CHOPPED ENGINE GUARD
J062252021-01-11
GENERAL
Kit Number
49000105A, 49000114A, 49000117A, 49000235
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
WARNINGRider 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)
WARNINGIf Equipped: Front and/or rear guards are not intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022d)
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.
REMOVAL
FLTR Models Only
- Remove the outer fairing following the instructions in the service manual.
- See Figure 1. Remove the two screws (1) and mounting clamp (2) from the fairing support (5).
- Remove and retain the screw (3) and washer (4) that attach the stock fairing support to the motorcycle. Remove the stock fairing support. Repeat on opposite side.
| 1 | Screw (2) |
| 2 | Mounting clamp |
| 3 | Screw |
| 4 | Washer |
| 5 | Fairing support |
Figure 1. Remove Engine Guard
ALL Models
- Remove and retain the two screws that attach the bottom of the stock engine guard to the motorcycle frame.
- Remove and discard the hex socket screw and washer holding the top of the guard. Remove the engine guard from the frame, taking care not to scratch the finish on the motorcycle.
INSTALLATION
Install Engine Guard
- See Figure 2. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screws (2) and flat washers (3) from the kit.
- Install the bottom brackets to the motorcycle frame with the two TORX screws (1), removed earlier.
- Tighten the top mount screws to 10.8–12.2 N·m (96–108 in-lbs) and the bottom two mounts screws to 20.3–27.1 N·m (15–20 ft-lbs).
1 Screw (2) 2 Screw (2) 3 Washer (2) Figure 2. Install Engine Guard
2016 and earlier: Install additional flat washers between engine guard and frame.
Install Fairing Support Assembly (FLTR Models Only)
| 1. | See Figure 3. Hold the fairing support assembly in position, and loosely fasten the mid fairing support mount with the new hex socket screws (2, 8), flat washers (3, 7) and nut (9) from the kit. | |
| 2. | Install the side brackets to the motorcycle with the two screws (5) and washers (6) removed earlier. | |
| 3. | Tighten upper mid fairing mount screw. Torque: 21.6–24.4 N·m (16–18 ft-lbs) Mounting screw | |
| 4. | Tighten lower mid fairing mount screw. Torque: 5.4–6.7 N·m (48–60 in-lbs) Mounting screws | |
| 5. | Tighten two side mounts. Torque: 10.8–12.2 N·m (96–108 in-lbs) Mounting screw |
| 1 | Fairing support assembly |
| 2 | Screw (2) |
| 3 | Washer (3) |
| 4 | Frame |
| 5 | Screw |
| 6 | Washer |
| 7 | Washer |
| 8 | Screw |
| 9 | Nut |
Figure 3. Install Fairing Support
SERVICE PARTS
Figure 4. Service Parts: Engine Guard Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Fairing Support Assembly (Kit 49000117A and 49000235 only) | 47200354 |
2 | Engine Guard Assembly | Not Sold Separately |
3 | Screw (2) | 3601 |
4 | Washer (Kit 49000117A and 49000235 only) | 6116 |
5 | Washer (6) | 6703 |
6 | Flange Nut (Kit 49000117A and 49000235 only) | 7716 |
7 | Screw (Kit 49000117A and 49000235 only) | 2708A |
8 | Screw (Kit 49000117A and 49000235 only) | 4069A |
Items mentioned in text, but not included in kit: | ||
A | Screw | 3787 |
B | Washer | 6703 |
C | Screw | 4924 |