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DYNA CHOPPED REAR FENDER KITS
J040012009-10-13
GENERAL
Kit Number
59860-10BEO, 59860-10DH
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of a Side-Mount License Plate Bracket Assembly is required. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for more information.
Tools and Supplies Required
The help of an assistant will be needed for some removal and installation procedures.
An Amp Multilock Crimper (HD-41609) is required for the proper installation of this kit.
Loctite® 243 Threadlocker and Sealant - Blue (H-D Part No. 99642-97) is required for the proper installation of this kit. This item is available from a Harley-Davidson dealer.
Electrical Contact Lube (H-D Part No.99861-02) or equivalent is required for the proper installation of this kit. This item is available from a Harley-Davidson dealer.
WARNING
Rider 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Electrical Overload
This fender kit takes no more current than an original equipment (OE) rear lighting circuit.
Kit Contents
See Figure 6 and Table 1.
INSTALLATION
Preparation
1. Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level.
WARNING
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:
  • Passenger seat strap.
  • Fender seat nut and nylon retaining clip.
  • Hole plugs.
  1. Raise the rear of the vehicle to relieve the load on the shock absorbers.
  2. Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle. Save the fasteners for later assembly.
  3. Raise the rear of the vehicle further to allow access to the underside of the rear fender.
  4. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware.
Rear Fender Removal
NOTE
Note the location and orientation of rear fender and turn signal mounting hardware, and save for later assembly.
  1. Follow the service manual instructions to disconnect the turn signal connectors from the tail lamp.
  2. Cut off and discard the connectors and terminal ends from the turn signal lamp wires.
  3. Refer to the service manual and follow the instructions given to remove the rear turn signal lamps, rear fender mounting brackets and fender from the vehicle.
1Housing
2Lens
3Bulb
4Gasket
5Reflector
6Bulb socket
7Spring
8Non-threaded hole
9Threaded hole
10Black wire
11Violet wire
12Blue wire
13Protective tubing
14Support
15Screw
16Washer
Figure 1. Stop/Tail/Turn Signal Lamp
Rear Lamp Wiring
  1. See Figure 1. Separate the turn signal lamps and supports (14), and set one lamp aside. The supports can be discarded.
  2. Insert a thin-blade screwdriver or similar tool into the slot at the bottom of the lens (2) of one of the turn signal lamps, and twist to unsnap the lens from the housing (1). Push the bulb (3) in and rotate counterclockwise to remove.
  3. Insert the thin-blade tool between the outer edge of the rubber gasket (4) and the inside of the housing. Gently pry up the reflector (5) until free.
  4. Guide the wires out of the non-threaded hole (8) in the lamp housing. The turn signal gasket, reflector, bulb, amber lens and wiring can be discarded.
  5. Route the wires (10, 11, 12) and protective tubing (13) from the new reflector/bulb socket assembly (5 and 6) through the center of the rubber gasket (4) and out through the non-threaded hole in the lamp housing.
  6. Assemble the lamp as follows:
    1. If out of position, insert the spring (7) and bulb socket (6) back into the reflector, aligning the locating tab on the bulb socket with the slot in the reflector directly opposite the ground wire cavity. The violet wire (11) should be closest to the tab on the socket.
    2. Seat the rubber gasket in the lamp housing, with the flat notch on the back of the gasket aligned with the two holes (8 and 9) in the housing.
    3. Gently pull the wires through the hole in the housing as the reflector assembly is seated in the rubber gasket, aligning the ground cavity on the reflector between the fins inside the lamp housing.
    4. Using the thumbs of both hands, apply even pressure around the outer edge of the reflector assembly until fully seated.
    5. Liberally apply electrical contact lubricant (H-D Part No. 99861-02 or equivalent) to the contact in the reflector socket and at the bottom of the bulb. Push in the bulb and rotate clockwise to install.
    6. Install the new red lens in the lamp and gently apply thumb pressure until it snaps into place. Rotate the lens to position the slot at the bottom of the lamp. Set the lamp aside.
  7. Repeat steps 2 through 6 for the other turn signal lamp.
Rear Fender Assembly and Mounting
NOTE
Test fit the prime-coated fender prior to painting, but have the fender painted before assembly and final installation.
Protect the painted fender from scratches and damage during assembly steps.
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.
1STT lamp wire harness (2)
2Wire channel (2)
3P-clip (3)
4Pan head screw (3)
5Hex nut (3)
6Flat washer (6)
7Grommet
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.
Rear Lamp Wiring Connection to Vehicle
  1. See Figure 6. Install the stop/tail/turn signal converter module (16) in the area under the seat as follows:
    1. Position the converter module in the area under the seat.
    2. Feed the main harness connector [7A] and the STT harness connectors up through the large opening in the frame. Connect the eight-way socket housing [7B] on the converter module to the pin housing [7A] on the main vehicle harness.
  2. Route the STT and license illuminator wire harnesses through the large opening in the frame, then over to the converter module four-way pin housings [18A] and [19A] and the two-way pin housing [93A]. Connect pin housing [93A] on the module to the license plate illuminator socket housing.
  3. Follow the instructions in the service manual to crimp the six terminals (10) from the kit onto the STT wires. Insert the STT wiring socket terminals coming from one lamp into the correct cavities of one socket housing (11): Repeat for the remaining socket housing.
    1. Insert the black wire and terminal into cavity 1.
    2. Insert the violet wire and terminal into cavity 2.
    3. Insert the blue wire and terminal into cavity 3.
  4. Connect four-way pin housing [18A] (brown/white wire and white flag on harness leg) on the STT converter module to the right side STT harness socket housing. Connect four-way pin housing [19A] (violet/white wire, no flag) on the module to the left side STT socket housing.
  5. Tuck the STT module into the area under the large opening in the frame, to the rear of the negative battery cable. Tuck all the connectors and wiring into the area.
Reflector Mounting
  1. See Figure 6. Clean the rear underside of the fender, and the reflector mounting area of the reflector mounting block (12) with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly.
    2. NOTE
    Ambient temperature should be at least 16 °C (60 °F) for proper adhesion.
  2. Remove the liner from the adhesive backing of the reflector (13). Carefully position the reflector to the reflector mounting area of the mounting block, and press firmly into place. Hold the reflector in position with steady pressure for about one minute.
  3. Remove the liner from the adhesive backing on the mounting block tape. Position the flat upper edge of the reflector area, centered, against the rear edge of the fender. Rotate the block inward and press the tape firmly into place on the underside of the fender. Hold the mounting block in position with steady pressure for about one minute.
    4. NOTE
    The side reflectors (14 and 15) are side- and orientation-specific. The right side reflector is marked "TOP" on the back with the letter "R" beneath. The left is marked "TOP" with the letter "L" beneath.
    Some Dyna models have reflectors already mounted on the fender support covers. For those models, proceed to Rear Fender Pad Mounting.
  4. Clean the reflector mounting area of the fender (see Figure 3 ) with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly.
  5. Remove the liner from the adhesive back of one reflector (1). Carefully position the reflector to the fender, and press firmly into place. Hold the reflector in position with steady pressure for about one minute.
  6. Repeat Steps 4 and 5 with the other side reflector.
NOTE
Allow AT LEAST 24 hours after applying the reflectors before exposing the areas 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.
1Reflector (right side shown)
2Fender support cover
3Fender forward mounting hole
4About 1/8-inch (3.3 mm) above support cover
5About 1-1/2 inches (38 mm) to rear of hole
Figure 3. Side Reflector Placement
Rear Fender Pad Mounting (for Two-Up Seat)
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.
1Masking tape down center of fender
2Rearmost seat mounting hole
3Forward seat mounting hole
4Draw line on tape down center of fender
5Measure 3-3/8 inches (86 mm) forward, mark tape
6Masking tape crosswise to rear of mark
7Marks on tape one inch (25.4 mm) from center
8Measure 1/4-inch (6 mm) forward, mark tape
9Masking tape crosswise forward of mark
10Marks on tape one inch (25.4 mm) from center
11Position cushion to fender (4)
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.
Rear Fender Cushion Mounting (for Solo Seat)
NOTE
If only a Genuine Motor Accessory Solo Spring Saddle will be installed, no fender cushions are needed. Proceed to Return to Service
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.
1Masking tape down center of fender
2Rearmost seat mounting hole
3Forward seat mounting hole
4Draw line on tape down center of fender
5Measure 3-1/4 inches (83 mm) forward, mark tape
6Masking tape crosswise to rear of mark
7Marks on tape 1-3/4 inches (45 mm) from center
8Position round-end cushion to fender (2)
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.
Return to Service
NOTE
Verify that the ignition/light key switch is in the OFF position before attaching the battery cable.
  1. Verify that the ignition/key switch is turned to the OFF position. Refer to the service manual and follow the instructions given to attach the negative battery cable. Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
  2. Follow the service manual instructions to install the bottom shock absorber fasteners on each side of the vehicle.
  3. Lower the jiffy stand into position. Lower the motorcycle lift, and allow the vehicle to rest on the jiffy stand.
  4. Turn the ignition/key switch to IGNITION, but do not start the motorcycle. Check the tail, stop, rear turn signal and license lamps for proper operation.
    5. NOTE
    If the nylon seat retaining clip has been damaged or lost, DO NOT install the seat without the clip or substitute a clip of different material. Scratched fender paint will occur.
    A Fender Seat Nut Kit (H-D Part No, 59768-97) is available from a Harley-Davidson dealer.
  5. Install the following items removed from the original fender as needed. Location and usage depends on the seat that will be used:
  • Fender seat nut and nylon retaining clip.
  • Passenger seat strap (install and tighten per service manual instructions).
  • Hole plugs in unused holes.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
  1. Refer to the service manual, and follow instructions to install the seat.
  2. Install the license plate (if present) to the vehicle with the attaching hardware from the OE installation.
SERVICE PARTS
Figure 6. Service Parts, Dyna Chopped Rear Fender Kits
SERVICE PARTS
Table 1. Service Parts
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)