CVO STYLE REAR FENDER KITS

J059142022-03-10

GENERAL

Kit Numbers

59500245A, 59500246A, 59500470

Models

For up to date certified model fitment information, see the Parts and Accessories section of www.harley-davidson.com (English only).

Installation Requirements

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 motorcycle is required for this installation. One is available from a Harley-Davidson dealer.

A wallpaper seam roller is required for proper installation of the lighting harness in this kit.
The help of an assistant aids in the removal and placement of the fender.

These items are available at your local Harley-Davidson dealership.

Kit 59500246A: Separate purchase of LED Stop/Tail/Turn Assembly Kit (Part No. 67801090) is required.

Kit Contents

See Figure 5 and Table 1.

PREPARATION

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

NOTE

Vehicles WITH security siren: With security fob present, turn ignition switch ON. Disarm security system. IMMEDIATELY remove the main fuse per the service manual.
Vehicles WITHOUT security siren: See the service manual to remove the main fuse.

Remove saddlebags. See service manual.
Remove left and right side covers. See service manual.
Remove seat. Retain seat and all mounting hardware. See service manual.
Remove license plate (if installed). Set aside for later installation. License plate bracket and reflector can remain on the fender.
See service manual to remove and save the following items if present:

Tour-Pak^® luggage rack or Tour-Pak support,
Rider backrest,
Passenger backrest,
Grab rail, reinforcement plate and fasteners.

Release air pressure in rear suspension. See service manual.
Disconnect right side shock absorber hose at one end.

FENDER REMOVAL

NOTE

The help of an assistant aids in the removal of the fender.

1.	See service manual to remove rear fender from vehicle, with the following exception: a. Tail lamp assembly, turn signal bar, rear fender tip lamp, rear lighting harness (and when present, rear fascia and rear fascia lamp) can remain on fender.
2.	Figure 1 Remove following items from Original Equipment (OE) fender (1). Set aside for later installation to new fender: a. Stud plate (2), two nuts (3) and two washers (4) at front of fender. b. Saddlebag to fender support bracket (5), two screws (6) and two locknuts (7) at rear of fender. c. Saddlebag supports (12).

1	OE rear fender
2	Stud plate
3	Nut (2)
4	Washer (2)
5	Saddlebag to fender support bracket
6	Screw (2)
7	Locknut (2)
8	Screw (4)
9	Nut (4)
10	Fender mounting washer (4)
11	Fender inner mounting boss (4)
12	Saddlebag support

Figure 1. Remove Rear Fender Items

FENDER ASSEMBLY

NOTE

Finish paint the rear fender, fascia and license plate light cover before assembly.

1	Rear fender
2	Stud plate
3	Nut (2)
4	Washer (2)
5	Rear harness
6	Black two-way pin housing
7	Black six-way socket housing
8	Version with center tail lamp
9	Wire hole in front of fender
10	Conduit end 2.5 in (64 mm) from hole
11	Conduit 1.5 in (38 mm) minimum from fender centerline

Figure 2. Install Rear Fender Harness

Harness Installation

NOTE

Ambient temperature must be at least 16 °C (60 °F) for proper adhesion of harness conduit to fender.
Allow AT LEAST 24 hours after applying harness before exposing area to strong water spray or extreme weather.
Adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.

1.	Figure 2 Clean fender (1) underside along harness mounting path as shown with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely. Do not use solvents or harsh chemicals that damage painted surfaces. NOTE The two branches of rear lighting harness without adhesive conduit remain outside the fender.
2.	Get stud plate (2) removed from OE fender.
3.	Position plate to inside front of fender with channel positioned nearest wire hole.
4.	Loosely assemble plate to fender with the OE nuts (3) and washers (4). Do not fully tighten.
5.	Install rear harness (5) to underside of fender: a. Feed main body of harness (with adhesive conduit), from outside, through hole (9) in front of fender. b. Lay harness along length of fender. c. Position forward end of adhesive conduit about 64 mm (2 ½ in) from wire entry hole. d. Lay conduit a minimum of 38 mm (1 ½ in) from centerline of fender. e. Mark position of conduit on fender. f. Beginning at rear, pull tab on harness conduit to expose adhesive while pressing conduit into place along length of fender. g. Use a wallpaper seam roller to press conduit securely in place. h. At the front, capture wire harness under stud plate channel. i. Tighten stud plate nuts. Torque: 6.8–10.9 N·m (60–96 in-lbs) Hex nut

NOTE

Proceed with assembly and installation of fender, but do NOT pull or reposition adhesive conduit.
Allow adhesive 72 hours to cure fully.

1	License plate bracket
2	License lamp
3	License lamp wires
4	License lamp cover
5	Screw, 1/4-20 x 0.75 in (19 mm) long (4)
6	Gasket, license plate bracket
7	Reflector and bracket assembly
8	Washer (2)
9	Rear fender
10	Wire hole in rear fender
11	Stud plate
12	Foam tape pad (2)
13	Screw, 1/4-20 x 0.75 in (19 mm) long (2)
14	Two-way socket housing
15	Secondary lock
16	License lamp connector cover
17	Flange nut, 1/4-20
18	Tab (remove if present)

Figure 3. License-Plate Lamp and Bracket Installation

License Lamp Installation

NOTE

Some license lamps have a tab (see Figure 3 inset, Item 18) that prevents installation. Remove tab before proceeding.

1.	Figure 3 Assemble license lamp (2) and cover (4) to license plate bracket (1).
2.	Tighten screws (5). Torque: 6.4–7.8 N·m (57–69 in-lbs) Hex socket head screw
3.	Get stud plate (11) and two foam tape pads (12) from kit.
4.	Remove liner from adhesive backing on one side of one pad.
5.	Carefully position pad to a flange of stud plate, on side opposite of nuts, and press firmly into place.
6.	Repeat with second pad on remaining flange.
7.	Remove liner from exposed side of pads.
8.	Feed lamp wires (3) through license bracket (1) and hole (10) in fender (9).
9.	Hold stud plate (11) in place on underside of fender.
10.	Secure license plate bracket (1) to stud plate with washers (8) and screws (5).
11.	Tighten screws securely.
12.	Insert license lamp wires into two-way socket housing (14). See service manual.
13.	Secure with secondary lock (15).
14.	Plug two-way pin housing on rear harness into license lamp socket [45B].
15.	Install license lamp connector cover (16).
16.	Secure with a flange nut (17). Tighten. Torque: 3.4–5.1 N·m (30–45 in-lbs) Hex flange nut
17.	Secure wire harness with clip on inside of fender.
18.	Install to reflector and bracket assembly (7) as shown.

Center Stop/Tail Lamp Installation (If Equipped)

Install new center stop/tail lamp from kit (59500245A). See service manual.

Rear Fascia Installation

1.	Figure 1 Install a new fender mounting boss (11), from inside, through one of four holes in sides of fender.
2.	Place a washer (10) onto threads of boss and fasten with a nut (9). Tighten. Torque: 20.3–27.1 N·m (15–20 ft-lbs) Hex nut
3.	Repeat for remaining three holes.
4.	Figure 4 Remove liner from adhesive backing of 44.5 x 19 x 1.6 mm (x in) rubber pad (2).
5.	Position pad to center of fascia (1), just below the slot as shown, and press firmly into place.
6.	Position fascia under rear edge of fender.
7.	Align three holes on each side of fascia with mating holes in the fender.
8.	Insert three studs of a stud plate (3), from beneath fender, through fender holes and fascia on one side.
9.	Install a fascia support bracket (stiffener plate, 4) over studs.
10.	Loosely install three flange nuts (5) onto stud threads. NOTE U.S. models only: Fascia-mounted LED lamps are identical. International models: Fascia-mounted LED lamps are side-specific. Label on back of left side lamp is marked "LEFT". Right side lamp is marked "RIGHT". Remove blue film from lens faces before lamps are installed in fascia.
11.	Loosely fasten other side of fascia with remaining stud plate, support bracket and flange nuts.
12.	Alternately tighten each flange nut. Torque: 3.4–5.1 N·m (30–45 in-lbs) Hex flange nut
13.	Install a rear fascia lamp (6) into correct-side opening in fascia from behind.
14.	Fasten with three black #10 TORX^® screws (7).
15.	Alternately tighten each screw. Torque: 1.6–2.1 N·m (14–18 in-lbs) TORX pan head screw
16.	Repeat for remaining fascia lamp.

1	Rear fascia
2	Rubber pad
3	Stud plate (2)
4	Fascia support bracket (2)
5	Flange nut, 1/4-20 (6)
6	Rear lamp assembly (left shown)
7	Screw, #10 x 0.5 in (12.7 mm) long (6)

Figure 4. Rear Fascia Installation

Antenna Relocation on FLHX and FLHTRX Models

1.	Figure 5 Disconnect antenna cable from antenna base assembly.
2.	Unscrew antenna mast from antenna base.
3.	Remove lower locknut.
4.	Remove antenna base from mounting bracket.
5.	Remove two screws and lockwashers retaining the antenna mounting bracket.
6.	Remove and discard any cable straps securing antenna cable to fender support and saddlebag rear support brackets.
7.	Figure 5 Position new antenna bracket (30) near fender supports and fasten bracket to fender supports: a. Assemble thin washer (37) to screw threads. b. Install screws (36) and washers (37) through antenna bracket from rear. c. Figure 5 Slide spacers (34 and 35) onto threads that are extending through bracket. Note spacer lengths. d. Align and fasten this bracket and fastener assembly to fender support. Tighten. Torque: 20.3–27.1 N·m (15–20 ft-lbs) Fastener assembly
8.	Install tooth lockwasher (32) from kit onto larger threads of antenna base (31) under hex nut (33).
9.	Insert antenna base through hole in antenna mounting bracket.
10.	Install second hex nut (33) onto threads of antenna base.
11.	Place a wrench on upper nut and tighten lower nut. Torque: 8 N·m (6 ft-lbs) Lower nut
12.	Plug antenna cable connector into antenna base.
13.	Tighten knurled nut to secure connector to antenna base.
14.	Allow slack in cable at antenna base to avoid kinking or binding at connection.
15.	Fasten antenna cable to fender support bar with a cable strap.
16.	Use a second cable strap to tie antenna cable (FLHX models, excess rear fascia lamp wires) to frame rail, near suspension air lines, underneath painted cover.
17.	DO NOT tie cable to air lines.
18.	Thread antenna mast assembly securely onto antenna base (31).

FENDER INSTALLATION

NOTE

The help of an assistant aids in the placement of the fender onto the motorcycle.
Protect lower edges of fascia beneath tail lamps with tape to prevent mufflers damaging the paint during fender installation.

1.	Carefully roll forward the new fender into position between rear frame rails.
2.	Figure 5 Get four 5/16-18 x 25.4 mm (1 in) long fender mounting screws (5) from kit.
3.	Loosely install a screw through rear frame rail into rearmost fender mounting boss on each side.
4.	Align front mounting holes.
5.	Loosely install remaining screws through frame rails into forward fender mounting boss on each side.
6.	Get two 5/16-18 x 25.4 mm (1 in) long fender mounting screws and flanged locknuts saved earlier.
7.	Install screws, from the front, through saddlebag support lower rear mounting holes and saddlebag to fender support bracket.
8.	Loosely install flanged locknuts onto screw threads. NOTE FLHX Models: The electrical caddy must be loosened to allow the harness connector to fit through.
9.	Route harness leg with gray four-way connector between front of fender and left side fender support.
10.	Plug connector [18] into left side fascia lamp.
11.	Route harness leg with black four-way connector between front of fender and right side fender support.
12.	Plug connector [19] into right side fascia lamp.
13.	Alternately tighten four fender mounting screws. Torque: 20.3–27.1 N·m (15–20 ft-lbs) TORX pan head screw
14.	Install rear shock absorber air hose to air valve assembly on left side.
15.	Figure 1 Install saddlebag supports (12).
16.	Loosely install passenger grab strap.
17.	Figure 5 Use a clip (7) from kit to fasten a harness leg to clip slot on underside of each saddlebag support.

COMPLETION

NOTE

To prevent possible damage to sound system, verify that ignition switch is OFF before installing main fuse.

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

1.	Install main fuse. See service manual.
2.	Verify that all lights are working properly before putting the vehicle in service.

SERVICE PARTS

Figure 5. Service Parts, FL Touring CVO-Style Rear Fender Kits

SERVICE PARTS

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	Fender, rear (Prime paint, no center tail lamp opening) (kit 59500246A) Fender, rear (Prime paint, with center tail lamp opening) (kit 59500245A)	60463-09A 60472-09A
2	Boss, fender mounting (4)	59786-01
3	Washer, fender mounting (4)	59788-01
4	Hex nut, 1/2-13 (4)	7880
5	Screw, pan head TORX, self-tapping, 5/16-18 x 25.4 mm (1 in) long (4)	3684
6	Cushion, saddlebag support (2)	11100068
7	Clip (6) (kit 59500246A) Clip (2) (kits 59500245A, 59500470)	69200313
8	Spacer, rubber, adhesive-backed, 44.5 x 19 x 1.6 mm (x in)	11891
9	Fascia, rear fender (unpainted) (kits 59500246A, 59500245A)	59500107
10	Stud plate (2)	59500018
11	Fascia support bracket (2)	67900185
12	Large flange nut, 1/4-20 (7)	7499
13	LED Stop/Tail/Turn Assembly, Red Lens (kit 59500245A or 59500246A)	67800201
	LED Stop/Tail/Turn Assembly, Amber Lens, Right (kit 59500470)	67800203
	LED Stop/tail/Turn Assembly, Amber Lens, Left (kit 59500470)	67800204
14	Screw, pan head TORX, black, #10 x 12.7 mm (0.5 in) long (6)	3152
15	Bracket, license plate	67900233
16	Cover, license light (unpainted) (kits 59500246A, 59500245A)	60934-10
17	Screw, 1/4-20 x 19mm (0.75 in) (4)	940
18	Light, license plate	60920-09
19	Socket housing, 2-way, black	74112-98BK
20	Secondary lock	74152-98
21	Gasket, upper license plate	67900232
22	Stud plate	59840-09
23	Connector cover	60916-09
24	Foam pad, adhesive-backed, license plate bracket (2)	11100008
25	Reflector and bracket assembly	67900244
26	Washer (2)	6119
28	Clip, adhesive-backed (2)	10102
29	Harness, rear lighting (kit 59500246A) Harness, rear lighting (kits 59500245A, 59500470)	69200720 69200719
30	Antenna bracket, rear	76555-09
31	Antenna base assembly (includes items 32-33)	76335-87
32	Lock washer	7129
33	Nut (2)	76259-86
34	Spacer, antenna, front	12400091
35	Spacer, antenna, rear	12400092
36	Screw, button head TORX, 5/16-18 x 41.3 mm (1.62 in) long, Grade 8 (2)	3148
37	Flat washer (2)	6702
Items used in kits 59500245A and 59500470 only:
38	Light assembly, tail lamp (includes items 39-44)	68142-04
39	Lens, tail lamp (includes item 40)	68558-03
40	..... Screw, tail lamp (2)	68026-99
41	Bulb and socket assembly, tail lamp (includes item 42-44)	69187-03A
42	..... Bulb, tail lamp, wedge mount	68167-04
43	..... Socket housing, four-way	73154-96BK
44	..... Socket terminal, #16-20 AWG (3)	73191-96
45	Tail lamp base assembly (includes items 46-47)	68066-99A
46	..... Tail lamp base (chrome)	68296-99A
47	..... Circuit board and cover	68830-99A
48	Screw, socket head, 1/4-20 x 16 mm (⅝ in) long	3022A
49	J-nut	7964
A,C	Kits 59500245A, 59500470
B	Kit 59500246A