XL Sprocket
Kit Number
40413-04, 40414-04, 40418-04, 40422-04, 40482-04, 40282-05, 42200068, 42200069
Kit numbers 42200068, 42200069, 40413-04, 40414-04, 40418-04, 40422-04, 40482-04 and 40282-05 fit all 2004 and later model Sportsters. These kits will not fit Japanese XL models.
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)
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
All sprockets listed install in the same manner as the original equipment sprocket. Refer to the Laced or Cast Rear Wheel section in your Service Manual. Remove existing sprocket according to Service Manual instructions.
The cotter pin or spring clip for the rear axle nut must be replaced during re-assembly and is available for purchase from your dealer.
Apply two drops of LOCTITE THREADLOCKER 262 (red) (Harley-Davidson part number 94759-99) to each of the five sprocket mounting screws. Follow the bolt torque procedure in your Service Manual or, if installing an accessory hardware kit, in the Instruction-sheet included with the hardware kit.
If you will be installing this sprocket using original equipment bolts, follow the bolt torque procedure in your Service Manual when tightening the bolts.If you will be installing this sprocket using Chrome Sprocket Bolt Kit, Part Number 94708-98, follow the bolt torque procedure in the instructions sheet included with that kit.
Normal Tooth Warranty
This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt.
All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed.
Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue.
Decorative external chrome carries the standard parts and accessories warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue.
All warranty claims must be pursued through your authorized Harley-Davidson Dealer.
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