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
WARNINGRider 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:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
PREPARE
| 1. | Remove and reposition horn. See service manual. | |
| 2. | Figure 2 Remove front engine mount screws (2). |
| 1 | Front engine mount |
| 2 | Screw (2) |
Figure 2. Front Engine Mount Screws
INSTALL
WARNINGIf 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. | 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. | 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) |
| 1 | Down tube |
| 2 | Flat-Out bar |
| 3 | Clutch cable |
| 4 | Clutch cable clip |
Figure 3. Clutch Cable Routing
| 1 | Nut |
| 2 | Screw (2) |
| 3 | Flat-Out bar |
| 4 | Socket head screw |
| 5 | Washer |
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. | 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) |
| 1 | Screw (1) |
| 2 | Bumper (1) |
Figure 5. Bumper Replacement