0/0
BULLET FRONT SPOILER KITS
J040842007-06-18
GENERAL
Kit Numbers
57039-xxx (prime or finish paint), 57006-08 (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 5 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 5. Obtain the voltage regulator removed earlier, and the following new items from the kit:
  • voltage regulator caddy (2)
  • top spoiler bracket (4)
  • rear spoiler bracket (5)
  • two U-bolts (7)
  • two spoiler mounting blocks (8)
  • rear spoiler cover bracket (9)
  • four lock nuts (10)
  • four flat washers (11)
  • two shoulder screws (12)
  • two rubber washers (13)
  • one "fir tree" type cable strap (22)
  • front bullet spoiler (24)
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 5 , 22) from the kit.
7. Clip the jiffy stand sensor wiring into the lower retainer, near the bottom of the voltage regulator caddy.
NOTE
For 2007 models: The voltage regulator ground wire must be attached at the original location with the left-side bolt for adequate ground.
8. See Figure 2. Install the top spoiler bracket (1) to the engine using the two hex socket head screws (2) saved from Steps 5 and 7. For 2007 models, fasten the voltage regulator ground wire (4) with the left-side bolt. For ALL models: Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
1Top spoiler bracket
2Hex socket head screw (2)
3Voltage regulator
4Voltage regulator ground wire (2007 only)
5Voltage regulator mount bracket
6Button head screw (2)
7Flat washer, silver (2)
Figure 2. Regulator and Top Spoiler Bracket Installation
9. See Figure 5. Install the U-bolts (7) 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 (8) onto the U-bolt threads.
10. Slip a cable strap (23) up through one of the slots (C) at the rear of the voltage regulator caddy (2), then down through the mating slot (D) near the back of the rear spoiler bracket (5). Repeat for the opposite side.
11. 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.
12. Install the rear spoiler cover bracket (9) over the U-bolt threads. Install a flat washer (11) and lock nut (10) to each U-bolt end. Do not fully tighten at this time.
13. Place a rubber washer (13) onto the shoulder of two of the shoulder screws (12) from the kit. Insert a screw through the two top holes in the front bullet spoiler (24) and into the threaded inserts in the rear spoiler bracket (5). Tighten the screws to 1.2–1.7 N·m (10.6–15 in-lbs).
14. For 2007 models: Slide the conduit of both regulator wires up to the base of the voltage regulator. Wrap a cable strap (23) about 1.5-2.0 inches (38-51 mm) from the regulator base. Pull the strap to tighten around both conduits and wires. For 2008 and later models: Re-connect both plugs to the back of the voltage regulator. Secure the connections by firmly pressing the clips on the back of the voltage regulator over the plugs.
15. For ALL models: Obtain the following items from the kit:
  • voltage regulator mount bracket (3)
  • two 1-1/4 inch (31.8 mm) long socket head cap screws (6)
  • two 1/4 inch (6.3 mm) flat washers, silver (11)
  • two 3/8 inch (9.5 mm) long button head screws (15)
  • two 1/4 inch (6.3 mm) flat washers, chrome (16)
  • two 1/2 inch (12.7 mm) long button head screws (17)
1Voltage regulator mount bracket
2Voltage regulator
3Voltage regulator wires (2007 only)
4Rear spoiler mount bracket
5Socket head cap screw (2)
6Button head screw (2)
7Flat washer, chrome (2)
Figure 3. Regulator and Rear Spoiler Bracket Installation
  1. See Figure 2. Position the voltage regulator mount bracket (5) behind the voltage regulator (3), resting the top bent tab on the top of the top spoiler bracket (1).
  2. Use the two 1/2 inch (12.7 mm) long button head screws (6) and silver flat washers (7) to loosely assemble the voltage regulator mount bracket to the top of the top spoiler bracket. Do not fully tighten at this time. See Figure 3. For 2007 models: Route the voltage regulator wires (3) between the two lower tabs of the voltage regulator mount bracket (1) and the two upper tabs of the rear spoiler mount bracket (4).
  3. For ALL models: Using the two new 1-1/4 inch (31.8 mm) long socket head cap screws (5) from the kit, assemble the voltage regulator (2) to the voltage regulator mount bracket (1) as follows:
  • For 2008 and later models: thread the screws into the two lower threaded inserts in the front regulator bracket.
  • For 2007 models: thread the screws into the two upper threaded inserts in the front regulator bracket.
Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
16. Place a chrome flat washer (7) onto the threads of the two 3/8 inch (9.5 mm) long button head screws (6). Insert the screws through the holes in the lower tabs of the front voltage regulator bracket (1), and into the threaded inserts in the upper tabs of the rear spoiler bracket (4). Tighten the screws to 5.6–9 N·m (50–80 in-lbs).
17. See Figure 5. Tighten the screws (17) attaching the top of the front voltage regulator bracket to the top of the engine mount bracket to 5.6–9 N·m (50–80 in-lbs). Tighten the four U-bolt lock nuts (10) to 2.3–4.5 N·m (20–40 in-lbs).
18. 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 new cable straps (23) from the kit.
19. Obtain the following items from the kit:
  • two shoulder screws (12)
  • two rubber washers (13)
  • two shoulder screw spacers (14)
  • one short (18) and one long (19) hanger bracket
  • two quarter-turn studs (20)
  • two nylon washers (21)
  • right- and left-side bullet spoiler rails (25 and 26)
20. Install the longer right-side frame rail hanger bracket (19) into the right-side spoiler rail (25), as shown in Figure 4. Install the shorter left-side bracket (18) into the left-side spoiler rail (26) in the same manner.
1Frame rail hanger bracket
2Insert ends into pivot holes in spoiler rail
3Quarter-turn stud
4Nylon washer
Figure 4. Quarter-Turn Stud, Nylon Washer and Hanger Installation
21. Swing open the hanger bracket on the right-side spoiler rail. Starting at the forward end, install the spoiler rail around the lower frame rail of the motorcycle, brake line and wires. Slide the spoiler rail forward, resting the front edge on top of the front spoiler, lining up the holes.
22. Place a rubber washer (13), then a shoulder screw spacer (14) onto one of the shoulder screws (12) from the kit. Insert the screw through the spoiler rail, the front bullet spoiler (24) and into the threaded inserts in the rear spoiler bracket (5). Do not fully tighten at this time.
23. Close the rail hanger over the frame, lining up with the hole near the lower edge of the spoiler rail. Install a nylon washer (21) onto a quarter-turn stud (20). Insert the stud through the hole in the spoiler rail, and rotate to grasp the hanger and secure the spoiler rail to the vehicle.
24. Install the left-side spoiler rail in a similar manner.
25. Align the spoiler sections with the frame and each other, then tighten the two screws to 1.2–1.7 N·m (10.6–15 in-lbs).
26. Secure the clutch cable to the frame down tube, away from the spoiler, using a cable strap (23). Use more than one strap if necessary to ensure the clutch cable does not contact the spoiler.
27. Refer to the Service Manual and follow the instructions given to reinstall the Maxi® Fuse.
SERVICE PARTS
Figure 5. Service Parts, Softail Bullet Front Spoiler
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Hardware kit, Softail bullet spoiler (includes items 2 through 23)
57050-08
2
  • Caddy, voltage regulator electrical
70398-07
3
  • Bracket, spoiler/regulator (front)
57048-08
4
  • Bracket, top spoiler (engine mount)
57051-08
5
  • Bracket, spoiler (rear)
57049-08
6
  • Cap screw, socket head (with washer), 1/4-20 x 1-1/4 in. (2)
4740A
7
  • U-bolt, 1/4-20 x 1 in. I.D. (2)
5228
8
  • Block, spoiler mounting (2)
58445-00
9
  • Bracket, spoiler cover (rear)
57027-07
10
  • Lock nut, 1/4-20 (4)
7686
11
  • Flat washer, silver finish (6)
6703
12
  • Shoulder screw, button head, hex socket, 1/4-20 (4)
CA0018.02A8
13
  • Washer, rubber (4)
6585
14
  • Spacer, shoulder screw (2)
6598
15
  • Screw, button head, hex socket, 1/4-20 x 3/8 in. (2)
3652
16
  • Flat washer, chrome (2)
6436
17
  • Screw, button head, hex socket, 1/4-20 x 1/2 in. (2)
4365
18
  • Hanger bracket, frame rail (left, short)
49929-03A
19
  • Hanger bracket, frame rail (right, long)
49903-03A
20
  • Stud, quarter-turn (2)
91285-03
21
  • Washer, nylon (2)
6425
22
  • Cable strap, anchored ("fir tree" type) (2)
10177
23
  • Cable strap (6)
10006
24
Bullet spoiler (front), Softail (painted, for kits 57039-xxx)
Bullet spoiler (front), Softail (chrome, for kit 57006-08)
57045-xxx
57013-08
25
Rail, bullet spoiler (right) (painted, for kits 57039-xxx)
Rail, bullet spoiler (right) (chrome, for kit 57006-08)
Not sold separately
Not sold separately
26
Rail, bullet spoiler (left) (painted, for kits 57039-xxx)
Rail, bullet spoiler (left) (chrome, for kit 57006-08)
Not sold separately
Not sold separately
Items mentioned in text, but not included in kit:
A
Original equipment voltage regulator bracket mounting bolts to engine crankcase (2)
B
Original equipment voltage regulator
C
Cable strap slot in voltage regulator electrical caddy (2, not visible in this view)
D
Cable strap slot in rear spoiler bracket (2)