XL Passenger Pad
J029632015-01-17
GENERAL
Kit Number
51539-04, 51546-04, and 51810-05
WARNINGRider and passenger safety depend upon the correct installation of this kit.
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. (00308b)
WARNINGDo not install these seat kits on motorcycles that are not equipped with an appropriate grab strap and passenger footpegs. If footpegs and grab strap are not installed, passenger could fall from moving motorcycle or grab onto operator, causing loss of control and death or serious injury. (00410b)
Models
Table 1. Models
Kits | Models |
|---|---|
Kit 51539-04 | Designed to match solo seat number 51538-04 and fits 2004 and later XL883C and XL1200C model motorcycles. |
Kit 51546-04 | Designed to match the stock XL883 solo seat and fits 2004 and later XL883 standard or XL883L models with the XL883 stock seat installed. |
Kit 51810-05 | Designed to fit 2005 and later XL883L models with stock solo seat. |
REMOVAL
- Remove original seat according to the Owner's Manual instructions.
NOTICE
Detach passenger seat strap before removing seat. Failure to do so can result in damage to rear fender paint. (00225a)
INSTALLATION
- Remove the seat bracket located on the bottom of the stock seat on XL883 and XL883L models or from accessory seat 51538-04 (or the equivalent) for XL883C and XL1200C models. Save the bracket and hardware for installation onto the pillion.
| 1 | Seat retention nut |
| 2 | Seat retention washer |
| 3 | Plastic plug |
Figure 1. Seat Retention Nut and Washer Locations
Table 2. Seat Retention Nut and Lockwasher
XL88C/XL1200C | XL883 (Kit 51546-04) | |||
|---|---|---|---|---|
Kit 51539-04 | XL883L (Kit 51810-05) | |||
A | Grabstrap mounts to center location of fender. | B | Passenger pad mounts to rear location of fender. | |
| 1. | Kit 51539-04 on XL883C and XL1200C models: See Figure 1. Seat retention nuts and washers are required in both the middle and rear fender holes as shown. If only one additional nut is required, use the kit nut. If two are required, the nut must be removed from the front fender hole and used in the middle or rear location. Kit 51546-04 on XL883 (and XL1200R with XL883 stock seat installed) and Kit 51810-05 on XL883L See Figure 1. The seat retention nut and washer are required in the rear hole only. If the retention nut is not present at the rear hole location, remove the retention nut from the center fender hole and install it in the rear hole. | |||||
| 2. | Place the stock seat (on XL883 and XL883L models) or the solo accessory seat (for XL883C and XL1200C models) upside down on a work surface and fasten the passenger pad (4) to the bottom of the solo saddle with two hex head flange screws (6) and two flat washers (5). Tighten the screws securely. | |||||
| 3. | Place the stock seat (on XL883 and XL883L models) or the solo accessory seat (for XL883C and XL1200C models) upside down on a work surface and fasten the passenger pad (4) to the bottom of the solo saddle with two hex head flange screws (6) and two flat washers (5). Tighten the screws securely. | |||||
| 4. | Install the rear bracket removed earlier onto the pillion. Secure with screws removed earlier. Tighten to 4.5–6.8 N·m (40–60 in-lbs). Kits 51546-04 and 51810-05 only. See Figure 2. Install the grabstrap onto the bottom of the seat, by hooking one side of the grabstrap onto the tang on the underside of the seat and then looping the strap over the seat and fastening the remaining side onto the remaining tang. | |||||
| 5. | Kit 51539-04 only: To install seat assembly, push on rear corners of passenger pad to compress foam and slide rear of pad through installed passenger strap. It may take some time to get the seat properly in position. All models: See Figure 3. The seat and pillion assembly is attached to the vehicle at three points. Install the seat and pillion as follows: Angle the front of the new seat into place so the tongue engages the slot at the rear fuel tank mounting location. Continue to push the seat forward and rotate the rear of the seat downward until the seat contacts the frame. Flex the seat slightly in the middle and slide the seat towards the rear so that the keyhole slot on the seat bottom engages with the center seat post on the frame. It may take some practice to get the seat properly into place. The foam cushioning of the seat will need to be compressed as the seat is slid forward to get the seat in a forward enough position to engage the post on the frame when the seat is dropped into place. When properly installed, the front tongue on the underside of the seat should fit snugly in the groove at the fuel tank rear mounting location and the keyhole on the underside of the seat will lock the seat to the post. a. The tongue fits under the rear fuel tank bracket. b. The keyhole locks onto the seat post. c. The rear mounting bracket attaches to the rear seat nut in the fender with a screw. | |||||
| 6. | Pull up on the center of the seat to verify that it is locked into place. (There will be a small amount of play, but the seat should only come up about a half an inch and then will be held firmly in place by the post on the underside of the seat.) If the seat is not firmly in place, repeat Step 5 until the seat is firmly in place. Reference the Owner's Manual for further instruction on seat placement if needed. | |||||
| 7. | Install the screw and fasten the seat mounting bracket to the top of the rear fender. | |||||
| 8. | Tighten the mounting bracket screw. | 
Figure 2. Underside of Seat Showing Grabstrap Installed 
Figure 3. Seat Post | ||||
| 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) | ||||||
| 9. | Pull up on the front and rear of the seat again to verify that it is properly secured. |
SERVICE PARTS
Figure 4. Service Parts: XL Passenger Pad Kit
Table 3. Service Parts Table
Kit Contents in Kit 51539-04 | Kit Contents in Kits 51546-04 and 51810-05 | |||||
|---|---|---|---|---|---|---|
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
1 | Nut, seat retention | 7488 | 3 | Cable strap | 10039 | |
2 | Washer, retention | 7489A | 4 | Passenger pad | Not sold separately | |
3 | Cable strap | 10039 | 5 | Plain washer (2) | 6036 | |
4 | Passenger pad | Not sold separately | 6 | Hex head flange screw (2) | 3574 | |
5 | Plain washer (3) | 6036 | 8 | Grab strap (not shown) | 52293-04 | |
6 | Hex head flange screw (3) | 3574 | Items mentioned in text, but not included in kit: | |||
7 | Grab strap | 51188-00 | A | Items saved in Step 1. | Reference only | |