SPORTSTER CHROME SPROCKET TRIM COVER KIT
J024602004-03-25
GENERAL
Kit Number
34944-04
Models
This kit fits 2004 and later XL (Sportster®) model motorcycles.
Additional Parts Available
For a complete chrome appearance, ask your Harley- Davidson Dealer about these items:
- Chrome Gearcase Trim Cover Kit,
- Chrome Timer Cover or a timer cover from one of the many collections,
- Chrome Timer Cover Screw Kit.
These items can be easily installed at the same time as this kit.
INSTALLATION
| 1. | See Figure 1. Remove and save the carriage bolt (2) and acorn nut (3) from the exhaust bracket clamp (4). Remove and discard the stock 3/8-16 screw (5). Remove and save the washer (6). Discard the exhaust bracket clamp (4). | |||||||||||||||||
| 2. | Remove and discard the 1/4-20 x 2-1/4 inch socket head screw (7) and the 1/4-20 x 1-3/4 inch socket head screw (8), keeping track of hole location for new screw length difference. Leave the original sprocket cover (1) in place. | |||||||||||||||||
| 3. | See Figure 2. Obtain the chrome sprocket trim cover and hardware from the kit. Position the chrome sprocket trim cover (1) over the original sprocket cover, being careful to match all the screw holes. | |||||||||||||||||
| 4. | With the chrome sprocket trim cover (1) positioned close to the original sprocket cover complete the following Steps. | |||||||||||||||||
| 5. | Insert a longer chrome screw (4) from the outside, through the upper right hole and through the chrome sprocket trim cover. Place a thinner spacer (5) over the threads. | |||||||||||||||||
| 6. | Using a 5/32 inch hex key on the screw head, grip one of the Nylon keeper washers (7) with a pliers. Install washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. | |||||||||||||||||
| 7. | Insert the short chrome screw (3) from the outside, through the lower hole and through the chrome sprocket trim cover. Place a thicker spacer (6) over the threads. | 
Figure 1. Sprocket Cover Removal | ||||||||||||||||
| 8. | Thread a Nylon keeper washer (7) onto the threads as described in Step 6. | |||||||||||||||||
| 9. | Install and thread the screws of the chrome sprocket trim cover assembly into the existing matching threaded holes in the transmission case. | |||||||||||||||||
| 10. | Position the exhaust bracket in place on the trim cover, being careful to match the existing holes. Insert the 3/8-16 button head screw (8) through the 3/8 washer (C) saved in Step 1, exhaust bracket clamp (2), sprocket trim cover (1) and the original sprocket cover and into the threads of the transmission case. Tighten to 40.7–44.8 N·m (30–33 ft-lbs). | |||||||||||||||||
| 11. | Tighten the 1/4-20 button head screws (3,4) to 9–13.6 N·m (80–120 in-lbs). | |||||||||||||||||
| 12. | Reinstall exhaust bracket to rear exhaust pipe with carriage bolt (A) and acorn nut (B) making sure exhaust bracket fits between the ends on the exhaust pipe clamp. | |||||||||||||||||
| 13. | Tighten rear exhaust pipe clamp nut (B) to 20.4–25.8 N·m (15–19 ft-lbs). |
SERVICE PARTS
Figure 2. Service Parts: Chrome Sprocket Trim Cover Kit
Table 1. Service Parts: Sprocket Trim Cover Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Trim Cover, Sprocket assembly, (chrome) | Not Sold Separately |
2 | Hardware Kit, sprocket cover/XL (includes items 4 thru 9) | 94438-04 |
3 | Bracket, exhaust mounting clamp, (chrome) | Not Sold Separately |
4 | Hex socket screw, button head 1/4-20 x 2 inch long, w/lock patch, (chrome) | Not Sold Separately |
5 | Hex socket screw, button head 1/4-20 x 2-1/4 inch long, w/lock patch, (chrome) | Not Sold Separately |
6 | Spacer, (steel) .06 inch thick | Not Sold Separately |
7 | Spacer, (steel) .16 inch thick | Not Sold Separately |
8 | Washer, keeper, nylon (2) | Not Sold Separately |
9 | Hex socket screw, button head 3/8-16 x 2-1/2 inch long w/lock patch, (chrome) | Not Sold Separately |
Original Parts Retained (not part of kit) | ||
A | Carriage bolt, 3/8-16 x 7/8 inch long | |
B | Acorn nut, 3/8-16 | |
C | Washer, 3/8 inch | |