Fit Shop Bike Conversion Kit - Certain Sportster Models
J053462011-02-11
GENERAL
The Fit Shop Bike Conversion Kit converts certain Sportster model motorcycle into the Fit Shop Bike; an interactive dealer tool to aid customers in picking out accessories that will best suit their riding styles. The Fit Shop Bike Conversion Kit also allows the motorcycle to be converted back into a stock motorcycle when all OEM parts are installed according to service manual procedures.
Models
This Fit Shop Bike Conversion Kit is designed for certain 2004-2011 Sportster motorcycles. Consult www.h-dnet.com for actual fitments.
Kit Contents
Figure 1. Fit Shop Bike Kit Contents
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Grip clamps with fasteners (10) | Not Sold Separately |
2 | Handlebar adapter (10) | Not Sold Separately |
3 | Seat pin (2) | Not Sold Separately |
4 | Center post label | Not Sold Separately |
5 | Nut: 5/16-18 | Not Sold Separately |
6 | Seat retainer fender nut (1) | Not Sold Separately |
7 | Cable strap | Not Sold Separately |
8 | Thumb screw nut | Not Sold Separately |
9 | Footrest kit | Not Sold Separately |
10 | Protective tape (3) | Not Sold Separately |
HANDLEBAR AND SEAT
NOTE
Retain all parts removed from motorcycle and mark box with motorcycle VIN number to verify parts will be available to return motorcycle to stock condition.
| 1. | Remove seat. | |
| 2. | Remove battery. | |
| 3. | Cover fuel tank and front fender to protect finish. | |
 WARNINGGasoline can drain from the fuel line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00260a) | ||
| 4. | Drain fuel and remove fuel tank according to service manual procedure. | |
| 5. | Remove air cleaner assembly according to service manual procedure. | |
| 6. | Remove cable straps near steering neck of frame that secure wires. | |
| 7. | Disconnect handlebar wire harnesses at main harness connection points. | |
| 8. | Remove throttle cables from throttle body per service manual procedure. | |
| 9. | Remove clutch lever from handlebar and disconnect clutch cable from lever according to service manual procedure. | |
| 10. | Disconnect front brake line from secured points on front fork and triple clamp. | |
| 11. | Disconnect front brake caliper from front fork to allow complete front brake system removal with the handlebars. | |
| 12. | Remove headlamp visor according to service manual procedure. | |
| 13. | See Figure 2. Remove handlebar riser mounting bolts and with the help of an assistant, remove complete handlebar assembly containing complete front brake system, throttle cables, control and mirror assemblies from motorcycle. |  Figure 2. Handlebar and Components |
| 14. | See Figure 3. Position clutch cable along left side of frame backbone, inside of frame caddy. Secure cable with cable ties. |  Figure 3. Route Clutch Cable |
| 15. | Remove OEM brake rod assembly. | |
| 16. | Remove right side footpeg and brake lever assembly. | |
| 17. | Remove brake pedal and bushing from footpeg assembly. | |
| 18. | Remove frame plugs for installation of Fit Shop footrest assemblies. Retain frame plugs. | |
| 19. | See Figure 4. Install right side footpeg to motorcycle, minus brake pedal. NOTE Certain Sportster models are equipped with forward-mounted footpegs and others are equipped with mid-mounted footpegs. Depending on model being used for this conversion, it will be necessary to install either forward or mid-mounted footpegs. |  Figure 4. Mid-Mount Footrest |
| 20. | Install second set of footpegs (forward or mid-mount), minus controls. Tighten brackets according to service manual specifications. | |
| 21. | Install fuel tank according to service manual procedure. | |
| 22. | Install air cleaner assembly according to service manual procedure. | |
| 23. | Install supplied warning tags and install desired seat. |
Handlebar and Riser Preparation
| 1. | Remove all factory components from handlebar assembly and store items. | |
| 2. | Install handlebar adapters (2) (provided in kit) onto handlebar riser. Tighten adapters as much as possible by hand. DO NOT use tools to tighten. | |
| 3. | Install clamp and riser to handlebar. Adjust handlebars and tighten. | |
| 4. | Install handlebar assembly into upper fork bracket. | |
| 5. | Adjust handlebar as necessary, first loosening clamp and riser. | |
| 6. | Install desired hand grips with clamps and fasteners (1). Tighten grip clamp fasteners to 2.8–3.4 N·m (25–30 in-lbs). | |
| 7. | Assemble remaining handlebars with Fit Shop components. |
Seat and Rear Fender
NOTE
When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs.
| 1. | See Figure 5. Remove seat post. |  Figure 5. Seat Post |
| 2. | Install yellow tag with screw from kit in place of seat post and finger tighten. | |
| 3. | See Figure 6. If motorcycle was originally equipped with a solo seat: Remove plug from rearmost hole in rear fender and install seat retainer nut using cable strap as shown by installing retention nut on cable strap and inserting cable strap through hole in fender. Lock retention nut in fender using clip. | |
| 4. | Install seat pin in rear most hole in rear fender. | |
| 5. | If motorcycle was originally equipped with a two-up seat: Remove plug from front hole in rear fender and install seat retainer nut using cable strap as shown by installing retention nut on cable strap and inserting cable strap through hole in fender. Lock retention nut in fender using clip... |  Figure 6. Retention Nut and Clip Installation with Cable Strap |
| 6. | See Figure 1.When mounting solo seat configurations, use thumb screw nut (8). Two-up seat configurations will use seat pin. | |
| 7. | Save all original equipment parts to be used when converting motorcycle back for street use. |
Return Motorcycle to Service
| 1. | Cover fuel tank and front fender to protect finish. | |
| 2. | Remove fit shop seat and seat pin from motorcycle. | |
| 3. | Remove fit shop handlebar assembly from riser. | |
| 4. | Remove Fit Shop accessories from OEM handlebar. | |
| WARNING Gasoline can drain from the fuel line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00260a) | ||
| 5. | Remove fuel tank according to service manual procedure. | |
| 6. | Remove air cleaner assembly. | |
| 7. | Remove clutch cable from tucked position on frame backbone. | |
| 8. | Install handlebar bushings and spacers in upper fork bracket according to service manual procedure. | |
| 9. | Install factory handlebar assembly to upper fork bracket according to service manual procedure. | |
| 10. | Install switch housings and hand grips to handlebar according to service manual procedure. | |
| 11. | Connect turn signals and both left side and right side control connections and main wiring harness. | |
| 12. | Install throttle and throttle cables per service manual procedure. | |
| 13. | Install complete front brake system to motorcycle according to service manual. | |
| 14. | Remove Fit Shop footrest assemblies and install factory frame plugs. | |
| 15. | Install air cleaner assembly according to service manual procedure. | |
| 16. | Install clutch bracket to handlebar, install and adjust clutch cable according to service manual procedure. | |
| 17. | Install fuel tank according to service manual procedure. | |
| 18. | Install wiring according to service manual procedure. | |
| 19. | Install headlamp visor according to service manual procedure. | |
| 20. | Install battery according to service manual. | |
| 21. | Install brake rod and adjust according to service manual. | |
| 22. | Remove screw and tag from seatpost location and install seatpost according to service manual procedure. Tighten seatpost to 2.3–4.5 N·m (20–40 in-lbs) | |
| 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) | ||
| 23. | Install seat. | |
| WARNING Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) WARNINGAfter repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) WARNINGBe sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
| 24. | Verify all fastener torques of equipment installed and operation of all lights, controls and brakes before placing motorcycle into service. |