XL FRAME REPAIR TOOL
J043112009-07-24
GENERAL
Kit Number
SRVHD-48999
Models
This tool is used to install a new jiffy stand spring anchor on 2004 through 2008 XL model motorcycles.
Additional Materials Required
Proper installation of this kit requires the separate purchase of a spring anchor (H-D Part No. 3718M).
Loctite® 243 Threadlocker and Sealant - Blue (H-D Part No. 99642-97) is required for the proper installation of this kit. Cutting oil will also be required.
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation .
PROCEDURE
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1. Refer to the service manual and remove the main fuse.
2. Refer to the service manual and remove the seat.
3. Secure the motorcycle in the upright position, refer to the service manual and remove the jiffy stand from the mounting bracket on the frame.
NOTE
Frame preparation before using tool:
  • Remove the remaining fragment of jiffy stand stud with a suitable cutting wheel. This will properly prepare the frame for use of the Frame Repair Tool.
  • Follow instructions provided for proper installation of new jiffy stand spring anchor.
4. See Figure 1. Install the base (1) onto the frame in the jiffy stand mounting bracket and secure with the hex cap screw (3) and washer (2).
1Base
2Washer
3Hex cap screw
Figure 1. Install Base on Jiffy Stand Mounting Bracket
WARNING
Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury. (00466c)
5. Using blocks, hoist or lift as necessary, carefully lean the motorcycle toward the left side.
6. See Figure 2. Install the facing tool guide (2) into the base (1) and secure with the lock screw (4).
7. Install the facing tool (3) into a suitable drill. Then, using the facing tool and cutting oil, remove the jiffy stand stud material until the facing tool stop contacts the facing tool guide.
8. Remove the facing tool, lock screw and facing tool guide from the base, and clean any loose material from the base.
1Base
2Facing tool guide
3Facing tool with stop
4Lock screw
Figure 2. Use Facing Tool
1Base
2Lock screw
3Socket head screw
4Drill bit with stop
5Drill bit guide
6Locating fixture
Figure 3. Use Drill Bit
9. See Figure 3. Install the locating fixture (6) into the base (1) and secure with the socket head screw (3).
10. Install the drill guide (5) into the locating fixture and secure with the lock screw (2).
11. Install the drill bit (4) into a suitable drill. Then, using cutting oil, drill a hole at the stud location until the drill stop contacts the drilling guide.
12. Remove the lock screw and drilling guide, then clean any loose material from the base and locating fixture.
1Base
2Locating fixture
3Socket head screw
4Lock screw
5Tap
6Tap guide
Figure 4. Use Tap
13. See Figure 4. Install the tap guide (6) into the locating fixture (2) and secure with the lock screw (4).
14. Install the tap (5) into a suitable tap handle, then tap the drilled hole until the tap bottoms out.
15. Remove the hex cap screw, washer and base (1) from the motorcycle.
16. Use the black paint pen included in the kit to paint the bare metal of the faced-off area. Be careful not to allow any paint into the threads.
1Spring anchor
Figure 5. Install Spring Anchor
17. See Figure 5. Apply Loctite® 243 (blue) to the threads of the spring anchor (H-D Part No. 3718M, purchased separately), then install it into the tapped hole. Tighten the spring anchor to 7–9 N·m (62–79 in-lbs).
18. Using a hoist or lift as necessary, carefully lift the motorcycle to the upright position and secure it in place.
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)
19. Refer to the service manual and install the seat.
20. Refer to the service manual and install the jiffy stand.
21. Refer to the service manual and install the main fuse.
1Facing tool guide
2Facing tool
3Locating fixture
4Lock screw
5Drill bit guide
6Drill bit
7Tap guide
8Tap
9Socket head screw
10Base
11Flat washer
12Hex cap screw
13Lock screw
14Paint pen (black)
Figure 6. XL Frame Repair Tool Components