80-SPOKE REAR WHEEL KIT

J042432011-11-15

GENERAL

WARNING

Install only wheels and installation kits approved for your model motorcycle. Contact a Harley-Davidson dealer to verify fitment. Mismatching wheels and installation kits or installing wheels not approved for your model can cause loss of control, which could result in death or serious injury. (00610c)

Kit Numbers

42962-08, 40750-08

Models

For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

NOTE

Accessory hub caps are not compatible with this wheel.

Kit Contents

See Figure 10 and the Service Parts tables for kit contents.

Additional Parts Required

This kit includes the custom wheel only.

Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley-Davidson dealer:

Wheel Installation Kit (See Table 5 through Table 7 to determine required installation kit.)
Brake Disc Screws (See Table 1 to determine proper hardware.)
Rear Sprocket Screws (See Table 1 to determine proper hardware.) See the P&A Retail Catalog for chrome sprocket hardware.
Wheel Bearing Remover and Installer (94134-09)

The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning:

Harley^® Bright™ Chrome Cleaner (94683-99)
Harley^® Glaze™ Polish and Sealant (99701-84)
Harley^® Wheel and Spoke Brush (43078-99)
Harley-Davidson^® Wheel and Tire Cleaner (94658-98)
Harley^® Preserve Bare Aluminum Protectant (99845-07)

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 references service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.

Table 1. Rear Disc and Sprocket Hardware Fitment

Hardware	Fitment
Rear Disc Screws (select stock or chrome hardware)
5 Stock disc screws (43567-92)	All models
Chrome screw kit (46647-05) includes 5 screws	All models
Rear Sprocket Screws (select stock or chrome hardware)
5 Sprocket screw, stock (3109)	2007 and later Dyna and Softail, 2007 Touring
Chrome screw kit (94773-07) includes 5 screws and washers	2007 and later Dyna and Softail
5 Sprocket screw, stock (3737A)	2000-2005 Dyna, 2000-2006 Softail, 2004-2006 Touring
Chrome screw kit (94773-00A) includes 5 screws and washers	2000-2005 Dyna, 2000-2006 Softail
5 Sprocket screw, stock (3814)	2008 Touring
5 Sprocket screw, stock (3873)	2006 Dyna
5 Sprocket screw, stock (3899)	2000-2003 Touring, 2001 and later Sportster (except Japanese models)
5 Sprocket screw, stock (40439-01)	2002-2006 VRSC and 2007 VRSCR models
5 Sprocket screw, stock (4552)	2007 and later VRSC models (except VRSCR and VRSCSE models)
Rear Sprocket Washers
5 Sprocket washer, stock (6516HW)	2006 and earlier Dyna, Softail and Touring and 2000 and later Sportster models (except Japanese models)
5 Sprocket washer, stock (7039)	2002 and later VRSC

INSTALLATION

1.	Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. NOTE Remove the rear brake caliper before removing the wheel.
2.	Install the tube and tire on wheel. Refer to REAR WHEEL in the service manual. NOTE Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER.
	NOTICE Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTICE Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b)
3.	Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to REAR WHEEL in Service Manual.
4.	Install rear wheel (1), stock axle and stock axle nut. Refer to REAR WHEEL in service manual.

WHEEL LACING PROCEDURE

NOTE

If only the rim is to be replaced, tape the spokes together to hold the position on hub and remove spokes from rim. Install taped hub/spoke assembly to the new rim and tighten spokes. Then remove the tape and true wheels.

The nipple fitting of the spoke uses a standard T-30 TORX^® bit for removal and installation.

1	Hub
2	Rim

Figure 1. Spoke Wheel Components

The 80-spoke wheel uses two lengths of spokes, installed in the inner and outer rows on the hub. See Figure 2.

1	Inner spoke row
2	Outer spoke row
3	Machined directional groove

Figure 2. Spoke and Directional Groove Location on Hub

See Figure 3 and Table 2. Measure distance "A" (outer) to determine outer and inner spoke lengths. Separate outer and inner spokes in preparation for installation to hub and rim.

Figure 3. Spoke length

Table 2. Spoke Lengths

Spoke	Length (A)
Outer spoke	5.19 inch (132 mm)
Inner spoke	5.59 inch (142 mm)

See Figure 4. Place the hub on table with machined groove side up. Insert a spoke in each hole of the outer row as shown. Angle the spokes clockwise.

Center the rim over the hub assembly with the valve stem hole facing up. See Figure 5.

See Figure 4. Using any outer row spoke, insert the first spoke into the rim hole to the left of the valve stem hole on the upper half of the rim centerline. Loosely assemble the spoke nipple.

Figure 4. Install Outer Spokes on Hub

1	Outer spoke location on rim
2	Valve stem hole

Figure 5. Install Outer Spokes

Install the rest of outer row spokes in every fourth hole. Loosely assemble the spoke nipples.

See Figure 6. Insert the first inner row spoke into the hub. Angle the spoke counterclockwise crossing four outer row spokes. Loosely assemble the spoke nipples.

Figure 6. Install Inner Spokes

Install the inner row spokes into every fourth remaining hole above the rim centerline. Loosely assemble the spoke nipples.

See Figure 7. Turn rim over so brake disc side faces down. Place any outer row spoke into hub. Angle spoke counterclockwise and insert into rim hole angled to accept it. Loosely assemble the spoke nipple.

Figure 7. Install Outer Spokes

Insert the remaining outer row spokes, angled counter-clockwise, into hub and rim. Loosely assemble the spoke nipples.

Insert inner row spoke into hub and angle spoke clockwise, crossing over 4 outer row spokes. Place spoke into appropriate rim hole. Loosely assemble the spoke nipples.

10.

See Figure 8. Install remaining inner row spokes. Loosely assemble the spoke nipples.

11.

Tighten spoke nipples to 2.2–4 N·m (19–35 in-lbs).

Figure 8. Remaining Inner Spoke Installation

TRUING LACED WHEELS

The rim must be trued both laterally and radially. If new bearings were installed, wheels may be trued with only the bearings and center spacer installed. See Figure 9 and Table 3 for the proper offset dimensions for your wheel.

1	Cast-in marking or groove side of hub.

Figure 9. Offset Dimension

Table 3. Wheel Offset Dimensions

Kit Number	"A"	"B"
42962-08	1.41 inch (35.7 mm)	1.05 inch (26.6 mm)
40750-08	1.86 inch (47.3 mm)	1.05 inch (26.6 mm)

See TRUING LACED WHEELS the service manual for your model motorcycle.

MAINTENANCE AND CLEANING

Chrome parts must be maintained regularly to keep their original shine and luster.

Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner applied with the Harley Wheel and Spoke Brush.
Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner.
After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant.

SERVICE PARTS

Figure 10. Service Parts: 80-Spoke Rear Wheel

Table 4. Service Parts and Wheel Kit Contents

Kit	Item	Description (Quantity)	Part Number
42962-08	1	Wheel	Not Sold Separately
	2	Rim strip	43147-40
	3	Rim	43087-04
	4	Hub	41137-04A
	5	Spoke and nipple kit (contains 20 inner spokes, 20 outer spokes and 40 nipples)	41899-05
40750-08	1	Wheel	Not Sold Separately
	2	Rim strip	43147-40
	3	Rim	43087-04
	4	Hub	40752-08
	5	Spoke and nipple kit (contains 20 inner spokes, 20 outer spokes and 40 nipples)	41899-05

Table 5. REAR 3/4 Inch Bearing Wheel Installation Kit (43854-08A)

REAR 3/4 Inch Bearing Wheel Installation Kit (43854-08A)		Item (Quantity Used and Description)
Fitment	Wheel Size	A	C	D	E	H	I
2007 FLST, FLSTN and FLSTC	16 x 3.0 in	2	1	0	0	*	*
2003-2006 FLST, FLSTN and FLSTC; 2003-2006 FLSTF (except FLSTFSE2); 2003-2005 FXST, FXSTB and FXSTS	16 x 3.0 in	2	1	0	0	*	*
2000-2005 Dyna; 2000-2002 Softail (except FXSTD)	16 x 3.0 in	2	1	0	0	*	*
2000-2004 XL; 2000-2001 FLT	16 x 3.0 in	2	1	0	0	*	*
2000-2007 FXSTD	17 x 4.5 in	2	1	0	0	*	*
2006 FXST, FXSTB, FXSTS and FLSTFSEi	17 x 6.0 in	2	0	1	0	*	*
2007 FLSTF, FXST, FXSTB and FXSTC	17 x 6.0 in	2	0	0	1	*	*
Installation kits are designed to work with many different wheel styles and fitments. Contact a Harley-Davidson dealer to verify that the wheel and installation kits are both designed and approved for the motorcycle they are being installed on. NOTES: * See NOTE above valve installation step in INSTALLATION to determine which valve stem to use for your particular kit. Discard other valve stem(s).		A	Bearing, regular (2)			9267
		C	Axle sleeve			43608-00
		D	Axle sleeve			43618-06
		E	Axle sleeve			43618-07
		H	Valve stem, short			43157-83A
		I	Valve stem, long			43206-01

Table 6. REAR 25mm Bearing Wheel Installation Kit (43878-08B)

REAR 25 MM Bearing Wheel Installation Kit (43878-08B)		Item (Quantity Used and Description)
Fitment	Wheel Size	A	C	D	F	H	I	J
2008 and later FLSTN, FLSTC, FLS and FXS without ABS	16 x 3.0 in	2	1	0	0	*	*	0
2008 FLT without ABS	16 x 3.0 in	2	0	1	1	*	*	0
2008 and later XL (except 2011 and later XL883L)	16 x 3.0 in	2	0	1	**	*	*	*
2008 and later FXSTB, FXSTC, FLSTF, FLSTSB and FLSTFB without ABS	17 x 6.0 in	2	1	0	0	*	*	0
2008 and later FXSTB, FXSTC, FLSTF, FLSTSB and FLSTFB without ABS	18 x 6.0 in	2	1	0	0	*	*	0
Installation kits are designed to work with many different wheel styles and fitments. Contact a Harley-Davidson dealer to verify that the wheel and installation kits are both designed and approved for the motorcycle they are being installed on. NOTES: * See NOTE above valve installation step in INSTALLATION to determine which valve stem to use for your particular kit. Discard other valve stem(s). See NOTES for your wheel kit above the wheel assembly step in INSTALLATION to determine which bearing shim to use for your particular wheel kit and fitment. * Bearing shim installed under primary bearing.		A	Bearing, regular (2)			9276
		C	Axle sleeve			41696-08
		D	Axle sleeve			41900-08
		F	Bearing shim***			43904-08
		H	Valve stem, short			43157-83A
		I	Valve stem, long			43206-01
		J	Valve stem, pull thru			40999-87

Table 7. REAR 25 MM Bearing ABS Wheel Installation Kit (43077-11)

REAR 25 MM Bearing ABS Wheel Installation Kit (43077-11)		Item (Quantity Used and Description)
Fitment	Wheel Size	A	B	C	D	H	I
2011 and later FLSTN, FLSTC, FLS and FXS with ABS	16 x 3.0 in	1	1	0	1	*	*
2011 and later FXST, FLSTF and FLSTFB with ABS	17 x 6.0 in	1	1	0	1	*	*
2011 and later FXST, FLSTF and FLSTFB with ABS	18 x 6.0 in	1	1	0	1	*	*
2011 and later FXCWC with ABS	18 x 8.0 in	1	1	1	0	*	*
Installation kits are designed to work with many different wheel styles and fitments. Contact a Harley-Davidson dealer to verify that the wheel and installation kits are both designed and approved for the motorcycle they are being installed on. NOTES: * See NOTE above valve installation step in INSTALLATION to determine which valve stem to use for your particular kit. Discard other valve stem(s). ** Primary bearing. Bearing must be installed with red side facing the wheel.		A	Bearing, regular			9276
		B	Bearing, ABS**			9252
		C	Axle sleeve			41358-08
		D	Axle sleeve			41696-08
		H	Valve stem, short			43157-83A
		I	Valve stem, long			43206-01