VEHICLE PROTECTION KIT
J059692021-01-20
GENERAL
WARNINGIf tip occurs, check all controls for proper operation. Restricted control movement can adversely affect the performance of the brakes, clutch or ability to shift, which could result in loss of vehicle control and death or serious injury. (00350a)
NOTE
- This kit is for closed course training only and is not for use on public roads.
- This kit is not for retail sale and is not to be installed on a customer's motorcycle.
- Touch-up paint is available for separate purchase (Part No. 98601DKA).
Kit Number
49000035A
Models
This kit is for use on Harley-Davidson™ Riding Academy XG500 models only.
Installation Requirements
NOTE
- These kit components must be removed and the vehicle returned to its original configuration prior to purchase by a retail customer. This includes flashing the ECM back to original configuration. Retain all removed original components for installation prior to retail delivery of this vehicle.
- This kit requires the use of a service manual.
- Installation of this kit requires the separate installation of the Power Limit Calibration using Digital Technician II.
To Return Vehicle to Original Configuration
Every component of this kit MUST BE REMOVED and the ECM MUST BE
FLASHED to the original configuration prior to delivery to a retail customer.
Kit Contents
This kit is made up of several sub-kits. ALL sub-kits must be installed. Refer to the individual kit instruction section in this instruction sheet for available service parts.
KEEP THIS INSTRUCTION SHEET for future reference. If repair parts are needed, the sub-kit part numbers and their associated service part numbers are only available from this instruction sheet.
INSTALLATION OUTLINE
NOTE
Refer to each sub-kit instruction beginning on page 3 for specific installation procedures.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1. | Remove main fuse. See service manual. | |
| 2. | Remove the seat. See service manual. | |
| 3. | Install each sub-kit following the instructions for that kit. All kits must be installed. | |
| 4. | Install Power Limit Calibration to ECM using Digital Technician II. | |
| 5. | Install main fuse. See service manual. | |
| 6. | Verify bank angle sensor shut-off. Refer to Verify Tip Sensor Shut-Off below. | |
| 7. | Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. |
Verify Bank Angle Sensor Shut-Off
NOTE
Front Guard Kit (Part No. 49000036A) must be installed for this test to be valid.
- Start engine. Leave transmission in neutral.
- Lean vehicle over until front guard contacts the ground. Engine should stop running within one second after contact.
- To reset:
- Turn run switch off for 5 seconds.
- Turn run switch on and start engine.
- Repeat steps for opposite side.
- If engine does not stop, check wiring, connectors and bank-angle sensor bracket mounting to confirm correct installation. Repeat test.
KIT CONTENTS
Figure 1. Kit Contents: Vehicle Protection Kit
Table 1. Kit Contents
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Front Guard Kit | 49000036A |
2 | Dual Bank-Angle Sensor Kit | 32700040 |
3 | Exhaust Guard Kit | 49000040 |
4 | Exhaust Slider Guard Kit | 49000067 |
5 | Swingarm Guard Kit | 49000058 |
6 | Rear Guard Kit (2) | 49000060 |
7 | Handlebar Guard Kit, right | 49000089 |
8 | Handlebar Guard Kit, left | 49000055 |
9 | Rider Nameplate Kit | 67900214 |
FRONT GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
49000036A
Removal
- See Figure 2. Remove front upper engine mount screws (1) and nut plate assemblies (not shown). Retain hardware to return vehicle to original configuration in the future.
- Remove existing engine guard, if equipped. Retain hardware to return vehicle to original configuration in the future.
- Remove front O2 sensor. Record locations of cable straps securing harness. See service manual.
NOTE
Left engine mount screws may also secure horn bracket.
Installation
NOTE
Do not tighten hardware until all hardware is installed.
| 1. | See Figure 2. Position guard weldment. a. From below vehicle, position right mounting plate behind right frame down tube into area (4). b. Bring left mounting plate back past frame. c. Raise guard into position. | |
| 2. | See Figure 3. Secure front guard using hardware (2, 3, 4, 5, 6) provided. Vehicles with horn mounted on left side engine mount: Install short (2) spacers between horn bracket and front guard on left side. Install long spacers (6) between front guard and frame on right side. Vehicles with horn mounted behind radiator: Install long spacers (6) between front guard and frame on left and right side. | |
| 3. | See Figure 2. Secure lower bracket to frame cross member (3) with U-bolt (2) and flange nuts. | |
| 4. | Tighten upper hardware (1). Tighten. Torque: 47.5 N·m (35 ft-lbs) Engine mount screws | |
| 5. | Tighten U-bolt flange nuts evenly to prevent end from protruding beyond mounting bracket recess. Tighten. Torque: 13.5 N·m (120 in-lbs) U-bolt nuts | |
| 6. | Verify starter cable is routed downward and is at least 6.4 mm (¼ in) from end of right engine mount screws. | |
| 7. | Install front O2 sensor. See service manual. Secure harness as recorded during removal with cable straps provided. |
| 1 | Upper hardware |
| 2 | U-bolt |
| 3 | Frame cross member |
| 4 | Open area |
Figure 2. Front Guard Installed
SERVICE PARTS, FRONT GUARD KIT
Figure 3. Kit Contents: Front Guard Kit
Table 2. Kit Contents
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Guard weldment | Not sold separately |
2 | Spacer, left (short) (2) | Not sold separately |
3 | Screw, left, M10 x 1.5 x 70 (2) | 10200245 |
4 | Flange Locknut, M10 x 1.5 (4) | 10100045 |
5 | Screw, right, M10 x 1.5 x 60 (2) | 10200244 |
6 | Spacer, (long) (4) | 49000083 |
7 | U-bolt | Not sold separately |
8 | Flange nut (2) | Not sold separately |
- | Cable strap (4) (not shown) | 10006 |
DUAL BANK ANGLE SENSOR KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
32700040
Kit Contents
NOTE
These kit components must be removed and vehicle returned to its original configuration prior to purchase by a retail customer.
Installation
- See Figure 4. Remove existing bank angle sensor. Retain sensor for assembly.
- See Figure 5. Release flasher relay (1) from top caddy. Allow to hang out of the way.
- See Figure 6. Secure new bank angle sensor bracket/sensor assembly (3) in location where original sensor was retained. Place front of bracket under hooks first and rotate back of bracket down to lock into position.
- Install both sensors (A, 1) in slots of new bracket (3).
- Connect wye harness (2) to both sensors.
- Connect remaining connector of the wye harness to vehicle harness. Secure connector in features (B) on top caddy.
- See Figure 5. Install flasher relay on top caddy with connector to the front.
- Secure sensor harness, relay harness and main harness with a cable strap (provided).
- Prior to riding the vehicle, perform the shut-off test. Refer to Verify Tip Sensor Shut-Off on page 1.
| 1 | Top caddy |
| 2 | Existing bank-angle sensor |
| 3 | Connector retaining features |
Figure 4. Remove Original Sensor
| 1 | Flasher relay |
| 2 | Cable strap location |
Figure 5. Finalize Installation
SERVICE PARTS, BANK ANGLE SENSOR KIT
Figure 6. Service Parts: Dual Bank Angle Sensor Kit
Table 3. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Bank-angle sensor | 32700089 |
2 | Harness | Not serviced |
3 | Dual sensor bracket | Not serviced |
- | Cable strap (2) (not shown) | 10006 |
Items mentioned in text but not included in kit | ||
A | Original bank-angle sensor | |
B | Retaining features on top caddy | |
EXHAUST GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
49000040
PREPARATION
- Remove muffler. See service manual.
- See Figure 8. Remove two screws (2). Retain for assembly.
Installation
| 1. | Disconnect brake switch connectors. | |
| 2. | See Figure 10. Remove four screws (2) and hoop (3). | |
| 3. | See Figure 9. Install bracket (1) using screws (2) removed earlier. Tighten. Torque: 25–30 N·m (18.4–22.1 ft-lbs) Muffler bracket screws | |
| 4. | Route the brake switch connectors through hole in bracket (1). Connect to brake switch. | |
| 5. | Install the muffler. See service manual. | |
| 6. | See Figure 10. Apply threadlocker to screws (2).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) | |
| 7. | Install hoop (3) with four screws (2). Tighten.
Torque: 40.7 N·m (30 ft-lbs) Muffler guard hoop screws | |
| 8. | Verify muffler does not contact guard. Readjust muffler for clearance as necessary. |
| 1 | Muffler bracket |
| 2 | Screws |
Figure 8. Remove Screws
| 1 | Bracket weldment |
| 2 | Screws |
Figure 9. Install Bracket
| 1 | Bracket weldment |
| 2 | Screw (4) |
| 3 | Hoop |
Figure 10. Install Guard
EXHAUST SLIDER GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
49000067
Kit Contents
This kit contains two guard shells and a clamp. There are no service parts.
Installation
- See Figure 11. Loosen worm drive clamp (2).
- Slide guard assembly (3) onto muffler (1) until joint between muffler tip and muffler is just hidden by rear edge of guard.
- Push guard halves together to create the smallest gap at the top.
- Rotate clamp so screw is at approximately the 8 o'clock position (arrow). Tighten clamp securely.
| 1 | Muffler |
| 2 | Worm drive clamp |
| 3 | Guard |
Figure 11. Install Guard
SWINGARM GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
49000058
Kit Contents
See Figure 12. This kit contains no service parts.
| 1 | Guard |
| 2 | Screw |
Figure 12. Swingarm Guard Kit
Installation
| 1. | Raise vehicle to remove the weight from the rear suspension. | |
| 2. | See Figure 13. Remove the lower screw and nut (4) securing the left rear shock absorber. Retain the nut for assembly. Retain the screw and washer (3) to return vehicle to original configuration in the future. | |
| 3. | Apply a few drops of LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue) to the threads of the new screw (2). | |
| 4. | Install new screw through guard (1), shock absorber eye and swingarm. Install nut (4). Tighten. Torque: 61–68 N·m (45–50 ft-lbs) Shock absorber lower screw |
| 1 | Guard |
| 2 | Screw |
| 3 | Washer |
| 4 | Nut (not visible) |
Figure 13. Swingarm Guard Installation
REAR GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
49000060
Installation
NOTE
Install one side at a time. Removing screws from both sides will allow the rear fender to fall.
| 1. | See Figure 14. Remove two screws (A). Retain screws to return vehicle to original configuration in the future. NOTE Verify that the spacer between fender and support bracket cover is in place during installation of guard. | |
| 2. | Install guard with new screws (2, 3). Tighten. Torque: 54.2 N·m (40 ft-lbs) Fender support screws | |
| 3. | Repeat with opposite side. |
| 1 | Guard weldment |
| 2 | Screw, rear, M10 x 1.5 x 50 lg |
| 3 | Screw, front, M10 x 1.5 x 60 lg |
Figure 14. Install Guard
KIT CONTENTS, REAR GUARD KIT
Figure 15. Rear Guard Kit
Table 4. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Guard weldment | Not serviced |
2 | Screw, rear, M10 x 1.5 x 50 lg | Not serviced |
3 | Screw, front, M10 x 1.5 x 60 lg | Not serviced |
Items included in text | ||
A | Fender support screws | - |
HANDLEBAR GUARD KIT
NOTE
This kit is part of Part No. 49000035A Vehicle Protection Kit.
Kit Number
4900055 (left side), 49000089 (right side)
Kit Contents
| 1 | Screw, M6 x 1 x 60 |
| 2 | Guard |
| 3 | Clamp |
Figure 16. Handlebar Guard Kit, left
| 1 | Screw, M6 x 1 x 60 |
| 2 | Guard |
| 3 | Spacer |
| 4 | Spacer, tapered |
| 5 | Clamp |
Figure 17. Handlebar Guard Kit, right
Installation
NOTE
Be sure to cut the right grip large enough to prevent contact with the guard or spacer.
| 1. | See Figure 18. Carefully cut the end of the grip. a. Left grip: Cut to the size of the inner diameter of the handle bar. b. Right grip: Cut to the size of the twist grip inner sleeve. | |
| 2. | Assemble guard components: | |
| 3. | See Figure 19. Insert assembly into the end of the handlebar until the shoulder (2) or spacer (right side) contacts the handlebar. | |
| 4. | Tighten screw securely. | |
| WARNING Before starting engine, be sure throttle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or serious injury. (00390a) | ||
| 5. | Verify that throttle control does not bind and operates freely. NOTE To remove, loosen screw. Tap on end of screw with hammer and punch to loosen clamp. |
Figure 18. Cut End of Grip
| 1 | Guard |
| 2 | Shoulder |
| 3 | Clamp |
Figure 19. Install Guard
RIDER NAME PLATE KIT
Kit Number
67900214
Installation
| 1. | See Figure 20. Remove fairing (B). See service manual. | |
| 2. | Install the name plate bracket (1) to the lower support bracket (A) with two screws, four washers and two locknuts. Tighten. Torque: 6.2–6.8 N·m (55–60 in-lbs) Name plate bracket | |
| 3. | Install name plate (2) on bracket (1) with part number facing bracket. Secure with two screws, four washers and two locknuts. Tighten. Torque: 6.2–6.8 N·m (55–60 in-lbs) Name plate | |
| 4. | Install fairing (B). See service manual. |
| 1 | Bracket |
| 2 | Name plate |
Figure 20. Install Front Plate Kit
How to Use
Use a dry erase pen to write on the name plate. Use dry erase cleaner to remove writing.
SERVICE PARTS
Figure 21. Service Parts: Name Plate Kit
Table 5. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Locknut (4) | Not serviced |
2 | Washer (8) | Not serviced |
3 | Bracket | 67900162 |
4 | Name plate | 67900089 |
5 | Screw, socket head (4) | 10200127 |