180 MM WIDE TIRE KIT
J047842009-08-11
GENERAL
Kit Number
43779-09
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
A Dunlop® tire must be purchased for the front wheel when using the wide tire kit on the 2010 model year Dyna.
Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
WARNINGDealer installation is required. Proper installation of this kit requires specific alignment procedures to ensure proper tire clearance. Tire contact with chassis components can lead to tire failure, which could result in death or serious injury. (00428c)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation.
INSTALLATION
Install Wide Tire
| 1. | Place motorcycle on a lift and secure front tire. | |||||||||||||||||||||
| 2. | Place a scissor jack under the frame so that the rear wheel can be raised and lowered. | |||||||||||||||||||||
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||||||||||||||||||||||
| 3. | Disconnect battery negative (-) cable. | |||||||||||||||||||||
| 4. | Refer to the appropriate Service Manual and remove the rear wheel. | |||||||||||||||||||||
| 5. | Installation without saddlebags or docking points installed: See Figure 1. Remove three screws and tail light base. Disconnect the tail light connector (2) and set the tail light and gasket aside. NOTE Before disconnecting the turn signals, mark the connectors to identify the right and left connections of the fender harness. | 
Figure 1. Disconnect Rear Lights 
Figure 2. Replace Fender Bracket | ||||||||||||||||||||
| 6. | See Figure 1. Disconnect the turn signal connectors (1) and remove clip (4). | |||||||||||||||||||||
| 7. | See Figure 2. Remove screw (3) and washer (4) from inside of the fender and remove the rear turn signal and mount assembly. Discard screw (3) and washer (4) NOTE The washer (6) between the fender strut and fender is held in place with an adhesive. Do not remove. | |||||||||||||||||||||
| 8. | Remove screw (5) and stock rear fender bracket (2). Save the screw, and discard rear fender bracket. | |||||||||||||||||||||
| 9. | Install rear fender bracket (1) from kit loosely with screw (5) from previous step. | |||||||||||||||||||||
| 10. | Apply 2-3 drops of Loctite 243 (blue) to the screw (3) from the kit, route the turn signal wire into the fender and loosely install turn signal using the screw (3) from kit. | |||||||||||||||||||||
| 11. | See Figure 3. Keep the turn signal wire flat to the fender to verify the bracket seats properly against the contour of the fender. Use a heat gun (HD-25070 or equivalent) to conform the wire harness to the fender contour. | 
Figure 3. Keep Turn Signal Wire Flat to Rear Fender Wall 
Figure 4. Turn Signal Wire Routing | ||||||||||||||||||||
| 12. | See Figure 4. Route turn signal three wire bundle from behind and out the top of the fender bracket channel (2) and up the side of the fender wall and attach to clip (4). | |||||||||||||||||||||
| 13. | See Figure 2. Tighten turn signal mounting screw (3) to 19 N·m (14 ft-lbs). | |||||||||||||||||||||
| 14. | See Figure 2. Tighten fender strut cover screw (5) to 24 N·m (18 ft-lbs). | |||||||||||||||||||||
| 15. | Repeat Steps 7-13 for the opposite side of the motorcycle. | |||||||||||||||||||||
| 16. | Install tail light connector to housing and turn signals to previously marked connectors. | |||||||||||||||||||||
| 17. | Install the tail light assembly to the fender with three screws and tighten to 9.5–12.2 N·m (7–9 ft-lbs). | |||||||||||||||||||||
| 18. | See the appropriate Service Manual and remove the rear tire from the wheel and replace with the tire from the kit. Also, inspect the tire, check radial and lateral runout, and balance the wheel. | |||||||||||||||||||||
| 19. | See the appropriate Service Manual. Install the rear wheel and verify axle/swing arm alignment and belt deflection. | |||||||||||||||||||||
| 20. | Go to "Clearance Check". |
Install Wide Tire With Saddlebags and Turn Signal Relocation Kit
NOTE
Rear fender bracket (60181-09) is required for this installation and is purchased separately.
| 1. | Discard the brackets (60130-09) and screws from the wide tire kit. Discard the brackets (59542-09) from the turn signal relocation kit. NOTE Before disconnecting the turn signals, mark the connectors to identify the right and left connections of the rear harness. | |||||||||||||
| 2. | If turn signal relocation kit is already installed, remove the rear fender brackets and install the service part brackets (60181-09). Do not tighten fender brackets to leave room to route the turn signal wire harnesses. | 
Figure 5. Installation with Saddlebags and Turn Signal Relocation | ||||||||||||
| 3. | See Figure 5. Route the turn signal wire harness (1) as shown in Figure 5 through the corner of the fender bracket (6) and along the turn signal relocation bracket (2). The wire harness must be flat against the contour of the fender and inserted into the wire clip (5). Use a heat gun (HD-25070 or equivalent) to conform the wire harness to the fender contour. Repeat for other side. | |||||||||||||
| 4. | Tighten saddlebag/bracket screws to 34 N·m (25 ft-lbs). | |||||||||||||
| 5. | Install fender edging (4) as shown on both side and use a cable straps to secure the harnesses to the turn signal brackets. NOTE Skip Steps 6-8 if saddlebags are already installed. | |||||||||||||
| 6. | Install tail light connector to housing and turn signals to previously marked connectors. | |||||||||||||
| 7. | Install the tail light assembly to the fender with three screws and tighten to 9.5–12.2 N·m (7–9 ft-lbs). | |||||||||||||
| 8. | See the appropriate Service Manual and remove the rear tire from the wheel and replace with the tire from the kit. Also, inspect the tire, check radial and lateral runout, and balance the wheel. | |||||||||||||
| 9. | See the appropriate Service Manual. Install the rear wheel and verify axle/swing arm alignment and belt deflection. | |||||||||||||
| 10. | Go to "Clearance Check". |
Install Wide Tire With Docking Hardware Kit and Directional Relocation Kit
NOTE
Refer to the instructions for the Docking Hardware Kit and the Directional Relocation Kit for installation except for the following steps.
| 1. | See Figure 6. At 10.25 inches from the recess of the turn signal housing, cut a slit in the three-wire harness sheath exposing the wires past 10.25 inches. Cut the purple wire at 10.25 inches, the blue wire at 12 inches and the black wire a 12.375 inches. | 
Figure 6. Slit Wire Harness Sheath 
Figure 7. Wiring Sheath | ||||||||
| 2. | Remove the three wire pins from the connector making sure you label the connector and wires for reinstallation. Do not remove the crimped pins from the wires. | |||||||||
| 3. | Slide the uncut wire sheath from the wire harness. NOTE The following assumes that:
Refer to the other kit instruction sheets if necessary. | |||||||||
| 4. | See Figure 7. Carefully thread the three wires up under the rear fender bracket. Be careful not to kink the three wires coming out of the inner diameter of the stalk. | |||||||||
| 5. | Cut 4.5 inches of the remaining sheath and slide it over the three wires. |  Figure 8. Wiring Splices | ||||||||
| 6. | See Figure 8. Install the three sealed splice connectors as shown. Use the installation procedures from the directional relocation kit to crimp and seal the connectors on both ends of the exposed wire. Install the wire end connector. | |||||||||
| 7. | See Figure 9. Route the wire bundle flat up against the fender contour and under the fender wire support clip. Bend the fender wire clip as needed to install the wire bundle and retain the wire bundle flat up against the fender. | |||||||||
| 8. | See Figure 3. Use a heat gun (HD-25070 or equivalent) to conform the wire harness to the fender contour. | |||||||||
| 9. | Repeat Steps 1-8 for opposite side. | |||||||||
| 10. | Route the wire end connectors through the fender hole for the tail light and turn signals. Connect tail light to housing connector and turn signals to previously marked connectors. | |||||||||
| 11. | Install the tail light assembly to the fender with three screws and tighten to 9.5–12.2 N·m (7–9 ft-lbs). | |||||||||
| 12. | See Figure 10. Use High Performance Gray Sealant (99650-02) to fix wires coming out of the stalk and up under the fender bracket on both sides as shown. | |||||||||
| 13. | See the appropriate Service Manual and remove the rear tire from the wheel and replace with the tire from the kit. Also, inspect the tire, check radial and lateral runout, and balance the wheel. | 
Figure 9. Wire Support Clip 
Figure 10. Sealant Application | ||||||||
| 14. | See the appropriate Service Manual. Install the rear wheel and verify axle/swing arm alignment and belt deflection. |
Clearance Check
| 1. | Remove upper shock bolts and spacers from both sides of the motorcycle. | |||||||||
| 2. | Using the jack, lower the motorcycle until the rear fender strut almost rests on the belt guard. | 
Figure 11. Gauge Clearance  Figure 12. Rear Leverage Points (Right Side Shown, Left Side Similar) 
Figure 13. Front Leverage Points (Left Side Shown, Right Side Similar) | ||||||||
| 3. | Obtain a 24 in. length of straight, cold drawn, 3/16 in. round bar or square bar to use as a gauge. | |||||||||
| 4. | See Figure 11. Lay gauge across the tire's radial ridge (2) and check that the gauge (1) can pass through the fender without touching the turn signal mounting screw or the rear fender bracket. Repeat for opposite side of motorcycle. | |||||||||
| 5. | If gauge passes, proceed to the Return Motorcycle to Service section below. If gauge contacts screw or bracket , perform the Horizontal Adjustment procedure below. |
Horizontal Adjustment
The following adjustment procedure is meant to center the tire between the rear fender brackets. It requires two people.
| 1. | See Figure 14. Loosen the two front (5) and two rear (1) mount bolts. | |
| 2. | See Figure 12. Using a suitable tool wrapped in a clean, soft cloth, between the swingarm and frame, as indicated by the arrow, move the rear wheel to the left or right, as necessary, to provide clearance for the gauge. Tighten the rear mount bolts while maintaining pressure on the tool. Tighten bolts to 30–37 N·m (22–27 ft-lbs). | |
| 3. | See Figure 13. Using a suitable tool wrapped in a clean, soft cloth, between the front mount and frame (1), move the rear wheel to the left or right, as necessary, to provide clearance for the gauge. Tighten the front mount bolts while maintaining pressure on the tool. Tighten bolts to 30–37 N·m (22–27 ft-lbs). | |
| 4. | Repeat Clearance Check procedure. If further adjustment is necessary, proceed with the following step. If further adjustment is not necessary, proceed to RETURN MOTORCYCLE TO SERVICE section. | |
| 5. | See Figure 14. Loosen the two top bolts (3) of the T-bracket (4). | |
| 6. | See Figure 13. Use a suitable tool between the frame and T-bracket (2). Move the rear wheel to the left or right, as necessary, to provide clearance for the gauge. Tighten the T-bracket bolts while maintaining pressure on the tool. Tighten bolts to 34–41 N·m (25–30 ft-lbs). | |
| 7. | Repeat Clearance Check procedure. |
| 1 | Rear mount bolt (2) |
| 2 | Rear mount |
| 3 | T-bracket mount bolt (2) |
| 4 | T-bracket mount |
| 5 | Front mount bolt (2) |
| 6 | Front mount |
Figure 14. Vehicle Alignment
Return Motorcycle to Service
| 1. | Apply 2-3 drops of Loctite 243 (blue) to the upper shock bolts. Install upper shock bolts and spacers. Tighten upper shock bolts to 102–115 N·m (75–85 ft-lbs). | |
| 2. | Connect battery negative (-) cable. | |
| 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) | ||
| 3. | Verify turn signal, brake and tail light operation. | |
| 4. | See the appropriate Service Manual and perform the Vehicle Alignment procedure and verify rear wheel to front wheel parallelism. | |
| 5. | Verify that belt and belt guard are clear of the rear tire. | |
| 6. | To prevent excessive vibration, check for loose hardware and re-tighten as necessary. |
SERVICE PARTS
Figure 15. Service Parts: 180mm Wide Tire Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Tire, 180 / 60 - B17 | 43197-04A |
2 | Fender mounting brackets (2) | 60130-09 |
3 | Screws, hex socket button head (2) | 4971 |
4 | Cable strap (2) | 10065 |