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TRIKE REPLACEMENT BODY (MIDSECTION) KITS
J052272010-12-22
GENERAL
Kit Numbers
83000001CPC, 83000001CWA, 83000001CYS, 83000001DCK, 83000001DH, 83000001DJF, 83000001GY, 83000001QH, 83000002CYS, 83000002DH
Models
These kits fit 2009-2010 FLHTCUTG and FLHXXX models.
Additional Parts and Supplies Required
If studs, nuts and washers are used to attach the current rear fenders to the body, an appropriate Trike Replacement Rear Fender Kit (see Table 4 , Item K) will be required.
If TORX head screws, nuts and washers are used to attach the current rear fenders to the body, those fenders can be used with the new body.
If the original trunk lock mechanism U-clip is bent or damaged, obtain a new U-clip (Part No. 53868-06) for installation.
Loctite® 243 Threadlocker and Sealant - Blue (Part No. 99642-97), Electrical Contact Lube (Part No. 99861-02) or equivalent, and Harley® Lube (Part No. 94968-09) or equivalent are required for the proper installation of this kit.
These items are available from a Harley-Davidson dealer.
The help of an assistant will be needed for portions of the disassembly and assembly procedures.
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 refers to service manual information. A service manual for this year/model Trike is required for removal procedures. A service manual for 2011 model year Trikes is required for installation procedures.
  • It is strongly recommended that a Harley-Davidson dealer perform this installation.
Kit Contents
Each kit consists of a painted body (midsection) , trunk door , right and left side covers, and attaching parts to replace many of the original equipment (OE) components on 2009 and 2010 FLHTCUTG and FLHXXX model Trikes.
Some original items will be used with the replacement body. Retain ALL removed items and attaching parts for assembly to the new body unless instructed otherwise.
See Figure 1 , Table 1 , Table 2 , Table 3 and Table 4.
PREPARATION
NOTE
For vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
  1. Refer to the service manual and follow the instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
  2. Pull the left-side and right-side covers to remove. The side covers can be discarded.
BODY (MIDSECTION) REMOVAL
NOTE
Retain ALL removed items and attaching parts for assembly to the new body unless instructed otherwise.
  1. Open the vehicle trunk and Tour-Pak® (if equipped) and remove any items inside. Remove the trunk liners or mat.
  2. Unplug the electrical, sound system and antenna connectors per service manual instructions.
  3. Remove any previously installed Genuine Motor Parts or Accessories (or those from other sources) that are to be transferred to the new body per the instructions supplied with those items.
  4. Follow service manual instructions to remove the fasteners retaining the body to the rear and intermediate frames.
  5. With the help of an assistant, lift the body from the rear frame and set aside for disassembly.
Disassembly
  1. For models WITH Tour-Pak: Remove the Tour-Pak and rack from the body per service manual instructions. For models WITHOUT Tour-Pak: Remove the trim strips and gaskets from the body. Inspect the gaskets and rubber washers, and replace if damaged (gasket Part No. 8342, rubber washer Part No. 61121-04, purchased separately). Remove the antenna from the body side per service manual instructions. Inspect the gasket and replace if damaged (Part No. 8344, purchased separately).
    2. NOTE
    For ALL models: Make note of wire routings and mounting locations before removing the rear lighting harness from the original body and rear fenders.
  2. Follow the body disassembly instructions in the service manual to remove any items applicable to the specific vehicle with the following exceptions:
    1. If studs, nuts and washers are used to attach the current rear fenders to the body, removal of the rear fenders will not be necessary. If TORX head screws, nuts and washers are used to attach the current rear fenders to the body, remove the fenders for installation on the new body.
    2. For ALL applications: The trunk door seal does not need to be removed from the body.
INSTALLATION
Body (Midsection) Assembly
NOTE
Clean all residual threadlocking agent from original fasteners if being reused, and apply Loctite 243 - Blue before use in the new assembly.
  1. See Figure 1. Install the fenders to the new body per the instructions in the Rear Fender Kit (K) with the following exception:
  • If installing new fenders: DO NOT install the reflectors at this time.
1. Install the original rear lighting harness onto the new body and rear fenders following the wire routings and mounting notes made earlier and the instructions in the service manual.
2. Follow service manual instructions to install the tail lamps to the fenders.
3. For models WITH Tour-Pak:For models WITHOUT Tour-Pak:
a. Install the rack and Tour-Pak to the body per the instructions in the service manual.
b. Secure one end of the original ground strap (J) to the stud on the underside of the Tour-Pak mount reinforcement with a new hex locknut (22) from the kit and an original plain washer (I). Tighten the locknut to 10.8–13.5 N·m (96–120 in-lbs).
c. Install the trim strips to the top of the body per service manual instructions, using saved or new rubber washers and gaskets.
d. Install the antenna to the side of the body per service manual instructions, using the saved or new gasket.
e. Secure the ground wire to the antenna base per service manual instructions.
4. ALL models: With the help of an assistant, follow service manual instructions to set the new body onto the rear frame.
5. Connect the tail lamp harnesses per service manual instructions.
6. Feed the license lamp branch of the harness (and antenna lead on FLHXXX models) into the trunk and install the original grommet at the trunk wiring hole.
7. For models WITHOUT Tour-Pak: Place the original ground plate (G) in the trunk
8. ALL models: Initially secure the body to the rear and intermediate frame sections following the sequence shown in the service manual, using the fasteners listed below. DO NOT fully tighten at this time.
  • Models WITH Tour-Pak:Floor (inside), four screws (24) and washers (25) from the kit. Left front wall (inside), original ground stud (H) and washer (25) from the kit. Right front wall (inside), screw (21) and washer (25) from the kit. Lower front flange (outside), screw (48) and washer (23) from the kit.
  • Models WITHOUT Tour-Pak:
  • Floor (inside), four screws (24) and washers (25) from the kit. Front wall (inside), two screws (21) and washers (25) from the kit. Lower front flange (outside), screw (48) and washer (23) from the kit.
9. ALL models: Tighten all fasteners per service manual specifications.
10. For models WITH Tour-Pak: Install a plain washer (16) from the kit onto the ground stud (H). Secure the loose end of the ground strap (J) to the ground stud with a new hex locknut (22) and plain washer (16) from the kit. Tighten the locknut to 19–23 N·m (14–17 ft-lbs)For models WITHOUT Tour-Pak: Secure the AM-FM antenna ground wire to the ground plate with the original truss head screw. Tighten the screw to 2.3–4.5 N·m (20–40 in-lbs). Install the mast and attach the antenna cable.
Trunk Latch and Lockset Assembly
NOTE
If the U-clip (F) from the original trunk lock assembly (E) is bent or damaged, obtain a new U-clip (Part No. 53868-06) from a Harley-Davidson dealer.
  1. See Figure 1. Examine the foam trunk lockset sealing washer (9) at the lock opening on the body, and replace if damaged. Follow service manual instructions to install the new latch assembly (26) to the body, with the following exceptions:
    1. Position the new O-ring (39) from the kit around the lock opening in the latch assembly housing.
    2. Install the latch housing assembly with four new TORX® screws (38).
    3. Install the new latch cover (30) with two new flat head screws (37).
  2. Install the original trunk lockset through the body and into the lock mechanism (27) in the latch housing assembly.
Trunk Door Assembly
  1. See Figure 1. Use two new nuts (47), and the original washers (C) and O-rings to assemble the original license plate lamp to the new trunk door assembly (11) per service manual instructions.
  2. Assemble the original license plate bracket to the trunk door assembly with three original screws per service manual instructions. Install the license plate (if equipped).
  3. Loosely install the new latch pin assembly (43) to the trunk door using three TORX screws (38).
  4. Follow service manual instructions to install the left (A) and right (B) trunk door hinges to the door with the six original flat head screws (D).
  5. Examine the trunk door seal (8) around the door opening, and replace if damaged.
    6. NOTE
    If a Trunk Interior Light Kit (Part No. 83946-11) is being installed, refer to the instructions in that kit for installation of components to the trunk door hinge.
  6. Use new lock nuts (47) and original washers (C) to fasten the trunk door hinges to the stud plates on the body. Lubricate the hinges with Harley® Lube (Part No. 94968-09) or equivalent.
  7. Connect the license plate lamp connector, and capture the rear lighting harness under the retainer clips.
  8. Follow service manual instructions to install one end of each lanyard (41) to the tabs on each side of the trunk opening, using the shoulder bolts (42) from the kit.
    9. NOTE
    Give the lanyards a 180 degree twist toward the trunk opening before installing the second bolt.
  9. Install the other ends of the lanyards to the trunk door with the remaining shoulder bolts from the kit.
  10. Adjust the trunk door latch pin per service manual instructions.
  11. Install the trunk door inner cover (40) with four TORX screws (38) per service manual instructions.
Side Covers
See Figure 1. Remove the original side cover attaching hardware and install the new side covers per the instructions in the Side Cover Kit (17).
Final Assembly
  1. See Figure 1. Install the new vertical and bottom trunk liners (Items 19 and 20, FLHTCUTG) or original trunk mat (FLHXXX).
  2. Plug in the remaining electrical connections, sound system connections and antenna connectors per service manual instructions.
  3. Follow the body assembly instructions in the service manual to install any other items applicable to the specific vehicle.
  4. Install any Genuine Motor Parts or Accessories (or those from other sources) that are being transferred from the original body per the instructions supplied with those items.
  5. For new fenders, install the reflectors per the instructions in the fender kit.
RETURN TO SERVICE
NOTE
Verify that the ignition key switch is in the OFF position before attaching the negative battery cable.
1. Refer to the service manual and follow the instructions to attach the negative battery cable. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
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)
2. Refer to the service manual, and follow instructions to install the seat.
SERVICE PARTS
Figure 1. Service Parts, Trike Replacement Body Kits
SERVICE PARTS
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 83000001CPC
Dark Blue Pearl.
FLHTCUTG models.
1
Body assembly, Dark Blue Pearl (includes Items 2-10)
83318-11CPC
11
Trunk door assembly, Dark Blue Pearl (includes Items 12-15)
83341-11CPC
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Dark Blue Pearl
57200005CPC
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001CWA
Flame Blue Pearl.
FLHTCUTG models.
1
Body assembly, Flame Blue Pearl (includes Items 2-10)
83318-11CWA
11
Trunk door assembly, Flame Blue Pearl (includes Items 12-15)
83341-11CWA
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Flame Blue Pearl
57200005CWA
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001CYS
Red Hot Sunglo (2010).
FLHTCUTG models.
1
Body assembly, Red Hot Sunglo (2010) (includes Items 2-10)
83318-11CYS
11
Trunk door assembly, Red Hot Sunglo (2010) (includes Items 12-15)
83341-11CYS
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Red Hot Sunglo (2010)
57200005CYS
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001DCK
Flame Blue Pearl/
Bright Silver Pearl.
FLHTCUTG models.
1
Body assembly, Flame Blue Pearl (includes Items 2-10)
83318-11CWA
11
Trunk door assembly, Flame Blue Pearl (includes Items 12-15)
83341-11CWA
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Flame Blue Pearl
57200005CWA
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001DH
Vivid Black.
FLHTCUTG models.
1
Body assembly, Vivid Black (includes Items 2-10)
83318-11DH
11
Trunk door assembly, Vivid Black (includes Items 12-15)
83341-11DH
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Vivid Black
57200005DH
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001DJF
Red Hot Sunglo (2009).
FLHTCUTG models.
1
Body assembly, Red Hot Sunglo (2009) (includes Items 2-10)
83318-11DJF
11
Trunk door assembly, Red Hot Sunglo (2009) (includes Items 12-15)
83341-11DJF
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Red Hot Sunglo (2009)
57200005DJF
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001GY
Arctic White.
FLHTCUTG models.
1
Body assembly, Arctic White (includes Items 2-10)
83318-11GY
11
Trunk door assembly, Arctic White (includes Items 12-15)
83341-11GY
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Arctic White
57200005GY
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000001QH
Concord Purple.
FLHTCUTG models.
1
Body assembly, Concord Purple (includes Items 2-10)
83318-11QH
11
Trunk door assembly, Concord Purple (includes Items 12-15)
83341-11QH
16
Plain washer, 5/16 (2)
6702
17
Side cover kit, Concord Purple
57200005QH
18
Trunk liner kit (includes Items 19 and 20)
83447-11
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch
3445
22
Hex locknut, 5/16-18, with nylon insert (2)
7739
Kit 83000002CYS
Red Hot Sunglo (2010).
FLHXXX models.
1
Body assembly, Red Hot Sunglo (2010) (includes Items 2-10)
83530-11CYS
11
Trunk door assembly, Red Hot Sunglo (2010) (includes Items 12-15)
83341-11CYS
17
Side cover kit, Red Hot Sunglo (2010)
57200005CYS
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch (2)
3445
Kit 83000002DH
Vivid Black.
FLHXXX models.
1
Body assembly, Vivid Black (includes Items 2-10)
83530-11DH
11
Trunk door assembly, Vivid Black (includes Items 12-15)
83341-11DH
17
Side cover kit, Vivid Black
57200005DH
21
Screw, hex head, 5/16-18 x 19 mm (0.75 in), with lock patch (2)
3445
Table 2. Service Parts (Continued)
Kit
Item
Description (Quantity)
Part Number
Item 1, Body Assembly;
Available components:
2
Insert, spacer, flanged ("top hat") (2)
83798-11
3
Insert, press-in, 1/4-20 (4)
83782-11
4
Insert, "top hat", press-in, 1/4-20 (2)
83778-11
5
Insert, press-in, 5/16-18 (12)
83777-11
6
Clip, adhesive-back, small (17 used on FLHTCUTG, 22 on FLHXXX)
10102
7
Clip, adhesive-back, large (3)
10103
8
Seal, trunk door (cut to fit)
83991-11
9
Sealing washer, trunk lock
12300002
10
Foam tape (4)
83811-09
Item 11, Trunk Door
Assembly; Available
components:
12
Insert, molded-in, 1/4-20 (13)
83780-11
13
Insert, "top hat", press-in, 1/4-20 (2)
83778-11
14
Insert, blind "top hat", press-in, 1/4-20 (3)
83783-11
15
Clip, adhesive-back, small (2)
10102
Item 18, Trunk Liner
Kit components:
19
Trunk liner, vertical
83457-11
20
Trunk liner, bottom
83458-11
SERVICE PARTS
Table 3. Service Parts (Continued)
Kit
Item
Description (Quantity)
Part Number
Items common
to ALL kits.
23
Washer (2)
6116
24
Screw, hex head, 5/16-18 x 38 mm (1.5 in), with lock patch (4)
8369
25
Flat washer, 25.4 mm (1.0 in) OD (6)
6645
26
Latch housing assembly, trunk door (includes Items 27-36)
83346-11
27
  • Lock mechanism
83352-11
28
  • Screw, lock mechanism (2)
8366
29
  • Nut, lock mechanism (2)
8364
30
  • Latch cover
83296-11
31
  • Latch lever kit (includes Items 32-36)
53000077
32
  • ..... Screw, latch lever (3)
8365
33
  • ..... Cam latch
Not sold separately
34
  • ..... Latch retainer plate
Not sold separately
35
  • ..... Retention spring
Not sold separately
36
  • ..... Release link
Not sold separately
37
Screw, hex socket flat head, #10-24 x 25.4 mm (1.0 in) (2)
4239
38
Screw, TORX button head, with washer, 1/4-20 x 13 mm (0.5 in)
  • Trunk latch housing to body (4)
  • Trunk latch pin assembly to trunk door (3)
  • Trunk door inner cover to trunk door (4)
10200004
39
O-ring, trunk lock
8367
40
Cover, trunk door inner (includes label 83446-09)
83434-11
41
Lanyard, trunk door (2)
83344-11
42
Shoulder bolt, 1/4-20 x 11 mm (0.438 in) (4)
8359
43
Latch pin assembly (includes Items 44-46)
83538-11
44
  • Latch pin
83781-11
45
  • Bracket, latch pin
Not sold separately
46
  • Hex jam nut
7763W
47
Nut, Nylok, 1/4-20 (6)
7686
48
Screw, hex socket head, with lock patch (2)
5/16-18 x 25.4 mm (1.0 in) long
2708A
SERVICE PARTS
Table 4. Service Parts (Continued)
Kit
Item
Description (Quantity)
Part Number
Items mentioned
in text, but
not included
in kits.
A
Original left-hand trunk door hinge
B
Original right-hand trunk door hinge
C
Original plain washers (6)
D
Original Phillips flat head screws, 1/4-20 x 12.7 mm (0.5 in) long> (6)
E
Original trunk lockset assembly
F
Original trunk lock U-clip
G
Original antenna ground plate (FLHXXX models only)
H
Original ground stud (FLHTCUTG models only)
I
Original plain washer (FLHTCUTG models only)
J
Original ground strap (FLHTCUTG models only)
K
Trike Replacement Rear Fender Kit:
  • Dark Blue Pearl with pinstripe
  • Flame Blue Pearl with pinstripe
  • Red Hot Sunglo (2010) with pinstripe
  • Flame Blue Pearl/Bright Silver Pearl, with pinstripe
  • Vivid Black with pinstripe
  • Red Hot Sunglo (2009) with pinstripe
  • Arctic White with pinstripe
  • Concord Purple with pinstripe
  • Red Hot Sunglo (2010), no pinstripe
  • Vivid Black, no pinstripe
Part Number:
59500033CPS
59500033CWB
59500033CYT
59500033DCK
59500033BHY
59500033DJG
59500033CCP
59500033CZ
59500033CYS
59500033DH