Sportster Bobtail Fender Installation Kit
J034072006-07-01
GENERAL
Kit Number
69714-04B
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).
Additional Parts Required
NOTE
Some Harley-Davidson International customers will need to install a License Plate Adapter Kit, Part Number 60081-00 (sold separately). See a Harley-Davidson Dealer for further information.
NOTE
The Bobtail Fender IS NOT included in this kit. Primed or painted fenders are available. See a Harley-Davidson Dealer for more details.
If a prime-coated fender is used, test fit prior to painting, but have the fender painted before final installation.
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 required for this installation and is available from a Harley-Davidson Dealer.
INSTALLATION
Original Equipment Fender Removal
NOTE
Before removing the lower shock mounts you must securely support the vehicle. Failure to securely support the vehicle could allow the vehicle to tip over which could result in death or serious injury.
When performing this installation, removing the lower shock mounts (bolts) will lower the rear wheel and provide more room to access the fender mounting hardware. Follow the Service Manual instructions to remove the lower shock mounts.
| 1. | Place the motorcycle on a center stand with the rear wheel off the ground. NOTE For 2006 and later motorcycle models, follow the Rear Fender Removal instructions in the applicable Service Manual. For 2004 and 2005 motorcycle models, follow Steps 2 through 4 below. | |||||||||||||||
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||||||||||||||||
| 2. | Follow the instructions in the applicable Service Manual to remove the seat and disconnect the negative cable at the engine crankcase. Retain all seat mounting hardware. | |||||||||||||||
| 3. | Refer to REAR FENDER, REMOVAL in the Service Manual and follow the instructions given to remove the rear fender strut covers with attached turn signal assemblies from fender, and the rear fender from the vehicle. Note the location of all hardware for proper reassembly. Remove the circuit board from the tail/brake lamp base and set it aside for later reassembly. NOTE Refer to the AMP Multilock Electrical Connectors section of the Service Manual for terminal removal procedures. | |||||||||||||||
| 4. | See Figure 1. At the lamp end of the rear lighting harness, disconnect the wire socket pins from the rear lamp power connector [94B]. Pull the rear lighting harness out from the conduit on the underside of the fender. Discard the rear fender along with the tail/brake lamp base, but retain all of the remaining parts. | 
Figure 1. Rear Lighting Power Connector Location 
Figure 2. Rear Lighting Power Connector Pin Locations |
Bobtail Fender Preparation
| 1. | See Figure 9. Obtain a new Bobtail Fender (A, sold separately), the rear lighting wire harness removed from the original fender and the wire harness conduit (12) from the kit. NOTE Prior to routing the rear lighting harness wiring through the conduit, the wiring harness must be installed through the "D" opening at the front of the fender. NOTE Make certain the socket terminal slot (on the same side of the terminal as the crimp tails) faces the connector release button. | |||||||||||
| 2. | See Figure 3. Slide the rear lighting wiring harness through the "D"-shaped hole in the new fender and secure by installing the "D" insert (3) surrounding the harness to the fender. | 
Figure 3. Conduit Positioning Under Fender (2007 and Later XL Bobtail Fender Shown) | ||||||||||
| 3. | Route the wiring through the conduit (1). | |||||||||||
| 4. | See Figure 1 and the AMP Multilock Electrical Connectors section of the Service Manual. Install the harness wire terminals into the cavities of connector [94B] as indicated. | |||||||||||
| 5. | Close the secondary lock on the socket housing. | |||||||||||
| 6. | With the rear lighting wiring harness installed into the conduit, perform the following: a. Thoroughly clean the inside surface of the fender with soap and water until it is free of dirt, oil or other debris. b. Dry the surface, then wipe the approximate area where the conduit will be placed with isopropyl alcohol. Allow to dry completely. c. See Figure 3. Measure and mark a line 2-3/8 to 2-1/2 inches (60-65 mm) from the fender centerline, then mark a line even with the front fender mounting hole. d. See Figure 4. Remove the protective strip covering the adhesive on the conduit and lightly position the conduit in place. e. See Figure 5. Use a wallpaper corner roller (available at most home improvement stores), to roll along the conduit to purge the air from between the adhesive and fender. NOTE Do not rub the conduit to make it adhere to the fender. This will not do an adequate job of purging the air from between the adhesive and fender. Once the adhesive is in place, it requires 72 hours to fully cure. Do NOT pull or try to reposition the conduit during this period. NOTE When performing the next step, note that the location for installing the seat retention nut and washer depends on the seat style being mounted. Determine the correct location for your seat prior to installation. | 
Figure 4. Remove Protective Strip From Conduit Adhesive 
Figure 5. Air Removal Using Corner Roller | ||||||||||
| 7. | See Figure 9. Obtain the seat retention nut (9) and washer (10) from the kit. Install the retention nut from the underside of the fender, and retain with the washer. | |||||||||||
| 8. | Obtain the rear fender extension (4), five pop rivets (5) and rivet washers (6) from the kit. Carefully align and rivet the fender extension to the new bobtail fender. | |||||||||||
| 9. | Obtain the paint protector tape (7) from the kit and install around the front seat mounting hole. | |||||||||||
| 10. | Install the rubber fender isolation grommet (3) into the center hole at the front of the fender. Install the spacer (2) into the isolation grommet from the bottom. |
Rear Fender Installation
| 1. | See Figure 9. Carefully place the fender into position between the fender supports. | |||||||||||||||||||
| 2. | Secure the front of the fender to the frame tab using the seat mounting stud and washer saved during removal of the original fender. Finger tighten only. | |||||||||||||||||||
| 3. | Route the rear lighting harness connector [7B] between the frame cross member and the top of the oil tank. Plug the connector into main harness connector [7A]. | |||||||||||||||||||
| 4. | For 2007 and later motorcycle models equipped with H-DSSS: Make sure antenna harness feeds up between oil tank and fender on right side of vehicle, and is not pinched between fender and frame crossmember. | |||||||||||||||||||
| 5. | For 2004-2006 motorcycle models: Secure the ignition control module to the studs on the frame with the original lock nuts. Tighten to 12-15 in-lbs (1.4-1.7 Nm). | |||||||||||||||||||
| 6. | Align the holes in the fender support cover with the holes in the new fender, and feed the turn signal wires through the fender supports and the fender. | |||||||||||||||||||
| 7. | Obtain two washers (15), two locknuts (16) and the two 1-3/4 inch (44 mm) long button head screws (14) from the kit. Line up the front side holes in the fender support cover with the holes in the fender support and fender. Install a screw with a washer and secure with a locknut, but do not fully tighten. Repeat for the opposite side. | |||||||||||||||||||
| 8. | Obtain the tail lamp/license plate bracket (18), the left-side (20) and right-side (19) brackets, and two locknuts (16) from the kit. Align and position the plates to the left and right sides of the bracket as shown. | |||||||||||||||||||
| 9. | While holding the left and right brackets against the tail lamp/license plate bracket, carefully install the assembly under the rear of the fender, aligning the holes in the plates over the turn signal mounting studs. Install the locknuts to secure the brackets to the left and right turn signal studs. Finger tighten only. | |||||||||||||||||||
| 10. | Obtain two 1-1/4 inch (35 mm) long button head screws (13) and washers (15) from the kit. Install a screw with a washer through the fender support cover and fender support, into the threaded hole in the tail lamp/license plate bracket. Repeat for the opposite side. Finger tighten only. | |||||||||||||||||||
| 11. | Return to the front and tighten the seat mounting nut and bolt to 8-13 ft-lbs (11-18 Nm). | |||||||||||||||||||
| 12. | Tighten the two forward (fender cover to support and fender) screws and locknuts to 11-18 ft-lbs (15-24 Nm). NOTE When performing the next two steps, hold the tail lamp bracket up against the inside top of the fender. | |||||||||||||||||||
| 13. | Tighten the two directional signal mounting stud nuts to 11-18 ft-lbs (15-24 Nm). | |||||||||||||||||||
| 14. | Tighten the two rearmost (fender cover to support, fender and tail lamp/license plate bracket) screws to 11-18 ft-lbs (15-24 Nm). | |||||||||||||||||||
| 15. | See Figure 6. Install the original-equipment circuit board assembly as shown to the tail lamp/license plate bracket by pushing the circuit board assembly studs into the sockets in the bracket. | 
Figure 6. Rear Lamp Connections | ||||||||||||||||||
| 16. | Gently pull the the rear lighting harness back to the tail lamp/license plate bracket, and insert the rear lamp (power in) connector [94] into the proper circuit board socket. NOTE Because the circuit board is mounted 180 degrees from its original position, the left-hand turn signal connector must be inserted into the right-side socket, and the right-hand turn signal connector must be inserted into the left-side socket. | |||||||||||||||||||
| 17. | Gently pull the turn signal wiring back, crossing the left and right turn signal wires behind the bracket. Insert the two-place connectors [18] and [19] into the sockets as shown. | |||||||||||||||||||
| 18. | See Figure 9. Capture the turn signal wires with the tabs located on the left-side (20) and right-side (19) inner brackets. | |||||||||||||||||||
| 19. | Rotate the stock tail lamp assembly 180 degrees from its original position. Connect the tail lamp connector [93] into the circuit board assembly. Install the tail lamp lens onto the bracket with the two screws saved earlier. Tighten to 20-24 in-lbs (2.3-2.7 Nm). | |||||||||||||||||||
| 20. | Insert the rear lighting harness through the front opening in the fender, and connect to the main harness. Use the nuts saved during removal to re-install the ignition module to the frame. Tighten the nuts securely. | |||||||||||||||||||
| 21. | H-DSSS equipped vehicles: See Figure 7. Place security antenna (5) into recess in ECM caddy (9) with flat side of antenna facing up and connector (6) facing right side of vehicle. Press down gently on antenna until it snaps in place. Route harness around right side of caddy and through harness retainer (8). | |||||||||||||||||||
| 22. | Lower ECM (1) onto locating pins in ECM caddy with ECM connector [78A] facing right side of vehicle. Press down gently on ECM until it snaps in place. H-DSSS equipped vehicles: Make sure antenna harness is not pinched underneath ECM. | |||||||||||||||||||
| 23. | Plug ECM connector [78A] (2) into ECM. | 
Figure 7. Security Antenna (H-DSSS only) and ECM Removal/Installation |
Reflector Installation
WARNINGFederal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b)
- See Figure 9. Install a reflector (17) on each side of the fender directly above the fender supports.
- For Domestic Versions: Affix the rear reflector (21) to the reflector bracket (22), and snap the tabs on the reflector bracket into the slots in the tail lamp/license plate bracket (7) For HDI Versions: Affix the rear reflector (23) to the license plate bracket (24), and snap the tabs on the reflector bracket into the slots in the tail lamp/license plate bracket (18).
Final Assembly
| 1. | For 2004-2005 motorcycle models: Refer to the Service Manual and follow the instructions given to re-attach the negative battery cable. For 2006 and later motorcycle models: Open left side cover and install Maxi-Fuse. Close left side cover. | |||||||||
| 2. | Turn ignition switch ON and check the following: a. Make sure tail lamp is lit. b. Depress turn signal switches and make sure both turn signals are operating properly. c. Operate front or rear brake and make sure brake lamp illuminates. | |||||||||
| 3. | See Figure 9. Remove and install the new seat mounting bracket (8) using the original hardware. NOTE Seat styles Stripper, Sidekick, Sidekick Custom and Ralley Runner will require the installation of an isolation washer, Part Number 90669-06. For installation of these seats refer to your seat installation instructions. | |||||||||
| WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||||||||||
| 4. | See Figure 8. The isolation washer (1) must be installed between the new seat (3) and fender (4) using the original hardware (2). | |||||||||
| 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) | ||||||||||
| 5. | Follow the instructions in the Service Manual to install the stock seat. | 
Figure 8. Isolation Washer Installation (generic seat shown) |
SERVICE PARTS
Figure 9. Service Parts: XL Bobtail Fender Installation Kit (2007 and Later XL Bobtail Fender Shown)
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Screw, hex head, 5/16-18 x 3/4 inch | 3987 |
2 | Spacer, front fender mount | 7882 |
3 | Grommet, fender isolation | 11474 |
4 | Extension, rear fender | 59502-04 |
5 | Pop rivet, 5/32 inch (5) | 8692 |
6 | Flat washer, #8 (5) | 6192 |
7 | Protective tape, rear fender | 59547-04 |
8 | Bracket, seat mounting | 51655-04 |
9 | Nut, seat retention | 7488 |
10 | Washer, seat retention | 7489A |
11 | Hole plug, seat mount (2) | 761 |
12 | Conduit, wire harness | 70517-03 |
13 | Screw, button head, 5/16-18 x 1-1/4 inch (2) | 4778 |
14 | Screw, button head, 5/16-18 x 1-3/4 inch (2) | 4779 |
15 | Flat washer, 1/2 inch O.D. (4) | 6798 |
16 | Lock nut, flanged, 5.16-18 (4) | 7531 |
17 | Reflector (red) | |
Right side | 59287-92 | |
Left side | 59288-92 | |
18 | Bracket, tail lamp/license plate | 59577-04 |
19 | Bracket, license plate inner (right) | 60110-04A |
20 | Bracket, license plate inner (left) | 60109-04A |
21 | Reflector, rear (domestic) | 59988-72A |
22 | Bracket, rear reflector (domestic) | 60019-93A |
23 | Reflector, rear (HDI) | 59259-90 |
24 | Bracket, license plate (HDI) | 60123-02 |
25 | Isolator, seat | 90669-06 |
Items mentioned in text, but not included in kit: | ||
A | Bobtail Fender | |
B | Original equipment screw | |
C | Original equipment washer | |