FLAT-OUT BAR
941002572022-01-13
GENERAL INFORMATION
Table 1. General Information
Kits
Suggested Tools
Skill Level(1)
49000231, 49000232
Safety Glasses, Torque Wrench
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Flat-Out Bar
Table 2. Kit Contents: Flat-Out Bar
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
Notes
1
1
Flat-Out bar
Not sold separately
2
1
Nut
7593
Nut, black
10100165
3
2
Screw, button head TORX™
10201242
4
1
Washer
6702
Washer, black
10300201
5
1
Screw, TORX socket head
10201308
Screw, TORX socket head, black
10201302
6
1
Service kit (bumper and screw)
49000241
Sold separately
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
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 references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:
PREPARE
1. Remove and reposition horn. See service manual.
2. See Figure 2. Remove front engine mount screws (2).
1Front engine mount
2Screw (2)
Figure 2. Front Engine Mount Screws
INSTALL
WARNING
If Equipped: Front and/or rear guards are not intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022d)
1. See Figure 3. Check position of clutch cable clip (4).
2. Move clip (4) above flat-out bar (2).
3. Rotate so clutch cable (3) is not at front of down tube (1).
4. See Figure 4. Position flat-out bar (3) on top of front engine mount.
5. Loosely install button head screws (2).
6. Loosely install socket head screw (4), washer (5) and nut (1).
7. Tighten screws (2).
Torque: 61–68 N·m (45–50 ft-lbs)
8. Tighten screw (4).
Torque: 40.5 N·m (30 ft-lbs)
1Down tube
2Flat-Out bar
3Clutch cable
4Clutch cable clip
Figure 3. Clutch Cable Routing
1Nut
2Screw (2)
3Flat-Out bar
4Socket head screw
5Washer
Figure 4. Flat-Out Bar
COMPLETE
1. Install horn. See service manual.
a. Check operation of horn.
SERVICE
NOTE
Service kit has enough components for one side to be replaced.
Check flat-out bar for damage prior to replacing bumper. Replace as needed.
1. See Figure 5. Remove and discard screw (1) and bumper (2).
2. Install bumper (2).
3. Install screw (1). Tighten.
Torque: 27 N·m (20 ft-lbs)
1Screw (1)
2Bumper (1)
Figure 5. Bumper Replacement