Café Custom Tail Section
J063592017-01-16
GENERAL
Kit Number
59500560, 59500644, 67900360, 67900359
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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 this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Electrical Overload
This fender installation kit takes no more current than an original equipment (OE) rear lighting circuit.
Kit Contents
See Figure 20 , Figure 21 and refer to Table 1 , Table 2.
Tools and Supplies Required
The help of an assistant will be needed for some removal and installation procedures.
50:50 Isopropyl alcohol/water solution.
ADHESIVE PADS
Use the following procedure to apply adhesive pads.
1.
NOTE
  • Ambient temperature should be between 21–38 °C (70–100 °F) for proper adhesion. Do not apply below 10 °C (50.0 °F).
  • Parts cannot be repositioned after initial adhesive installation.
  • Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
  • The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
  • Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur.
Using a 50:50 isopropyl alcohol/water solution, thoroughly clean trim mounting surfaces. Allow to dry completely.
2.
Install item onto area.
a.
With the adhesive backing still in place, test fit the item to mounting area.
b.
Remove the adhesive backing.
c.
Install the item to the area.
d.
Press surface of item firmly to make sure that there is good adhesion.
REMOVAL
Preparation to install kit.
1.
NOTE
When removing the terminals from a connector, always label the wire with the terminal number that it was removed from. This is for ease of assembly.
Remove rear fender. See the service manual.
2.
Retain reflector brackets.
3.
All models except XL1200CX: Remove turn signal stalk bolt from turn signal supports and remove both turn signal lamps from the supports. See the service manual.
4.
XL1200CX: Retain both the complete turn signal and stalk assemblies.
5.
Discard fender strut covers.
6.
NOTE
When a solo seat is installed without a passenger seat, the passenger footpegs or footboards and the passenger grab strap must be removed.
If equipped, remove passenger footpegs or footboards.
7.
If equipped, remove passenger grab strap.
NON US ONLY:
8.
Remove the license plate (LP) lamp and retain the hardware.
9.
Remove the reflector brackets and reflector from lower LP bracket and retain hardware.
ASSEMBLE
1.
Attach the mud flap (11) to inner fender (10).
a.
With a clean shop towel placed down, lay the fender on a bench upside down.
b.
See Figure 1. Place the mud flap tabs on the in-board side of the inner fender.
c.
Unscrew, but do not remove the pin portion of the 3 fasteners (8).
d.
Align the holes in the tabs of the mud flap with the holes in the inner fender and insert fasteners (8). After the fasteners are fully seated, tighten pin.
Figure 1. Inner Fender and Fasteners
2.
Turn fender right side up on bench.
3.
Move the upper mud flap tab to the outer part of the fender bracket.
4.
See Figure 2. Attach the mud flap to fender.
a.
Align the hole in the tab of the mud flap with the hole in the fender and insert fastener (8). After the fasteners are fully seated, tighten pin.
Figure 2. Mud Flap and Fender
5.
NOTE
For ease of installation, use a 50:50 isopropyl alcohol/water solution sprayed on the grommets before inserting into fender.
See Figure 3 and Figure 20. Insert grommets (5) into fender.
a.
Insert the thin side of the grommet into the outer side of the fender holes.
b.
Verify that the grommets are fully seated on the inner side of the fender.
Figure 3. Grommet Location
6.
See Figure 4 and Figure 20. Install bumpers (15 and 16). See ADHESIVE PADS
a.
See Figure 5. Locate and measure from inner tip of fender on both sides of fender.
Length/Dimension/Distance: 32 mm (1.25 in)
b.
Align bottom surface of bumper with bottom of fender.
Figure 4. Bumper Location
Figure 5. Bumper Measurement
7.
US ONLY: See Figure 20 and Figure 6. Install reflector block (7) centered on fender with edge of adhesive pad aligned to fender edge. See ADHESIVE PADS.
Figure 6. Reflector Block Location - US VEHICLES
8.
NON US VEHICLES: See Figure 21. Attach license plate (LP) bracket (1) to the inside of inner fender.
a.
See Figure 7 and Figure 21. Attach the reflector (3) to the bracket (2). See ADHESIVE PADS
b.
See Figure 8. Align the holes and bushings in the bracket to the inner fender rear mounting nuts.
c.
Insert the two screws (5). Tighten to:
Torque: 7.34–7.9 N·m (65–70 in-lbs)
1Reflector
2LP Bracket
Figure 7. Reflector to LP Bracket
Figure 8. LP Bracket to Fender
9.
CANADA ONLY: See Figure 21. Install the taillight sub-assembly (6) onto bracket (2).
NOTE
Extra effort is needed when installing the screws into the lamp housing for the first time.
a.
Remove the screws (8) and washers (9) from the tail lamp assembly (7).
b.
See Figure 9. Route the lamp's wiring through the center hole.
c.
See Figure 10. Attach lamp assembly to LP bracket.
Torque: 1.6–1.8 N·m (14–16 in-lbs)
Figure 9. Lamp to LP Bracket
Figure 10. Lamp to LP Bracket
10.
NON US ONLY: See Figure 21. Install the carryover LP lamp and reflectors onto bracket (2).
a.
See Figure 9. Route the lamp's wiring through the center hole.
b.
See Figure 10. Attach lamp assembly to LP bracket.
Torque: 1.6–1.8 N·m (14–16 in-lbs)
c.
See Figure 11. Install the OE reflectors and brackets to the lower LP bracket.
Torque: 1.1–1.7 N·m (10–15 in-lbs)
Figure 11. Reflectors to Lower LP Bracket
INSTALLATION
1.
Position the left side of the fender to fit inside the left fender extension. Place clean shop towel over right hand strut to prevent damage.
2.
See Figure 12. Verify the frame tab is on the inside of the mud flap.
Figure 12. Mud Flap to Frame
3.
See Figure 20 and Figure 13. From the outer left side, insert the screw (1) and washer (2) through the forward fender extension and fender mounting hole.
Figure 13. LH Side Fender and Extension Arm
4.
See Figure 14. Install the left side reflector bracket.
a.
US vehicles will have a side mounted LP and lamp connected to the left side reflector bracket.
5.
See Figure 20 and Figure 14 . Loosely install nut (3) onto screw (1) on reflector bracket, do not tighten.
6.
See Figure 20 and Figure 14 . From the inside of the fender, insert the bolt (4) into the forward LH turn signal mounting hole.
1US reflector bracket
2Forward fender extension mounting hole
3Forward LH turn signal mounting hole
Figure 14. LH Side Reflector Bracket
7.
NOTE
The fender is slightly wider than the fender extension, compressing the fender together will allow the fender to fit.
See Figure 15 . Remove shop towel. Using your thumbs and pressing on the lower right side of the fender, install the right side of the fender into place.
Figure 15. Positioning Right Side of Fender
8.
See Figure 16. From the outer right side, insert the screw (1) through the forward fender extension and fender mounting hole.
9.
Install the right side reflector bracket.
10.
Loosely install nut (3) onto bolt, do not tighten.
11.
From the inside of the fender, insert the bolt (4) into the forward right side turn signal mounting hole.
12.
NOTE
CANADA and NON US: will have a bracket coming from the LP bracket that will mount with the rear mounting bolt (not shown).
All models except XL1200CX: See Figure 20. Route turn signal wires through the support (12). Using screws (17) install turn signal to support (12).
Torque: 13.6–19 N·m (120–168 in-lbs)
13.
Install both turn signal lamp assemblies.
a.
Route each turn signal harness through appropriate hole in fender extension and fender as the assemblies are installed.
b.
See Figure 20 and Figure 16 . In the rear turn signal mounting hole, install the bolt (4) and washer (14) on both sides.
1Turn signal wire routing
2Forward mounting hole and bolt
3Turn signal rear mounting with bolt and washer
Figure 16. Turn Signal Mounting: US Shown
14.
See Figure 14. Tighten fender and turn signal hardware.
Torque: 13.6–19 N·m (120–168 in-lbs)
15.
Install left rear turn signal harness and license plate lamp harness into fender harness clip on left side of fender. Install right rear turn signal harness into fender harness clip on right side of fender.
16.
Feed both rear turn signal harnesses and license plate lamp harness through the openings in the fender.
17.
See Figure 17. Install socket terminals as marked into the left and right turn signal [18B], [19B]. Install socket terminals as marked into the license plate lamp [40].
a.
Connect license plate lamp [40].
b.
Connect left rear turn signal [18].
c.
Connect right rear turn signal [19].
1Right turn signal [18]
2License plate lamp [40]
3Left turn signal [19]
Figure 17. Rear Lighting Harness
18.
US ONLY: With vehicles equipped with the Screamin' Eagle® Fully Adjustable Piggyback Shocks.
a.
See Figure 18. Remove both right and left reflector from reflector bracket.
b.
See Figure 20 and Figure 19. Install both right and left reflector (13) to fender extension. Point arrow towards turn signal. See ADHESIVE PADS
Figure 18. Remove Reflector
Figure 19. Installation of Reflector
19.
NOTE
New grommets are stiff and may cause the uses of extra effort to ensure that the seat is fully seated into the grommets.
See Figure 20. Install seat (9).
a.
Install the seat with the tab side under fuel tank bracket and press posts into grommets.
b.
Pull up on the seat to ensure that seat is secure.
20.
Install rear wheel. See the service manual.
21.
Install main fuse.
WARNING
Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b)
22.
Check operation of all lamps.
SERVICE PARTS
Figure 20. Service Parts: 59500560, 595005644
Table 1. Service Parts: 59500560, 595005644
Item
Description
QTY
Part Number
1
Screw, Torx® head 5/16-18
2
4779
2
Washer
2
6798
3
Locknut, flange
2
7531
4
Bolt, hex head 5/16-18
4
8336
5
Grommet
2
11651
6
Reflector, (US)
1
59359-06
7
Reflector, block (US)
1
68724-07
8
Fastener, tree
3
12600194
9
Seat
1
52000319
10
Fender, Sub-Assy
1
Not Sold Separately
11
Mud flap, tire
1
59600035
12
Support, turn signal
2
67800646
13
Reflector, strut
2
67900378
14
Washer
2
6702
15
Bumper, LH
1
59500666
16
Bumper, RH
1
59500665
17
Screw, socket head 5/16-18
2
4016
1Kits 67900359 and 67900360
6Only with kit 67900360
Figure 21. Service Parts: 67900359, 67900360
Table 2. Service Parts: 67900359, 67900360
Item
Description
QTY
Part Number
1
Bracket, LP
1
67900359/67900360
2
Bracket
1
Not Sold Separately
3
Reflector
1
69490-07
4
Bushing, limiter
2
Not Sold Separately
5
Screw, 1/4-20
2
10500038
6
Taillight, Sub-Assy
1
67800794
7
Tail lamp assy
1
73403-11
8
Screw
2
3387
9
Washer
2
Not Sold Separately
10
HSG Socket, 3-place
1
73153-96BK
11
Terminal, socket
3
73191-96