1. | Remove and save the acorn nuts that secure the spring bridge on top of the front fork. Remove and save the spring bridge and lockwashers. | |||||||||||||||||
2. | Remove and save the socket head screw attaching the headlamp mounting block to the front rigid fork assembly. Remove the headlamp and position so that the headlamp shell or any other chrome parts will not get scratched. | |||||||||||||||||
3. | Remove the cable straps that hold the handlebar wires to the handlebar risers. | |||||||||||||||||
4. | Remove and discard the socket button head screw on the right side of the fork that retains the brake line and throttle cable clamps. Remove and discard the clamps. | |||||||||||||||||
5. | Remove and discard the socket button head screw and external tooth lockwasher on the left side of the fork. NOTE Support the handlebars during handlebar clamp removal to avoid scratching the fuel tank. | |||||||||||||||||
6. | Loosen the four screws of the upper handlebar clamps. Remove and save the clamps and screws. Remove the handlebar and position so it will not scratch the fuel tank. | |||||||||||||||||
7. | Remove and save the left side handlebar riser and all related hardware. Note the order of the components for later reassembly. | |||||||||||||||||
8. | See Figure 5. Install foam tape (8) from the kit along the inside of the chrome windshield bracket (1) as shown. NOTE When sliding the chrome windshield bracket into place, be careful not to pinch or twist any wires. Pinched or twisted wires may cause headlamp failure. |
Figure 1. Routing Wires Around Bracket | ||||||||||||||||
9. | See Figure 1. Slide the chrome windshield bracket (1) into place. Keep the handlebar wires (2) to the outside front of the bracket. | |||||||||||||||||
10. | Install the left side handlebar riser with the original equipment (OE) washer and locknut, and any related hardware removed in Step 7. Tighten the locknut to 33.9–47.4 N·m (25–35 ft-lbs). | |||||||||||||||||
11. | Install the handlebar following the instructions in the service manual. | |||||||||||||||||
12. | Loosely install the headlight assembly using the OE socket head screw. | |||||||||||||||||
13. | See Figure 5. For ALL models: Obtain a new brake line clamp (9) and two lockwashers (5) from the kit, along with the correct mounting screws for the application as listed below. For 2007 and 2008 FXSTSSE and FXSTSSE2: Obtain the second brake line clamp (9) from the kit. For FXSTS or FXSTSB models WITH passing lamps: Obtain a 3/4 inch (19 mm) long button head screw (2) for the left side installation and a 7/8 inch (22 mm) long button head screw (3) for the right side installation. For FXSTS or FXSTSB models WITHOUT passing lamps: Obtain a 5/8 inch (16 mm) long button head screw (4) for the left side installation and a 3/4 inch (19 mm) long button head screw (2) for the right side installation. For FLSTS or FLSTSB models (with or without passing
lamps): Obtain a 5/8 inch (16 mm) long button head screw (4) for the left side installation and a 3/4 inch (19 mm) long button head screw (2) for the right side installation. NOTE Be careful not to cross-thread the screws. | |||||||||||||||||
14. | On the left side:For 2007 and 2008 FXSTSSE and FXSTSSE2 models: Position the brake line clamp (9) to the windshield bracket as shown in the upper inset (A). Failure to position the clamp correctly may cause scratches or other damage to the fuel tank. For 2008 and later FLSTSB models: Position the brake line clamp (9) to the windshield bracket as shown in the lower inset (B). Failure to position the clamp correctly may cause scratches or other damage to the fuel tank. For ALL models: Install the correct button head screw (see above) through a lockwasher, the clamp (if equipped), the windshield bracket and into the left side upper fork mounting hole. Do not tighten at this time. | |||||||||||||||||
15. | On the right side:For all models EXCEPT 2008 and later FLSTSB models: Position a brake line clamp to the windshield bracket as shown. Failure to position the clamp correctly may cause scratches or other damage to the fuel tank. Install the correct button head screw through a lockwasher, the clamp (if equipped), the windshield bracket and into the right side upper fork mounting hole. Do not tighten at this time. | |||||||||||||||||
16. | Tighten the headlamp mounting block screw to 40.7 N·m (30 ft-lbs). | |||||||||||||||||
17. | Tighten the two side screws to 25.8 N·m (19 ft-lbs). | |||||||||||||||||
18. | Install the spring bridge with the OE acorn nuts and lockwashers. Tighten the acorn nuts to 40.7–47.4 N·m (30–35 ft-lbs). NOTE Do not operate vehicle without spring bridge in place as this may adversely affect handling. | |||||||||||||||||
19. | For ALL models except 2007 and 2008 FXSTSSE and FXSTSSE2: Obtain the new throttle cable guide (10) from the kit. For 2007 and 2008 FXSTSSE and FXSTSSE2: Obtain the new throttle cable guide (11) from the kit. For 2008 and later FLSTSB models: Obtain the second brake line clamp (9) from the kit.. | |||||||||||||||||
20. | Install the throttle cable guide under the right side docking point screw head(s) as shown in Figure 2 , Figure 3 or Figure 4. For all models EXCEPT 2008 and later FLSTSB
models: Rotate the throttle cable guide down as far as it will go. For 2008 and later FLSTSB models: Rotate the throttle cable guide straight upward as shown. NOTE During installation, hold the bottom loop of the guide to prevent it from rotating while installing the screws. This prevents potential interference with the fuel tank. | Figure 2. Throttle Cable Guide (All Models Except FLSTSB, FXSTSSE and FXSTSSE2)
Figure 3. Throttle Cable Guide (FLSTSB)
Figure 4. Throttle Cable Guide (FXSTSSE and FXSTSSE2) | ||||||||||||||||
21. | Install four docking points to the chrome windshield bracket by inserting a 7/8 inch (22 mm) long button head screw (3) through the guide or P-clamp (if equipped), a flat washer (6), rubber bushing (7) and washer (6) as shown. Tighten the screws to 25.8 N·m (19 ft-lbs). |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Bracket, windshield, chrome | 58912-96 |
Bracket, windshield, black | 58019-09 | |
2 | Screw, button head, 3/4 inch (19 mm) long (2) | 94548-97 |
3 | Screw, button head, 7/8 inch (22 mm) long (5) | 94467-94T |
4 | Screw, button head, 5/8 inch (16 mm) long | 94468-94T |
5 | Lockwasher (2) | 94081-90T |
6 | Washer, flat (8) | 6373 |
7 | Bushing (4) | 67621-94 |
8 | Tape, foam | 58811-96 |
9 | Clamp, brake line (2) | 10192 |
10 | Guide, throttle cable, wire form (all EXCEPT 2007-2008 FXSTSSE/FXSTSSE2) | 10206A |
11 | Guide, throttle cable, wire form (for 2007-2008 FXSTSSE/FXSTSSE2 only) | 68339-08 |
12 | Cable strap (2) | 10006 |
Specific Model Installations: | ||
A | For 2007-2008 FXSTSSE/FXSTSSE2 Models | |
B | For 2008 and later FLSTSB Models |