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Sport Wind Deflector and Windshield Kits
J033062006-05-18
GENERAL
Kit Number
57858-05, 57861-06, and 57870-07
Models
These kits fit all 2004 and later V-Rod® model motorcycles.
Table 1. Models
Kits
Models
57858-05
Mid-Sport Windshield (VRSCB)
57861-06
Mid-Sport Windshield (VRSCD)
57870-07
Mid-Sport Windshield (VRSCDX)
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
See Figure 5 and Table 2 for Mid-Sport Windshield Kit Contents.
HEADLAMP VISOR INSTALLATION (2004 Only)
1Headlamp
2Headlamp bracket mounting screws
Figure 1. Remove Headlamp Mounting Screws (Left Side Shown)
1. See Figure 1. While holding the headlamp (1), remove the left and right headlamp bracket mounting screws (2).
2. See Figure 5. Obtain the headlamp visor (2) from the kit.
3. See Figure 2. Orient the headlamp visor (1) between the headlamp and headlamp mounting bracket (2) and reinstall the headlamp bracket mounting screws (3) securing the visor and headlamp to the headlamp mounting bracket.
4. Refer to the Service Manual and adjust the headlamp for the correct angle.
1Headlamp visor
2Headlamp mounting bracket
3Headlamp mounting bracket screw
Figure 2. Install Visor Between Headlamp and Mounting Bracket (Left Side Shown)
1"RT" or "LFT" marking
2Hinge-pin head faces up
3Clamp post socket faces outward
Figure 3. Fork Tube Clamp and Post Identification (Right-Side Clamp Shown)
WINDSHIELD INSTALLATION
  1. See Figure 5. Obtain one of the lower mount kits from the windshield kit carton. Identify the fork tube clamp for right-side (RT) or left-side (LFT) installation as indicated in Figure 3.
    2. NOTE
    The lower grommets (4) have been pre-installed into the Lexan® windshield.
  2. Insert the rounded end of the post into the socket in the fork-tube clamp, oriented as shown in Figure 5. Lining up the hole in the end of the post with the hole in the clamp. With a 3 mm hex key, fasten the post to the clamp with the flat-head screw (16) from the kit, and tighten to 6.8 Nm (60 in-lbs).
  3. Place the clamp around the correct-side fork tube with the hinge-pin head facing up. Insert the two longer screws (15) from the lower mount kit through the counterbored holes in the outboard side of the clamp, and thread the screws part-way into the tapped holes in the inboard half.
  4. Position the clamp so the top surface is approximately 6 to 13 mm (1/4 to 1/2 inch) below the upper triple-tree, and the hinge pin is straight forward. With a 4 mm hex key, tighten the screws just enough to hold the clamp in position.
  5. Obtain the remaining lower mount kit and repeat Steps 2 through 4 to install the clamp to the opposite fork tube.
  6. Obtain the upper mount kit from the windshield kit carton.
    7. NOTE
    The upper grommets (4), socket assemblies (3), windshield mount caps (6) and 5 mm screws (9) have been pre-installed into the windshield.
  7. Place one of the handlebar clamps (5) onto one side of the handlebar, in the straight section between the riser and the handlebar controls, oriented as shown in Figure 4.
NOTE
Temporarily disengage the switch harness retainer from the handlebar to allow installation of the clamp.
1Rod outboard of clamp (kit 57858-05)
2Rod inboard of clamp (kit 57861-06, 57870-07)
Figure 4. Properly Assembled Upper Windshield Mounts
  • For Kit 57858-05: the rod mounting hole should be outboard of the handlebar, facing roughly straight ahead.
  • For Kit 57861-06 and 57870-07: the rod mounting hole should be to the inboard side of the handlebar, facing roughly straight ahead.
  1. Place the threaded end of one of the rods (7) over the forward-facing hole of the handlebar clamp. Position the rod so the ball end is directly above the banjo fitting on the brake or clutch reservoir and is pointed roughly straight ahead.
  2. Insert a 6 mm screw (8) into the clamp from the rear, and thread the screw into the rod. With a 5 mm hex key, tighten the screw just enough to hold the clamp and rod in position.
  3. Repeat Steps 7 through 9 on the opposite side.
  4. Obtain the windshield assembly, and the caps (6) from the two Lower Mount kits. From the outer side of the windshield, install the caps into the lower grommets.
  5. Bring the windshield (with the sides curving away from you) to the front of the bike.
    6. NOTE
    Take care not to scratch the headlamp housing or visor while positioning the windshield to the snap-mount sockets.
  6. Straddle the front fender. Center the windshield around the headlamp and seat the two upper snap-mount sockets onto the ball ends of the upper windshield mount rods.
    7. NOTE
    It may be necessary to loosen, and rotate the pre-installed windshield components in order to align the socket assemblies (3) with the upper windshield rods.
  7. Obtain the remaining screw (9) and flat washer (14) from one of the Lower Mount kits.
  8. Adjust one of the lower clamp assemblies to align with the windshield. Place the washer between the lower mount post and the windshield grommet. Insert the screw through the cap and grommet. Using a 4 mm hex key, thread the screw into the post, tightening the screw just enough to hold the clamp and post in position.
  9. Repeat Steps 14 and 15 for the opposite side.
  10. Adjust the position of the windshield to be centered on the bike and not tilted at an angle.
  11. Alternately tighten the six lower mount fasteners first:
NOTE
When tightening the two long screws (15) that are on each clamp, alternate between the two to ensure that each is secure, but no more than twice at the torque value to prevent over-tightening the clamp.
  • With a 4 mm hex key, tighten the four clamp screws (15) to 5.1-5.7 Nm (45-50 in-lbs).
  • See Figure 5. Tighten the two post screws (9) to 8.5 Nm (75 in-lbs).
NOTE
As the upper mounts are tightened, the windshield may shift out of alignment. Some additional adjustment to clamp positioning may be needed.
  1. After the lower screws are tight, alternately tighten the two upper mount fasteners:
  • With a 5 mm hex key, tighten the two 6 mm screws (8) at the clamp end to 10.1 Nm (90 in-lbs).
  1. Adjust the position of the windshield to be centered on the bike and not tilted at an angle. If the brake or clutch line, or a reservoir banjo bolt interferes with the proper alignment of the windshield, first try to adjust the windshield location. If the windshield cannot be positioned securely, then refer to the following section.
BRAKE-LINE or CLUTCH-LINE INTERFERENCE
  1. If there is interference between the upper windshield mounts and the brake or clutch line, refer to the appropriate (CLUTCH or BRAKE) MASTER CYLINDER, REMOVAL and INSTALLATION sections of the VRSC Service Manual.
  2. Heed all applicable warnings and cautions, for instructions to remove and re-install the banjo bolt, reposition the fluid line and install new steel/ rubber washers.
SERVICE PARTS
Figure 5. Service Parts: Mid-Sport Windshield
Table 2. Service Parts Table
Item
Description (Quantity)
Part Number
Kit 57861-06 and 57870-07: Mid-Sport Windshield (VRSCD and VRSCDX):
1
Windshield, mid-sport
57862-06
Kit 57858-05: Mid-Sport Windshield (VRSC):
1
Windshield, mid-sport
57831-05
2
Visor (polished stainless steel)
69200-01
Upper Mount Kit, Mid-Sport Windshield:
3
Socket assembly, snap mount, (2)
57891-05
4
Grommet, thick-groove (2)
11572
5
Handlebar clamp (2)
57788-01
6
Cap, upper windshield mount (2)
57782-01
7
Rod, ball-end, "Z"-shape (2)
57839-04
Rod, ball-end, "Z"-shape (VRSCDX) (2)
57356-07
8
Cap screw, socket head, M6-1 x 20 mm long (2)
4252M
9
Cap screw, socket head, M5-0.8 x 14 mm long (2)
4476M
Lower Mount Kit (Right), Mid-Sport Windshield:
4
Grommet, thick-groove
11572
10
Fork tube clamp (right)
57877-05
11
Post (right)
57617-05
Post (right) (VRSCDX)
57355-07
Lower Mount Kit (Left), Mid-Sport Windshield:
4
Grommet, thick-groove
11572
11
Post (left)
57617-05
Post (left) (VRSCDX)
57358-07
12
Fork tube clamp (left)
57878-05
The following parts are common to both Lower Mount Kits:
6
Cap, lower windshield mount
57782-01
9
Cap screw, socket head, M5-0.8 x 14 mm long
4476M
14
Flat washer, 0.28 in. (7.1 mm) ID
6703
15
Cap screw, socket head, M5-0.8 x 20 mm long (2)
4475M
16
Cap screw flat head, hex socket, M5-0.8 x 12 mm long
4477M