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CHROME CALIPER AND ROTOR COVER KIT
J049252009-04-23
GENERAL
Kit Number
44013-09A
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
WARNING
Rider 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 your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
There are no service parts available for this kit.
INSTALLATION
Left Side Installation
1. See Figure 2. Assemble the wedge spacer halves (1 and 2) to the left lower caliper mounting bracket (3) with the screw (4) and washer (5).
2. See Figure 3. Install the left lower caliper mounting bracket (1) to the left fork slider by sliding the wedge spacer into the hole in the bottom of the fork slider. Tighten finger-tight.
1Rotor cover top mounting bracket
2Spacer (models without fender rails only)
3Screw (16)
4Caliper cover
5Wedge spacer
6Screw and flat washer
7Lower mounting bracket
8Caliper/rotor cover mounting bracket
9Caliper mounting bracket
10Long bolt, front fender mount (trike only)
Figure 1. Caliper and Rotor Cover Kit (Left Side Shown)
1Wedge spacer, D-lock half
2Wedge spacer, threaded half
3Left lower caliper mounting bracket
4Screw
5Flat washer
Figure 2. Assemble Left Lower Mounting Bracket
1Left lower mounting bracket
Figure 3. Install Left Lower Mounting Bracket
3. See Figure 4. Install the caliper/rotor cover mounting bracket (2) to the caliper cover bracket (1) with screw (3).
4. See Figure 5.
a. Install the left caliper mounting bracket by removing the caliper mounting bolts that attach the caliper to the fork slider.
b. Align the bracket over the holes.
c. Install the bolts and alternately tighten the bolts to 38–52 N·m (28–38 ft-lbs).
1Caliper cover bracket
2Caliper/rotor cover mounting bracket
3Screw
Figure 4. Install Rotor Cover Mounting Bracket to Caliper Cover (Right Side Shown)
1Caliper mounting bracket
Figure 5. Caliper Mounting Bracket (Left Side Shown)
1Nut
2Rotor cover bracket
3Spacer
4Fender mounting bolt
Figure 6. Install Trike Rotor Cover Top Mounting Bracket
5. See Figure 7. Bend the locking plate tabs (1) on the left forward fender mounting bolt. Remove the bolt.
NOTE
The bracket must be oriented with the threaded hole toward the bottom.
6. For the trike model, see Figure 6. Align the bracket as shown in Figure 6. Use longer bolts (4) and tighten to 32.5–38 N·m (24–28 ft-lbs). Repeat for the right side.
7. See Figure 8. Insert the fender mounting bolt (1) Tighten finger-tight.
a. through the locking plate tab,
b. through the rotor cover top mounting bracket (2),
c. through the spacer (3, on models WITHOUT fender rails.)
d. through the fender (4),
e. into the threaded hole in the fork slider (5).
1Locking plate tabs
Figure 7. Bend Locking Plate Tabs (Left Side Shown)
1Fender mounting bolt
2Rotor cover top mounting bracket
3Spacer (for models without fender rails only)
4Fender mounting bracket
5Front fork slider
Figure 8. Install Rotor Cover Top Mounting Bracket (Left Side Shown)
8. See Figure 9. From the bottom of the fork slider, slide the left rotor cover between the fork slider and rotor, over the lower and top mounting brackets.
9. Install screws (1-3). Tighten finger-tight.
10. See Figure 10. Slide the lower mounting bracket in or out to adjust the cover to the proper position. The edge of the rotor cover lip should align with the inside surface of the brake rotor.
NOTE
When tightening the top rotor cover mounting screw, use a ball-end wrench to avoid damaging the fork slider.
11. Align the rotor cover so the space between the rotor cover and brake rotor is even all around and the space between the rotor cover and fork slider is even. See Figure 9. Tighten the four screws (1-3) to 2.5 N·m (22 in-lbs).
12. Tighten the mounting bolt (refer to Figure 8 ) securing the left rotor top mounting bracket and front fender to the fork slider to 19–24 N·m (14–18 ft-lbs).
13. Bend the locking plate tabs (see Figure 7 ) against the side of the bolt head to lock the bolt into position.
14. See Figure 11. Install the left caliper cover (1) with three screws (2). Tighten the screws to 2.5 N·m (22 in-lbs).
1Lower mounting bracket screw (2)
2Rotor/caliper mounting bracket screw
3Rotor cover top mounting bracket screw
Figure 9. Install Rotor Cover Screws (Left Side Shown)
1Align cover with inside surface of rotor
Figure 10. Adjust Rotor Cover (Left Side Shown)
1Caliper cover
2Screw (3)
Figure 11. Install Caliper Cover (Left Side Shown)
Right Side Installation
1. See Figure 4. Install the caliper/rotor cover mounting bracket (2) to the caliper cover bracket (1) with screw (3).
2. See Figure 12. Install the right rotor cover lower mounting bracket (3) to the back of the right rotor cover (1) with two screws (2). Tighten finger-tight.
3. See Figure 5. Install the right caliper mounting bracket by removing the caliper mounting bolts that attach the caliper to the fork slider. Align the bracket over the holes. Install the bolts and tighten the bolts to 38–52 N·m (28–38 ft-lbs).
4. See Figure 7. Bend the locking plate tabs (1) on the right forward fender mounting bolt. Remove the bolt.
NOTE
The bracket must be oriented with the threaded hole toward the bottom.
1Rotor cover
2Screw (2)
3Right lower mounting bracket
Figure 12. Install Right Lower Mounting Bracket
5. See Figure 8. Insert the fender mounting bolt (1) Tighten finger-tight.
a. through the locking plate tab,
b. through the rotor cover top mounting bracket (2),
c. through the spacer (3, on models WITHOUT fender rails.)
d. through the fender (4),
e. into the threaded hole in the fork slider (5).
6. See Figure 13. Remove and discard the two nuts, lock washers and flat washers that secure the axle cap to the right fork slider.
NOTE
The axle cap may fall away from the fork slider when the hardware is removed.
7. From the bottom of the fork slider, slide the right rotor cover between the fork slider and rotor, over the caliper mounting bracket and the top mounting bracket.
8. Fasten the rotor cover lower mounting bracket (1) onto the right fork slider studs, against the axle cap (2) with the two flanged lock nuts (3) from the kit. Tighten the flanged lock nuts evenly to 12–18 N·m (9–13 ft-lbs).
NOTE
When tightening the top rotor cover mounting screw, use a ball-end wrench to avoid contacting the fork slider with the wrench.
9. See Figure 9. Install screws (1-3). Tighten finger-tight.
10. Align the rotor cover so the space between the rotor cover and brake rotor is even all around (see Figure 10 ) and the space between the rotor cover and fork slider is even. Tighten four rotor cover mounting screws (see Figure 9 , items 1-3) to 2.5 N·m (22 in-lbs).
11. See Figure 8. Tighten the fender mounting bolt to 19–24 N·m (14–18 ft-lbs).
12. Bend the locking plate tabs (see to Figure 7 ) against the side of the bolt head to lock the bolt into position.
13. See Figure 11. Install the right caliper cover (1) with three screws (2). Tighten the screws to 2.5 N·m (22 in-lbs).
1Right rotor cover lower mounting bracket
2Axle cap
3Flanged lock nut (2)
Figure 13. Install Rotor Cover to Fork Slider Studs