HARLEY DAVIDSON VRSC ACCESSORY SEATS AND PILLIONS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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INSTALLATION Installing Seat and Pillion Kits: 51584-01, 52028-02, 52036-01, 53432-02, or 52927-05 NOTE Proper installation of 53432-02 (Sundowner) and 52927-05 (Tallboy) requires installation of Fender Base Plate Kit 51120- 01 1. Refer to the appropriate Service Manual and remove the stock seat and pillion. 2. See Figure 2. Remove the two mounting bolts (2) from the passenger grabstrap (1). Save the bolts for re-installa- tion. NOTE The grabstrap must loop toward the rear. Check that the “Harley-Davidson” text on the grabstrap can be read from the front of the vehicle. 3. See Figure 2. Install stock grabstrap bolt, and one end of grabstrap as shown. While holding the grabstrap end parallel to the formed line of the fender, tighten the bolt to 8-12 Nm (71-106 in-lb ) . Repeat for opposite end of grabstrap. NOTES The new pillions included in Kits 52028-02 (Custom), 52036- 02 (Badlander) and 51584-01 (Leather Badlander) are installed from front-to-back. The pillion included in Kits 53432-02 (Sundowner) and 52927- 05 (Tallboy) must be installed through the grabstrap from back- to-front. To install the Sundowner or Tallboy Pillion on a motorcycle having a sissybar upright installed on Fender Base Plate Kit 51120-01, remove the upright before installing the pillion. Reinstall the upright after the Sundowner Pillion is installed. For kit numbers 52028-02 (Custom), 52036-01 (Vinyl Bad- lander) and 51584-01 (Leather Badlander) Seat Kits, be aware of the following: The 2003 Model Year 100th Anniversary VRSCA vehicle with two-tone sterling silver and vivid black paint has protective tape covering the rear under-the-seat area of the airbox cover. For the seats listed above, it will be necessary for cosmetic reasons, to carefully remove the protective tape and reapply it so it is in the correct position for these shorter-nose seats. Some trimming of the lower portion of the protective tape may be necessary to eliminate interference with the airbox cover latch. If necessary, reorder protective tape (48403-03). 4. Install new pillion into position through grabstrap. Prevent pinching TSSM control wiring by routing the cable through the channel on the underside of the pillion (see Figure 2) and away from the pillion mounting bolt. Pinched wiring may damage the TSSM system. 1 3 2 is00014 1. Pillion 2. Grabstrap 3. Pillion base mounting hole Figure 3. Pillion Base Mounting Hole 5. See Figure 3. Push the pillion (1) forward through the grabstrap (2) until the pillion mounting hole is approximately 25 mm (1 in.) forward of the hole (3) in the frame. 6. See Figure 2. Push down on the pillion and slide the pillion toward the rear to engage the pillion slot with the fender tongue (5). Push rearward until the pillion mounting holes align. After installing pillion, pull upward to be sure it is locked in position. While riding, a loose pillion can shift causing loss of control, which could result in death or serious injury. (00387a) 7. Install original pillion mounting bolt. Tighten bolt to 11-14 Nm (97-124 in-lb ) . 8. Re-install the sissybar upright, if removed earlier. 9. Position the seat (as if opened) onto the frame. Slide the seat forward to insert the seat-hinge pins into the bushings on the frame. 10. See Figure 1. Clip the plastic seat-hinge sleeve (2) over the seat hinge. 11. See Figure 1. Insert the seat tether (3) into the hole in the motorcycle frame. 12. Refer to the applicable Owner’s Manual and close the seat. Installing Seat Kits: 51595-05, 52024-01, or 51647-06 Kit 51595-05 requires the use of pillion kit 51594-05. Kit 51647-06 requires the use of pillion kit 51648-06. Kit 52024-01 requires the use of either the stock pillion or Touring Pillion 52023-01A. 1. Refer to the appropriate Service Manual and remove the stock seat.

HARLEY DAVIDSON DETACHABLE DYNA SIDEPLATE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Additional Parts Required The appropriate docking hardware and possibly a directional relocation kit must be installed prior to installation of this side- plate kit. These kits must be purchased separately from a Harley-Davidson Dealer. Table 1. Docking Hardware Kits Model Year Docking Hardware Kit FXDWG 53964-06 only Table 2. Directional Relocation Kits Model Year Docking Hardware and Directional Relocation Kit All except FXDWG 53961-06 and 53968-06 If mounting this kit with Saddlebags, part number 53968-06 is not required. Loctite® 262 (red), Part Number 94759-99, is available from your Harley-Davidson Dealer. Kit Contents Table 3. Kit Contents Part Number Description (Quantity) 52869-06 Side Plate, detachable, right 52870-06 Side Plate, detachable, left 94592-98 Button head screws (4) SISSYBAR INSTALLATION 2 3 1 4 1 is 01079 1. Sideplate 2. Sissybar 3. Buttonhead screw 4. Rotary latch Figure 1. Detachable Sissybar Sideplate Assembly See Figure 1. Install new or existing sissybar (2) to detachable sideplates (1) using four buttonhead screws (3). Apply Loctite® 262 (red) to screws before installation. Tighten screws to 96- 120 in-lbs (11-14 N-m)

HARLEY DAVIDSON XL SEAT KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1 2 is 00911 1. Tongue 2. Keyhole Figure 2. Underside of 2-up seat INSTALLATION NOTE If installing the seat with a sissybar/backrest pad present, remove the backrest pad prior to seat installation. This will prevent damage to the pad and/or seat. Reinstall backrest pad after the seat is installed. 1. Models equipped with solo seats: See Figure 1. a. Remove the plastic plug (1) from the rear hole location in the fender (2). Save the plastic plug for installation. b. Move the seat retention nut (4) and lockwasher (5) from the middle location to the rear location, where the plug was just removed. As shown in the inset, a cable strap (6) can be used as an installation aid. Place the retention nut (5) over the cable strap so that the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender, and through the fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. c. With the rib of the retention nut (4) seated into the notch in the fender hole, slide the retension washer (5) into place from the rear. This will lock the retention nut in place. d. Reinstall the plastic plug in the fender hole in the middle location. NOTE The foam cushioning of the seat needs to be compressed as the seat is slid forward to engage the post on the frame when the seat is dropped into place. When properly installed, the front tongue on the underside of the seat should fit snugly in the groove at the fuel tank rear mounting location and the keyhole on the underside of the seat will lock the seat to the post on the frame. 2. All models: See Figure 2. a. Angle the front of the new seat into place so the tongue (1) engages the slot at the rear fuel tank mounting location. b. Push the seat forward and rotate the rear of the seat downward until the seat contacts the frame. Flex the seat slightly in the middle and slide the seat towards the rear so that the keyhole slot (2) on the seat bottom engages with the center seat post on the frame. 3. See Figure 3. Pull up on the center of the seat to verify that it is locked into place. (There will be a small amount of play, but the seat should only come up about a half an inch and then will be held firmly in place by the post on the underside of the seat.) If the seat is not firmly in place, repeat Step 2 until the seat is firmly in place. Reference the Owners Manual for further instruction on seat placement if needed

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