SPORTSTER CHOPPED FENDER INSTALLATION KITS
J049402010-02-03
GENERAL
Kit Numbers
60947-10 (chrome), 60972-10 (black)
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of a Side-Mount License Plate Bracket Assembly (Part No. 60318-07) or Accessory Side-Mount License Plate Kit (Part No. 60947-10 or 60972-10) is required.
Test fit the prime-coated fender prior to painting, but have the fender painted before final installation.
Tools and Supplies Required
The help of an assistant will be needed for some removal and installation procedures.
An Amp Multilock Crimper (HD-41609) is required for the proper installation of this kit.
Electrical Contact Lube (H-D Part No.99861-02) or equivalent is required for the proper installation of this kit.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and 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.
INSTALLATION
Preparation
| 1. | Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||
| 2. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. | |
| 3. | Remove the battery from the vehicle per the instructions in the service manual. | |
| 4. | Raise the rear of the vehicle to relieve the load on the shock absorbers. | |
| 5. | Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle. Save the fasteners for later assembly. | |
| 6. | Raise the rear of the vehicle further to allow access to the underside of the rear fender. | |
| 7. | Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. |
Rear Fender Removal
NOTE
Note the location and orientation of rear fender mounting hardware, and save for later assembly.
- Refer to the service manual and follow the instructions given to remove the rear fender, with the following exceptions:
- Removal of the tail lamp from the fender is not necessary.
Rear Lamp Wiring
| 1. | Cut off and discard the socket housings and terminal ends from the turn signal wires. | |||||||||||||||||||||||||||||||
| 2. | See Figure 1. Unscrew and remove the turn signal stalk (15) from one of the turn signal lamps, and discard. Remove and retain the turn signal lamp and support (14) from the rear fender support cover. | |||||||||||||||||||||||||||||||
| 3. | Insert the blade of a small screwdriver into the slot at the bottom of the turn signal lamp lens (2), and twist to unsnap the lens from the housing (1). To avoid breakage, push the bulb (3) in and rotate counterclockwise to remove. | |||||||||||||||||||||||||||||||
| 4. | Separate the turn signal reflector (5) from the lamp housing using either or both of these methods as necessary: a. Insert the blade of a small screwdriver between the outer edge of the rubber gasket (4) and the inside of the housing. Gently pry up the reflector (5) until free. b. Insert a thin-blade screwdriver or similar tool through the threaded hole (9) in the housing (1), and gently push the reflector (5) and rubber gasket (4) free of the housing. | |||||||||||||||||||||||||||||||
| 5. | Guide the wires out of the unthreaded hole (8) in the lamp housing. The turn signal stalk, gasket, reflector, bulb, amber lens and wiring can be discarded. | |||||||||||||||||||||||||||||||
| 6. | See Figure 6. Obtain a reflector/bulb socket assembly (16), double-filament bulb (19) and red lens (20) from the kit. | |||||||||||||||||||||||||||||||
| 7. | See Figure 1. Route the wires (10, 11, 12) and protective tubing (13) from the reflector/bulb socket assembly through the center of the rubber gasket (4) and out through the unthreaded hole (8) in the lamp housing (1). | 
Figure 1. Tail/Stop/Turn Signal Lamp | ||||||||||||||||||||||||||||||
| 8. | Assemble the lamp as follows: a. If out of position, insert the spring (7) and bulb socket (6) back into the reflector, aligning the locating tab on the bulb socket with the slot in the reflector. The violet wire (11) should be closest to the tab on the socket. b. Seat the reflector assembly in the rubber gasket, aligning the tab on the reflector with the slot in the gasket. c. Install the reflector assembly, aligning the tab on the reflector with the slot inside the lamp and leaving about 25–50 mm (1–2 in) of wire inside the lamp housing. Carefully route the wires through the turn signal lamp support (14) and the third-rearmost hole in the fender support cover. d. Insert the long end of a new turn signal stalk (15), from the inside, through the second-rearmost hole in the fender support cover and the lamp support, and thread the stalk into the lamp housing. Tighten to 10.9–17.6 N·m (96–156 in-lbs). e. Using the thumbs of both hands, apply even pressure around the outer edge of the reflector assembly until fully seated. f. Liberally apply electrical contact lubricant (H-D Part No. 99861-02) or equivalent to the contacts (11, 12) in the reflector socket and at the base of the new bulb (3). Push in the bulb and rotate clockwise to install. g. Install the new red lens (2) to the lamp housing and gently apply thumb pressure until it snaps into place. Rotate the lens to position the slot at the bottom of the lamp. | |||||||||||||||||||||||||||||||
| 9. | Repeat Steps 2 through 8 for the remaining lamp. |
Rear Fender Assembly and Mounting
NOTE
Test fit the prime-coated fender prior to painting, but have the fender painted before assembly and final installation.
Protect the painted fender from scratches and damage during assembly steps.
| 1. | See Figure 6. Obtain the new, painted chopped rear fender (1), five pop rivets (14) and five washers (15) and the rear fender extension (23) from the kit. Line up the holes in the extension with the holes in the fender. Secure the extension to the fender with the pop rivets and washers. Line up the holes in the extension and wire troughs with the holes in the fender. Secure the extension and troughs to the fender with the pop rivets and washers. | |||||||||||||
| 2. | 2007 through 2009 models: Install the ECM caddy into the large hole in the fender. | |||||||||||||
| 3. | ALL models: Obtain the new license plate bracket assembly (Item I, purchased separately), or left side reflector mounting bracket (12) if installing accessory side mount license plate kit 60947-10, right-side reflector mounting bracket (11), rear fender brace (2), Phillips-head screw (3), two fender clips (4), two flange nuts (6), grommet (7) and spacer (8) from the kit, and the OE fender mounting hardware removed earlier. | |||||||||||||
| 4. | Install the grommet (7) into the seat mounting hole in the fender. | |||||||||||||
| 5. | Place the new spacer (8) onto the threads of the OE hex head seat mounting bolt (B). With an assistant holding the new fender in place between the fender supports, insert the bolt, from the underside, through the fender grommet and the frame tab. Place the OE washer and seat post (C) onto the screw threads, and tighten finger tight at this time. | |||||||||||||
| 6. | Position the right-side reflector mounting bracket (11) against the inside of the fender. Line up the holes in the bracket with the holes in the fender. Feed the right-side tail/stop/turn signal lamp wiring through the holes in the fender and reflector mounting bracket. | |||||||||||||
| 7. | Insert an OE 1.38 inch (35 mm) screw and washer (D) through the forward mounting hole in the support cover (E), the fender support, the mounting hole in the rear fender and the mating slot in the reflector mounting bracket. Install an OE flange nut (F) onto the screw threads, but do not fully tighten at this time. | |||||||||||||
| 8. | Install a new flange nut (6) from the kit onto the tail/stop/turn signal stalk (5) screw threads, but do not fully tighten. | |||||||||||||
| 9. | Position either the license plate bracket assembly (H) or left side reflector mounting bracket (12) if installing accessory side mount license plate kit 60947-10, against the inside of the fender on the left side. Line up the holes in the bracket with the holes in the fender. Feed the left-side tail/stop/turn signal lamp wiring through the holes in the fender and license plate bracket assembly. | |||||||||||||
| 10. | Insert the remaining OE 1.38 inch (35 mm) screw and washer through the forward mounting hole in the support cover, the fender support, the mounting hole in the rear fender and the mating slot in the license plate bracket assembly. Install the OE flange nut onto the screw threads, but do not fully tighten. | |||||||||||||
| 11. | Install the remaining new flange nut onto the tail/stop/turn signal stalk screw threads, but do not fully tighten. | |||||||||||||
| 12. | Position the rear fender brace (2) to the underside of the fender and align the center hole with the hole in the fender. Loosely fasten with the Phillips-head screw (3). | |||||||||||||
| 13. | See Figure 2. Make certain that the tab (3) on each nut plate (2) fits into the slot (4) in the fender brace (1) when securing the nut plates with the rearmost fender mounting screws and washers (5). Do not fully tighten. NOTE If installing accessory side mount license plate kit 60947-10, install according to instructions included with the kit before proceeding to step 14. | 
Figure 2. Rear Fender Nut Plate | ||||||||||||
| 14. | See Figure 6. Tighten all fender mounting hardware in the following sequence: a. Tighten the screw (B) and seat post (C) to 10.9–17.6 N·m (96–156 in-lbs). b. Tighten the forward (D) and rearmost (G) fender support screws on both sides of the fender to 14.9–24.4 N·m (132–216 in-lbs). c. Tighten the rear lamp stalk flange nuts (6) to 14.9–24.4 N·m (132–216 in-lbs). d. Tighten the rear fender brace screw (3) to 14.9–24.4 N·m (132–216 in-lbs). | |||||||||||||
| 15. | See Figure 3 if installing side mount license plate 60318-07. Disregard if installing 60947-10. Feed the license plate lamp harness (1) up through the harness channel (2). Insert the harness into the upper license plate bracket harness clips (3) and the wire trough (6) above the rear fender extension. | 
Figure 3. Rear Lamp Harness Routing | ||||||||||||
| 16. | 2007-2009 models: Install the ECM to the ECM caddy on the fender per service manual instructions. | |||||||||||||
| 17. | ALL models: See Figure 6. Obtain the reflector mounting block (9) and rear reflector (10) from the kit | |||||||||||||
| 18. | Clean the rear underside of the new fender, and the reflector mounting area of the reflector mounting block with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly. NOTE Ambient temperature should be at least 60 °F (16 °C) for proper adhesion. | |||||||||||||
| 19. | Remove the liner from the adhesive backing of the reflector. Carefully position the reflector to the reflector mounting area of the mounting block, and press firmly into place. Hold the reflector in position with steady pressure for about one minute. | |||||||||||||
| 20. | Remove the liner from the adhesive backing on the mounting block tape. Position the mounting block, centered, to the rear edge on the underside of the fender, and press firmly into place. Hold the mounting block in position with steady pressure for about one minute. | |||||||||||||
| 21. | Obtain the side reflectors (13) from the kit. | |||||||||||||
| 22. | Clean the reflector mounting area of the license plate bracket assembly with a mixture of 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry thoroughly. | |||||||||||||
| 23. | Remove the liner from the adhesive back of one reflector. Carefully position the reflector to the reflector mounting area of the bracket, and press firmly into place. Hold the reflector in position with steady pressure for about one minute. | |||||||||||||
| 24. | Repeat Steps 22 and 23 with the right-side reflector mount bracket (11) and the remaining side reflector. |
NOTE
Allow AT LEAST 24 hours after applying the reflectors before exposing the areas 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.
Rear Lamp Wiring Connection to Vehicle
| 1. | Obtain the tail/stop/turn signal converter module (21) and holder (22) from the kit. Insert the module into the holder, and install the module and holder in the battery area as follows: a. See Figure 4. Feed the converter module and interconnect harness connectors up through the battery compartment, forward of the battery strap bracket. b. Position the converter module up inside the frame, under the "Y" section. For 2009 and 2010 models: See the instructions in the service manual. For 2008 and earlier models: See Figure 5. Pull the rubber mounting tab through the hole in the frame to secure the module. |  Figure 4. Converter Module Installation  Figure 5. Converter Module Mounting Tab (2008 and Earlier) |
| 2. | Connect the six way pin housing [7B] on the tail lamp converter module to the socket housing [7A] on the main vehicle harness. Connect the pin housing [40B] on the tail lamp converter module to the socket housing on the license plate illuminator harness. Tuck the connectors and wiring into the area under the seat. | |
| 3. | See Figure 3. Route the tail/stop/turn signal wire harnesses (4) through the lower harness clips (5) and the wire troughs above the rear fender extension, then over to the tail lamp converter module connectors [18B] and [19B]. Cut the unterminated wires and tubing to allow sufficient length to make the connections. | |
| 4. | Obtain six terminals (17) and two socket housings (18) from the kit. | |
| 5. | Follow the instructions in the service manual to crimp the terminals onto the tail/stop/turn signal wires. Insert the tail/stop/turn signal wiring socket terminals coming from one lamp into the correct cavities of one socket housing: Repeat for the remaining socket housing. a. Insert the black wire and terminal into cavity 1. b. Insert the violet wire and terminal into cavity 2. c. Insert the blue wire and terminal into cavity 3. | |
| 6. | Connect the pin housings ([18B], right and [19B], left) on the tail lamp converter module to the socket housings on the tail/stop/turn signal wiring. Tuck the connectors and wiring into the area under the seat. | |
| 7. | Refer to the service manual, and follow the instructions to install the battery. |
Return to Service
NOTE
Verify that the ignition/light key switch is in the OFF position before attaching the battery cables.
| 1. | Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Refer to the service manual and follow the instructions given to attach the battery cables (positive cable first). | |
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) WARNINGAfter installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||
| 2. | Refer to the service manual, and follow instructions to install the seat. | |
| 3. | Follow the service manual instructions to install the bottom shock absorber fasteners on each side of the vehicle. | |
| 4. | Lower the jiffy stand into position. Lower the motorcycle lift, and allow the vehicle to rest on the jiffy stand. | |
| 5. | Turn the ignition/key switch to IGNITION, but do not start the motorcycle. Check the tail, stop, rear turn signal and license lamps for proper operation. | |
| 6. | Install the license plate (if present) to the vehicle with the attaching hardware from the OE installation. |
SERVICE PARTS
Figure 6. Service Parts: Sportster Chopped Fender Installation Kits
Table 1. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 60236-09BEO 2007-2009 (Prime) | 1 | Fender, Sportster rear (chopped) (Prime paint), with hole (A) for ECM | 59865-09BEO |
Kit 60236-10BEO 2004-2006 (Prime) 2010+ (Prime) | 1 | Fender, Sportster rear (chopped) (Prime paint), no hole (A) for ECM | 59865-10BEO |
Kit 60236-09DH 2007-2009 (Black) | 1 | Fender, Sportster rear (chopped) (Black), with hole (A) for ECM | 59865-07DH |
Kit 60236-10DH 2004-2006 (Black) 2010+ (Black) | 1 | Fender, Sportster rear (chopped) (Black), no hole (A) for ECM | 59865-10DH |
Parts common to ALL kits | 2 | Brace, rear fender | 59727-07 |
3 | Machine screw, truss head, Phillips | 3085 | |
4 | Clip, rear fender (threaded) (2) | 10323 | |
5 | Tail/stop/turn signal stalk (2) | 5531 | |
6 | Flange nut (2) | 7531 | |
7 | Grommet, fender isolation | 11474 | |
8 | Spacer | 7882 | |
9 | Mounting block, reflector (with tape) | 68724-07 | |
10 | Reflector, rear (red) | 59359-06 | |
11 | Bracket, reflector mounting (right) | 68704-07 | |
12 | Bracket, reflector mounting (left, not used in this application) | 68857-07 | |
13 | Reflector, side (red) (2) | 69490-07 | |
14 | Pop rivet (5) | 8692 | |
15 | Plain washer (5) | 6192 | |
16 | Reflector/bulb socket assembly (2) | 68497-07 | |
17 | Socket terminal (10, including spares) | 72991-01 | |
18 | Socket housing, four-way (2) | 72914-01BK | |
19 | Bulb, tail/stop/turn signal (#198) (2) | 68168-89A | |
20 | Lens, tail/stop/turn signal (red) (2) | 68559-07 | |
21 | Converter module and interconnect harness, tail/stop/turn signal | 68278-07 | |
22 | Holder, tail/stop/turn signal converter module | 68299-07 | |
23 | Rear fender extension | 59502-09A | |
24 | Socket housing, two-way (For license lamp wire. Not used in this application.) | 73152-96BK | |
Items mentioned in text, but not included in kit: | |||
A | Hole for ECM mounting (2007-2009 models) | ||
B | OE hex head bolt, one inch (25 mm) long | ||
C | OE seat post and washer | ||
D | OE fender mounting screw, 1.38 inch (35 mm) long (2) and washer (2) | ||
E | OE fender support cover (2) | ||
F | OE fender mounting flange nut (2) | ||
G | OE fender mounting screw, 1.75 inch (44 mm) long (2), and washer (2) | ||
H | License plate bracket assembly (includes items J through P) | 60318-07 | |
I |
| 68183-07 | |
J |
| Not sold separately | |
K |
| 60334-07 | |
L |
| 68702-07 | |
M |
| 5403B | |
N |
| Not sold separately | |
O |
| 7716 | |
P | OE turn signal housing (2) | ||
Q | OE turn signal support (2) | ||