0/0
SOFTAIL FRONT SPOILER KITS
J040832007-06-18
GENERAL
Kit Numbers
57040-xxx (prime or finish paint), 57101-08 (chrome)
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).
Service Manual Required
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 your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 2 and Table 1.
INSTALLATION
1. Position the vehicle on a motorcycle lift table.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse.
3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame.
1Voltage regulator
2Voltage regulator attaching screws (2)
3Voltage regulator bracket
4Bracket screw to engine crankcase (2)
5Voltage regulator caddy
6Voltage regulator caddy cover
7Four-pin voltage regulator connector (2007 only)
8Two-pin voltage regulator connector (2007 only)
9Cable strap (2 for 2007, 1 for 2008 and later)
10Lower voltage regulator cover (2007 only)
11Oxygen sensor connector
12Crank position sensor connector (2007 only)
13Horn connectors (some 2008 and later models)
Figure 1. Original Equipment Voltage Regulator
NOTE
For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground.
  1. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10).
  2. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator.
  3. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws.
  4. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine.
  5. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors.
  6. For 2008 and later models: Unclip the two-way O2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.
    1. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers.
    2. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting.
  7. See Figure 2. Obtain the voltage regulator removed earlier, and the following new items from the kit:
  • voltage regulator caddy (2)
  • front spoiler/regulator bracket (3)
  • rear spoiler bracket (4)
  • two long socket head cap screws (5)
  • two U-bolts (6)
  • two spoiler mounting blocks (7)
  • rear spoiler cover bracket (8)
  • four lock nuts (9)
  • six flat washers (10)
  • two short button head screws (11)
  • one "fir tree" type cable strap (15)
4. Hook the top clips of the voltage regulator caddy (2) around the tabs on the front of the engine casting.
5. See Figure 1 inset. Clip the oxygen sensor connector [138] (11) to the top of the voltage regulator caddy.
6. Clip the crank position sensor [79] (12) wiring into the upper retainer, near the bottom of the voltage regulator caddy, and fasten the connector to the caddy with a "fir tree" type cable strap ( Figure 2 , 15) from the kit.
7. While nesting the front (3) and rear (4) spoiler brackets together as shown, attach the voltage regulator (B) to the bracket assembly with the two long socket head screws (5). Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
8. Place a flat washer (10) onto the threads of the two short button head screws (11). Insert the screws through the lower holes in the front spoiler bracket, and into the threaded inserts in the rear spoiler bracket. Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
9. For 2008 and later models: Through the opening on the bracket assembly, re-connect both voltage regulator connectors. For 2007 models: Route both wires from the voltage regulator around the right side of the bracket. Re-connect both connectors.
10. Replace the "fir tree" type retainer on the jiffy stand sensor connector with the new retainer (16) included in this kit. Fasten the retainer to the left-side hole on the rear spoiler bracket.
NOTE
For 2007 models: The voltage regulator ground wire must be attached at the original location with the left-side bolt for adequate ground.
11. For ALL models: Install the spoiler bracket/voltage regulator assembly to the engine using the two hex socket head screws (A) saved from Steps 5 and 7, fastening the voltage regulator ground wire with the left-side bolt. Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
12. Check the tension on the regulator wires. If necessary, relieve any strain on the wires by clipping the cable straps that secure the wires routed along the lower frame and adjust the wires forward. Re-attach to the frame with cable straps (17) from the kit.
13. Install the U-bolts (6) over the lower engine mounting spacers (located on each side of the vehicle, between the engine and the frame tube). Assemble the spoiler mounting blocks (7) onto the U-bolt threads.
14. Slip a cable strap up through one of the slots (C) at the rear of the voltage regulator caddy, then down through the mating slot (D) near the back of the rear spoiler bracket. Repeat for the opposite side.
15. Fasten the caddy and bracket together with the cable straps, guiding the U-bolt threads through the holes in the spoiler bracket and pulling the straps tight. Trim off any excess cable strap length.
16. Install the rear spoiler cover bracket (8) over the U-bolt threads. Install a flat washer (10) and lock nut (9) to each bolt end. Tighten the nuts to 2.3–4.5 N·m (20–40 in-lbs).
17. For 2007 models: Obtain the corrugated black nylon shield (14) from the kit and cut it into two equal-length pieces. Wrap one piece around each voltage regulator wire (the shield may have to be trimmed to fit properly). Position the wires around the tab on the side of the front spoiler bracket (3), and secure in front using the remaining "fir tree" type cable strap (15) from the kit. Insert the strap retainer into the hole in the bracket. Secure the remainder of the shield with cable straps as needed.
18. For ALL models: Attach the spoiler (18) to the mounting brackets using shoulder screws (12) and nylon washers (13) from the kit. Align the spoiler with the frame as desired, then tighten all the screws to 1.2–1.7 N·m (10.6–15 in-lbs).
19. Secure the clutch cable to the frame down tube, away from the spoiler, using a cable strap (17). Use more than one strap if necessary to ensure the clutch cable does not contact the spoiler.
20. Refer to the Service Manual and follow the instructions given to reinstall the Maxi® Fuse.
SERVICE PARTS
Figure 2. Service Parts: Softail Front Spoiler
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Hardware kit, Softail spoiler (includes items 2 through 17)
57041-08
2
  • Caddy, voltage regulator electrical
70398-07
3
  • Bracket, spoiler/ regulator (front)
57043-08
4
  • Bracket, spoiler (rear)
57044-08
5
  • Cap screw, socket head (with washer), 1/4-20 x 1-1/4 in. (2)
4740A
6
  • U-bolt, 1/4-20 x 1 in. I.D. (2)
5228
7
  • Block, spoiler mounting (2)
58445-00
8
  • Bracket, spoiler cover (rear)
57027-07
9
  • Lock nut, 1/4-20 (4)
7686
10
  • Flat washer (6)
6703
11
  • Screw, button head, hex socket, 1/4-20 x 5/8 in. (2)
924
12
  • Shoulder screw, button head, hex socket, 1/4-20 (6)
CA0018.02A8
13
  • Nylon washer (6)
6599
14
  • Shield, wire (split, corrugated black Nylon. For 2007 models only)
63627-98
15
  • Cable strap, anchored ("fir tree" type) (2)
10177
16
  • Retainer, pin housing ("fir tree" type)
73213-07
17
  • Cable strap (6)
10006
18
Spoiler, Softail (painted, for kit 57040-xxx)
Spoiler, Softail (chrome, for kit 57101-08)
57042-01
57102-01A
Items mentioned in text, but not included in kit:
A
Original equipment voltage regulator bracket mounting screws to engine crankcase (2)
B
Original equipment voltage regulator
C
Cable strap slot in voltage regulator electrical caddy (2)
D
Cable strap slot in rear spoiler bracket (2)