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ROAD ZEPPELIN SEAT CUSHIONS
J055522015-01-12
GENERAL
Kit Numbers
52000084A, 52400060A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 17 and Table 1.
CUSHION ASSEMBLY
Removal
If installing a rider seat cushion only, no seat removal is required.
If installing a passenger pillion cushion, remove the rider seat and passenger pillion per the owner's manual. Retain all seat mounting hardware.
Rider Seat Cushion (Large)
NOTE
If installing only a passenger pillion cushion, proceed to "Passenger Pillion Cushion".
1. See Figure 17. Get the rider seat cushion cover (1), bladder assembly (2) and strap (5).
1Large seat cushion cover
2Cover zipper
3Main pouch
4Secondary sewn-in pouch
Figure 1. Cover and Pouch, Large Cushion
2. See Figure 1. Position the cover (1) with the seating surface facing upward and pouch (3) to the left. Open the zipper (2) to gain access to the pouch inner opening.
3. Inside the main pouch (3) is a secondary sewn-in pouch (4) that secures the bulb pump (part of the bladder assembly). Become familiar with the shape and location of the inner pouch. The stitching on the back side of the main pouch indicates the size and position of the inner pouch.
4. See Figure 2. Insert the bladder (2) into the seat cushion cover (1) with the bladder cells facing upward. Begin feeding the bulb pump and vent valve assembly into the main pouch (3) from the inside.
a. The pump/valve must be turned 90 degrees at the lower left corner of the main pouch to fit into the secondary pouch.
b. With the bulb pump (6) inserted into the secondary pouch, continue to coax the pump into position inside the pouch.
c. Position the vent valve (5) inside the secondary pouch with the relief button facing the embroidery of the pouch.
1Seat cushion cover
2Bladder
3Main pouch
4Bladder tube routing inside main pouch
5Vent valve location inside secondary pouch
6Bulb pump location inside secondary pouch
Figure 2. Bladder and Cover Assembly, Large Cushion
1Cover bottom (textured)
2Strap
3Right-side strap slot in cover
4Left-side strap slot in cover
5Strap buckle
Figure 3. Strap Installation, Large Cushion
5. See Figure 3. Flip the assembly over so the textured bottom (1) is facing upward. Note slots (3) and (4) in the front sides of the cover.
6. With one hand, reach inside the cover, between the cover bottom (1) and the bladder flat base. Find one of the slots (3). Start feeding the strap (2) end opposite the buckle (5) through the slot from outside the cover.
7. Feed the strap through the cover. Avoid twisting. Align the strap from inside the cover with the opposite slot (4), and feed the strap through the slot to the outside.
8. Position the strap in the cover slots with the buckle (5) near one of the slots. Buckle the strap.
9. See Figure 4. Adjust the strap length for cushion installation to the specific seat. To determine correct strap length, refer to "Cushion Installation to Seat", later in these instructions.
10. After the strap has been properly adjusted, insert the buckle through the nearest slot to rest inside the cover. Pull through any slack left in the strap. The strap should lay flat without any twists. Inside the cushion cover, the buckle and excess strap should lay flat between the cover and flat base of the bladder.
1Strap adjusted to length
2Strap buckle hidden in cushion slot
Figure 4. Adjust Strap Length and Hide Buckle, Large Cushion
1Zipper closed
Figure 5. Completed Large Cushion
11. See Figure 5. Make sure that the bladder does not get caught in the tracks and close the zipper (1).
12. See Figure 6. Perform an initial inflation of the cushion: Final inflation level will be determined after cushion installation.
a. Using the bulb pump (1), inflate the bladder cells until they just start to balloon the cushion cover.
b. Shift pressure from the far end of the cushion (opposite the pouch, as shown) by rolling in an attempt to deflate the cushion. Use the vent valve (2) to release the pressure as it resists the rolling.
c. After rolling about half the cushion (4) while venting the pressure, the near end will be inflated to bulging (3). Let go of the vent valve and unroll the cushion. Smooth out the partly inflated cushion to redistribute pressure evenly.
1Bulb pump for bladder inflation
2Vent valve for bladder deflation
3Near end inflated to bulging
4Rolled up, deflated far end
Figure 6. Initial Inflation, Large Cushion
Passenger Pillion Cushion
If NOT installing a Pillion Cushion, proceed to "Cushion Installation".
1. See Figure 17. Get the passenger pillion cushion cover (3), bladder assembly (4) and two straps (5).
1Pillion cushion cover
2Zipper
3Main pouch
4Secondary sewn-in pouch
Figure 7. Cover and Pouch, Pillion Cushion
2. See Figure 7. Position the cover (1) with the seating surface facing upward and pouch (3) to the left. Open the zipper (2) to gain access to the pouch inner opening.
3. Inside the main pouch (3) is a secondary sewn-in pouch (4) that will secure the bulb pump (part of the bladder assembly). Become familiar with the shape and location of the inner pouch. The stitching on the back side of the main pouch indicates the size and position of the inner pouch.
4. See Figure 8. Insert the bladder assembly (2) into the pillion cushion cover (1) with the bladder cells facing upward. Begin feeding the bulb pump and vent valve assembly into the main pouch (3) from the inside.
a. Insert the bulb pump/vent valve assembly straight into the secondary pouch (4) until the pump is in position (5).
b. Position the vent valve (6) inside the secondary pouch with the relief button facing the embroidery of the pouch.
1Pillion cushion cover
2Bladder assembly
3Main pouch
4Secondary sewn-in pouch
5Bulb pump
6Vent valve
Figure 8. Bladder and Cover Assembly, Pillion Cushion
5. See Figure 9. Flip the assembly over so the textured bottom (1) is facing upward. Note two sets of paired slots (3) and (4) in opposing corners of the cover.
6. With one hand, reach inside the cover, between the cover bottom (1) and the bladder flat base. Find one of the slots (3). Start feeding the strap (2) end opposite the buckle (5) through the slot from outside the cover.
7. Feed the strap through the cover. Avoid twisting. Align the strap, from inside the cover with the opposite slot (3) and feed the strap through the slot to the outside.
8. Repeat the strap insertion with the second strap (2) and slots (4).
9. Position one of the straps in the cover slots with the buckle (5) near one of the slots. Buckle the strap. Position and buckle the second strap in the same manner.
1Cover bottom (textured)
2Strap (2)
3Paired slots
4Paired slots
5Buckle (2)
Figure 9. Strap Installation, Pillion Cushion
1Strap (2) adjusted to length
2Strap buckle hidden in cushion slot (2)
Figure 10. Adjust Strap Length and Hide Buckles, Pillion Cushion
1Zipper closed
Figure 11. Completed Pillion Cushion
1Bulb pump for bladder inflation
2Vent valve for bladder deflation
3Near end inflated to bulging
4Rolled up, deflated far end
Figure 12. Initial Inflation, Pillion Cushion
10. See Figure 10. Adjust the strap lengths for cushion installation to the specific passenger pillion. To determine the correct strap length, refer to "Cushion Installation to Seat", later in these instructions.
11. After the straps have been properly adjusted, insert the buckles through the nearest slots to rest inside the cover. Pull through any slack left in the straps. The straps should lie flat without any twists. Inside the cushion cover, the buckles and excess straps should lie flat between the cover and flat base of the bladder.
12. See Figure 11. Make sure that the bladder does not get caught in the tracks and close the zipper (1).
13. See Figure 12. Perform an initial inflation of the cushion: Final inflation level will be determined after cushion installation.
a. Using the bulb pump (1), inflate the bladder cells until they just start to balloon the cushion cover.
b. Begin to shift the pressure from the far end of the cushion (opposite the pouch, as shown) by rolling in an attempt to deflate the cushion. Use the vent valve (2) to release the pressure as it resists the rolling.
c. After rolling about half the cushion (4) while venting the pressure, the near end will be inflated to bulging (3). Release the vent valve and unroll the cushion. Smooth out the partly inflated cushion to redistribute pressure evenly.
CUSHION INSTALLATION
NOTE
  • Adjust strap length to be snug. Use strap elasticity to add needed tension.
  • If there is no intention to move the cushion to any other seat, the excess strap length can be trimmed. Leave at least 25 mm (1 in) of strap length past the buckle
  • Strap elasticity will weaken over time, and periodic adjustment may be needed over the life of the seat cushion cover. Replacement straps are available. See Table 1.
  1. Determine proper strap length. Install the cushion:
The large rider cushion can mount to a rider seat or a large pillion.
  • When installing the large rider cushion on a rider seat, see Figure 13. Adjust the cushion strap (2) to fit over the front nose (1) of the seat.
  • When installing the large rider cushion on a large passenger pillion, see Figure 14. The large rider cushion should only be used on pillion surfaces as large as or larger than the rider cushion. Adjust the cushion strap (1) to fit completely around the belly (2) of the seat at the front of the pillion area.
  • When installing the passenger pillion cushion on a small passenger pillion, the cushion can be aligned lengthwise for longer, narrow pillions, or cross-wise for shorter, wider pillions (see Figure 15 or Figure 16 ), to suit pillion shape and passenger comfort. In either case, the cushion straps (2) crisscross around and under the pillion area (1). Place the cushion pouch (3) to the rear of the pillion, on the left or right side.
14. If not already done, position the strap buckles inside the cushion cover and eliminate any twisting or bunching of the straps. This will prevent the buckles from damaging painted surfaces or seat upholstery.
1Front nose of seat
2Cushion strap
Figure 13. Large Cushion Installed on Rider Seat
1Cushion strap
2Belly of seat at front of pillion area
Figure 14. Large Cushion Installed on Large Pillion
WARNING
After 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)
15. If the rider seat was removed, see the owner's manual and install the seat.
1Underside of pillion
2Cushion straps (2) crisscrossed
3Cushion pouch
Figure 15. Pillion Cushion Installed Lengthwise on Passenger Pillion
PRESSURE ADJUSTMENT
NOTE
  • Although this product is capable of being adjusted while in motion, it is best to get as close as possible to ideal seating pressure while stationary to avoid distraction while riding.
  • Proper adjustment can only be made while the rider is seated on the cushion, in normal riding position.
  • For optimum comfort, the goal should be to sink as deeply as possible into the cushion without hitting bottom. This is achieved by having no more air in the cushion than necessary.
1. With the cushion inflated to the initial pressure set before cushion installation, sit on the cushion in normal riding position, with feet on footboards or pegs.
1Pillion underside
2Cushion straps (2) crisscrossed
3Cushion pouch
Figure 16. Pillion Cushion Installed Crosswise on Passenger Pillion
2. While seated, adjust the air pressure by inflating with the bulb pump or deflating with the vent valve until you have sunk into the cushion with about a 13 mm (½ in) gap between you and the seating surface.
NOTE
Do not over-inflate! These cushions work most effectively with a minimum amount of air. Over-inflation will result in a floating, unstable feeling, and will not effectively distribute the seated pressure loads.
3. Check to see if there is adequate pressure in the cushion by shifting your weight, leaning your body (not the motorcycle) from side to side. The air within the cushion should transfer from cell to cell beneath you to redistribute the pressure.
a. If you feel you are touching the seat before sinking approximately 13 mm (½ in) into the cushion, inflate the cushion with the bulb pump.
b. If you feel you are floating and not touching the seat until sinking more than 13 mm (½ in) into the cushion, deflate the cushion with the vent valve.
CARE AND MAINTENANCE
Protect the seat cushions from sharp objects that could puncture the cushion bladder and cause deflation.
For minor punctures, any commercially available inner tube repair kit suitable for use with urethane materials may be used to seal the air leak.
The seat cushion covers can be removed and laundered. Machine wash in cold water. Do not use bleach. Air dry only. Do not iron or place in heated dryer. See the care label sewn inside each cover.
Avoid direct contact with hot engine or exhaust components, as they will damage the cushion materials.
Strap elasticity will weaken over time, and periodic strap adjustment may be needed over the life of the seat cushion cover. Replacement straps are also available. See Table 1.
IN USE
Do not use the cushion as a water flotation device.
SERVICE PARTS
Figure 17. Service Parts, Road Zeppelin Seat Cushions
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 52000084A
Rider Seat Cushion (Large)
1
Cover, rider seat cushion (large)
52000087A
2
Bladder assembly, large rider cushion
Not sold separately
5
Strap, adjustable
52000088
Kit 52400060A
Passenger Pillion Cushion
3
Cover, passenger pillion cushion
52400062A
4
Bladder assembly, passenger pillion cushion
Not sold separately
5
Strap, adjustable (2)
52000088
Items mentioned in text:
A
Bulb pump (inflator)
B
Vent valve (deflator)