outer surface of the fender in the area that will be covered by the seat with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly. |
Figure 5. Rear Fender Pad Placement, Solo Seat | ||||||||||||||||
2. | See Figure 5. Lay a strip of masking tape (1) down the center of the fender, starting about 25 mm (1 in) in back of the rearmost seat mounting hole (2) and ending about 130 mm (5 in) in front of the forward seat mounting hole (3). | |||||||||||||||||
3. | Pierce a hole through the tape into the center of each seat mounting hole. Draw a line (4) on the tape, down the center of the fender, from end to end of the tape. | |||||||||||||||||
4. | Measure forward (5) about 83 mm (3¼ in) from the forward seat mounting hole, and mark the tape from side to side. Lay a 130 mm (5 in) long strip of masking tape (6) crosswise on the fender, with the forward edge of the tape on the line. Draw a line (7) on the tape about 45 mm (1¾ in) from the centerline on each side, toward the forward edge of the tape. | |||||||||||||||||
5. | Remove the liner from the adhesive back of one rounded-edge fender cushion. With the rounded edge to the rear, carefully position the cushion to the fender at one of the shaded positions (8) as shown, and press firmly into place. Hold the cushion in position with steady pressure for a few seconds. Repeat with the second fender cushion. | |||||||||||||||||
6. | Remove the masking tape, and clean any tape residue from the fender. NOTE Allow AT LEAST 24 hours after applying the cushions before exposing the area to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature. |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 59860-10BEO Primed | 1 | Fender, chopped rear (primed) | 59867-10BEO |
Kit 59860-10DH Vivid Black | 1 | Fender, chopped rear (Vivid Black) | 59867-10DH |
Parts common to BOTH kits | 2 | Support, stop/tail/turn signal (chrome) (2) | 69438-06 |
3 | Hex head cap screw, 5/16-18 x 64 mm (2.5 in) long | 4068A | |
4 | Bracket, rear fender mounting (2) | 59512-06A | |
5 | Wire channel (2) | 72573-10 | |
6 | Grommet | Not sold separately | |
7 | Reflector/bulb socket assembly, stop/tail/turn signal lamp (2) | 68497-07 | |
8 | Lens, stop/tail/turn signal (red) (2) | 68559-07 | |
9 | Bulb, stop/tail/turn signal (#198) (2) | 68168-89A | |
10 | Socket terminal (10, including spares) | 72991-01 | |
11 | Socket housing, four-way (2) | 72914-01BK | |
12 | Mounting block, reflector (with tape) | 68724-07 | |
13 | Reflector, rear (red) | 59359-06 | |
14 | Reflector, right side (red) | 59287-92 | |
15 | Reflector, left side (red) | 59288-92 | |
16 | Converter module, stop/tail/turn signal | 68398-10 | |
17 | Wire retainer, P-clip (2) | Not sold separately | |
18 | Machine screw, pan head, #8-32 (3) | 2808 | |
19 | Hex nut, #8-32 (3) | 7608 | |
20 | Flat washer (6) | 6192 | |
21 | Cushion, fender, 25.4 mm (1 in) square (2) | 11576 | |
22 | Cushion, fender, 25.4 mm (1 in), round one end (2) | 11672 | |
Items mentioned in text, but not included in kit: | |||
A | Original equipment (OE) flat washer (2) | ||
B | OE button head TORX screw (2) | ||
C | OE spacer (2) |