AIR WING FENDER RAILS FOR TRIKE

J053972011-04-28

GENERAL

Kit Number

61400058

Models

For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Tools and Supplies Required

Loctite^® 243 Medium Strength Threadlocker and Sealant - Blue (Part No. 99642-97) is required for proper installation of this kit.

WARNING

Rider 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)

Kit Contents

See Figure 1 and Table 1.

PREPARATION

NOTE

For vehicles equipped with security siren:

Verify that the Hands-Free Fob is present.
Turn the ignition key switch to IGNITION.

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

1.	Refer to the owner's manual and follow instructions to remove the main fuse. NOTE Before lifting vehicle, set park brake and loosen four lug nuts in a crosswise pattern on each rear wheel. Never use differential housing as lifting point. Block the front wheel as necessary to prevent the vehicle from rolling.
	NOTICE When lifting a motorcycle using a jack, be sure jack contacts both lower frame tubes where down tubes and lower frame tubes converge. Never lift by jacking on cross-members, oil pan, mounting brackets, components or housings. Failure to comply can cause serious damage resulting in the need to perform major repair work. (00586d)
2.	Use a jack to lift the rear of the vehicle per owner's manual instructions.
3.	Remove the rear wheels. a. Remove the lug nuts and pull the wheel from the axle flange studs. b. Repeat for the other side.

TRIM RAIL INSTALLATION

1.	On one rear fender, measure up approximately 5-1/8 inches (130 mm) from the top center of the tail lamp base. Lay a piece of 2 inch (51 mm) wide masking tape across the fender with the rearward edge at the measured distance. NOTE Both trim rails are identical.
2.	See Figure 1. Using a scissors or utility knife, neatly cut all three plastic mounting washers (8) and mounting pads (9, 10, 11) from the runner of one set. Install the correct mounting pad over each of the three screw mounts on one trim rail (1).
3.	Place a trim rail (with mounting pads installed) into position on the fender with the trailing edge of the rear mounting pads at the rear edge of the tape.
4.	Lay a piece of 2 inch (51 mm) wide masking tape on the fender underneath the front mounting pad.
5.	Visually align the trim rail with the center of the tail lamp and parallel to the outer edge of the fender. Verify satisfactory appearance and alignment to the fender from all views, adjusting the trim rail placement as necessary.
6.	Use a pencil or other marking device to outline the mounting pads on the tape.
7.	Remove the trim rail and pads from the fender.
8.	Repeat steps 1-7 on the opposite fender.
9.	Set one pad at a time into its correct position as marked on the tape, and drill a 1/16 inch (2 mm) diameter pilot hole through the center of each mounting hole in both fenders.
10.	From the painted side of the fenders, drill a 1/4 inch (6.5 mm) diameter hole through the rearward hole in the left rear pad location. Drill a 7/32 inch (5.5 mm) diameter through hole at all other locations.
11.	Remove the tape. Lightly sand the hole edges to remove burrs and sharp edges. Clean the fender painted surfaces of tape residue with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water.
12.	Get one of the trim rails. If NOT installing an Air Wing Rail Light Kit (Part No. 68286-10 or 68388-10): Fasten the filler plate (5) to the underside of the trim rail rear crosspiece with two #8-32 screws (6) from the kit. Tighten to 3.1–3.5 N·m (27–31 in-lbs).
13.	Get three #10-24 screws (2) from the kit. Place first a lockwasher (4), then a plain washer (3) and a notched mounting washer (8) onto the threads of each screw.
14.	Insert one screw, from the unpainted side, through the forward hole in the fender. Insert the screw through the round mounting pad (9) and thread into the forward mounting hole in the trim rail, but do not fully tighten.
15.	Insert the other two screws through the rear holes in the fender. Insert the screws through the mounting pads and thread into the rear trim rail mounting holes, but do not fully tighten. NOTE Plastic mounting pads and washers should compress only slightly when screws are properly secured.
16.	Tighten the screws to 3.1–3.5 N·m (27–31 in-lbs).
17.	Repeat steps 12-16 for the opposite side fender trim rail.

SERVICE PARTS

Figure 1. Service Parts, Air Wing Fender Rails for Trike

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	Trim rail, Air Wing rear fender (2)	61400059
2	Machine screw, Phillips, #10-24 x 19 mm (¾ in) long (6)	1205
3	Plain washer (6)	6716
4	Lockwasher, split, #10 (6)	7069
5	Filler, fender trim rail rear (2)	61400065
6	Cap screw, hex socket head, #8-32 x 7.9 mm (5/16 in) long (4)	10500005
7	Mounting pad and washer set (includes items 8 through 11)	11100034
8	Washer, notched (3)	Not sold separately
9	Mounting pad, front (round)	Not sold separately
10	Mounting pad, left rear (two holes)	Not sold separately
11	Mounting pad, right rear (one hole)	Not sold separately

AIR WING LED LIGHT INSTALLATION (WIRE ROUTING ONLY) (SOLD SEPARATELY)

Refer to the service manual and follow the instructions given to remove the seat.

ALL installations: See Figure 1. Obtain a trim rail light assembly (1) from the kit.

Install the light to the underside of the trim rail rear cross bar with two screws (2) from the kit. Tighten the screws securely.

Insert the wires through the 1/4 inch hole in the rear left side mounting pad.

Route the light wiring to the rear of the fender and follow the taillight wire through the hole at the bottom corner of the fender. Continue routing the wiring up the inside of the body under the seat area. Use clips or cable straps as necessary to take any slack out of the wiring.

Repeat wire routing for the opposite side of the Trike.

1	Left and right wire harness

Figure 2. Routing Wire Harness to Accessory Connector

NOTE

Refer to the instruction sheet that came in the light kit (sold separately) for further wiring instructions.