w w w.hdonline s h o p .d e - HARLEY
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1. J04940 INSTRUCTIONS REV 2010 02 03 SPORTSTER CHOPPED FENDER INSTALLATION KITS GENERAL Numbers 60947 10 chrome 60972 10 black Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Separate purchase of a Side Mount License Plate Bracket Assembly Part No 60318 07 or Accessory Side Mount License Plate Kit Part No 60947 40 or 60972 10 is required Test fit the prime coated fender priorto painting but have the fender painted before final installation Tools and Supplies Required The help of an assistant will be needed for some removal and installation procedures An Amp Muttilock Crimpar HD 41609 is required for the proper installation of this kit Electrical Contact Lube H D Part No 99861 02 or equivalent is required for the proper installation of this kit Awarninc The rider s safety depends 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 00333a NOTE This instruction sheet refers to service manual information A service manual for this year mode motorcycle is required for this installation and is avail2. the reflector mounting area of the reflector mounting block with a mixture of 50 70 isopropyl alcohol and 30 50 distilled water Allow to dry thoroughly NOTE Ambient temperature should be at least 60 F 16 C for proper adhesion 19 Remove the liner from the adhesive backing of the reflector Carefully position the reflector to the reflector mounting area of the mounting block and press firmly into place Hold the reflector in position with steady pressure for about one minute 20 Remove the liner from the adhesive backing on the mounting block tape Position the mounting block centered to the rear edge on the underside of the fender and press firmly into place Hold the mounting block in position with steady pressure for about one minute J04940 21 Obtain the side reflectors 13 from the kit 22 Clean the reflector mounting area of the license plate bracket assembly with a mixture of 50 70 isopropyl alcohol and 30 50 distilled water Allow to dry thoroughly 28 Remove the liner from the adhesive back of ane reflector Carefully position the reflector to the reflector mounting area of the bracket and press firmly into place Hold the reflector in position with steady pressure for about one minute 24 Repeat Steps 22 and 28 with the right side reflector mount bracket 11 and the remaining side reflector NOTE Allow AT LEAST 24 hours atter applying the reflectors before exposing the areas to vigorous was
3. able from a Harley Davidson dealer Electrical Overload This fender installation kit takes no more current than an ori ginal equipment OE rear lighting circuit Kit Contents See Figure 6 and Table 1 INSTALLATION Preparal n 1 Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level J04940 To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo which could result in death or serious injury 00049a 2 Refer to the service manual and follow the instructions given fo remove the seat and disconnect the battery cables negative cable first Retain all seat mounting hardware 3 Remove the battery from the vehicle per the instructions in the service manual 4 Raise the rear of the vehicle to relieve the load on the shock absorbers 5 Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle Save the fasteners for later assembly 6 Raise the rearof the Vehicle further to allow access to the underside of the reat fender 7 Remove the license plate from the vehicle if installed Retain the plate and attaching hardwar
4. e Rear Fender Removal NOTE Note the location and orientation of rear fender mounting hardware and save for later assembly 1 Refer to the service manual and follow the instructions given to remove the rear fender with the following exceptions a Removal of the tail lamp from the fender is not necessary Rear Lamp Wiring 1 Cutoff and discard the socket housings and terminal ends from the turn signal wires 2 See Figure 1 Unscrew and remove the turn signal stalk 15 from one of the turn signal lamps and discard Remove and retain the turn signal lamp and support 14 from the rear fender support cover 3 Insert the blade of a small screwdriver into the slot at the bottom of the turn signal lamp lens 2 and twist to unsnap the lens from the housing 1 1of7 4 5 6 7 To avoid breakage push the bulb 3 in and rotate coun terclockwise to remove Separate the turn signal reflector 5 from the lamp housing using either or both of these methods as necessary a Insert the blade of a small screwdriver between the outer edge of the rubber gasket 4 and the inside of the housing Gently pry up the reflector 5 until free b Insert a thin blade screwdriver or similar tool through the threaded hole 9 in the housing 1 and gently push the reflector 5 and rubber gasket 4 free of the housing Guide the wires out of the unthreaded hole 8 in the lamp housing The turn signal stalk gasket
5. ems mentioned in text but not included in kit A Hole for ECM mounting 2007 2009 models OE turn signal housing 2 B OE hex head bolt one inch 25 mm long OE seat post andl washer D OE fender mounting screw 1 38 inch 35 mm long 2 and washer 2 E OE fender support cover 2 F OE fender mounting flange nut 2 G OE fender mounting screw 1 75 inch 44 mm long 2 and washer 2 H License plate bracket assembly includes items J through P 60318 07 tlluminator license plate 68183 07 J i Screw 2 Not sold separately K gt Holder license plate 60334 07 L Extension license plate holder 68702 07 M Carriage bolt 5403B N Nylon washer Not sold separately O Flange nut 7716 P a OE turn signal support 2 304940 7ot7
6. hing strong water spray or extreme weather The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature Rear Lamp Wiring Connection to Vehicle 1 __ Obtain the taillstop turn signal converter module 21 and holder 22 from the kit Insert the module into the holder and install the module and holder in the battery area as follows ail See Figure 4 Feed the converter module and inter connect harness connectors up through the battery compartment forward of the battery strap bracket b Position the converter module up inside the frame under the Y section For 2009 and 2010 models See the instructions in the service manual For 2008 and earlier models See Figure 5 Pull the rubber mounting tab through the hole in the frame to secure the module Figure 4 Converter Module Installation 40t7 Figure 5 Converter Module Mounting Tab 2008 and Earlier 2 Connect the six way pin housing 7B on the tail lamp converter module to the socket housing 7A on the main vehicle harness Connect the pin housing 408 on the tail lamp converter module to the socket housing on the license plate illumin ator harness Tuck the connectors and wiring into the area under the seat 3 See Figure 3 Route the tail stop turn signal wire harnesses 4 through the lower hamess clips 5 and the wire troughs above the rear fender extension then over to the tail lamp converter modu
7. le connectors 188 and 198 Gut the unterminated wires and tubing to allow sufficient length to make the connections 4 Obtain six terminals 17 and two socket housings 18 from the kit 5 Follow the instructions in the service manual to crimp the terminals onto the tail stoplturn signal wires Insert the tailistop turn signal wiring socket terminals coming from one lamp into the correct cavities of one socket housing a Insert the black wire and terminal into cavity 1 b Insert the violet wire and terminal into cavity 2 c Insert the blue wire and terminal into cavity 3 Repeat for the remaining socket housing 6 Connect the pin housings 18B right and 19B teft on the tail lamp converter module to the socket housings on J04940 the tail stop turn signal wiring Tuck the connectors and wiring into the area under the seat 7 Refer to the service manual and follow the instructions to install the battery Return to Service NOTE Verify that the ignition ight key switch is in the OFF position before attaching the battery cables 1 Verity that the ignitiovkey switch is turned to the OFF position Apply a light coat of Harley Davidson electrical contact lubricant Part No 99861 02 petroleum jelly or corrosion retardant material to the battery terminals Refer to the service manual and follow the instructions given to attach the battery cables positive cable first Awarnine Connect posi should c
8. ontact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a Awarnine After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 2 Refer to the service manual and follow instructions to install the seat 3 Follow the service manual instructions to install the bottom shock absorber fasteners on each side of the vehicle 4 Lower the jiffy stand into position Lower the motorcycle lft and allow the vehicle to rest on the jiffy stand 5 Turn the ignition key switch to IGNITION but do not start the motorcycle Check the tail stop rear turn signal and license lamps for proper operation 6 Install the license plate if present to the vehicle with the attaching hardware from the OE installation 50t7 SERVICE PARTS Figure 6 Service Parts Sportster Chopped Fender Installation Kits Table 1 Service Parts Kit Tem Description Quantity Part Number Kit 60236 09BEO 1 Fender Sportster rear chopped Prime paint with hole A for ECM 59865 09BEO 2007 2009 Prime Kit 60236 10BEO 1 Fender Sportster rear chopped Prime paint no hole A for ECM 59865 10BEO 2004 2006 Prime 2010 Prime Kit 60236 09DH 1 Fender Sports
9. reflector bulb amber lens and wiring can be discarded See Figure 6 Obtain a reflector bulb socket assembly 16 double filament bulb 19 and red lens 20 from the kit See Figure 1 Route the wires 10 11 12 and protective tubing 13 from the reflector bulb socket assembly through the center of the rubber gasket 4 and out through the unthreaded hole 8 in the lamp housing 1 oO Housing Lens Bulb Gasket Reflector Bulb socket Spring Unthreaded hole Threaded hole 10 Black wire 11 Violet wire 12 Blue wire 13 Protective tubing 14 Support 15 Stalk LPNPMRHN A Figure 1 Tail Stop Turn Signal Lamp 304940 8 Assemble the lamp as follows a Ifoutof position insert the spring 7 and bulb socket 6 back into the reflector aligning the locating tab on the bulb socket with the slot in the reflector The violet wire 11 should be closest to the tab on the socket b Seat the reflector assembly in the rubber gasket aligning the tab on the reflector with the slot in the gasket c Install the reflector assembly aligning the tab on the reflector with the slot inside the lamp and leaving about 1 2 inches 25 50 mm of wire inside the lamp housing Carefully route the wires through the turn signal lamp support 14 and the third rearmost hole in the fender support cover d Insert the long end of a new turn signal stalk 15 from the inside through the second rearmost hole in
10. t 60947 10 install according to instructions included with the kit before proceeding to step 14 J04940 Rear fender brace Nut plate 2 Tab Slot Mounting screw 2 Figure 2 Rear Fender Nut Plate 14 See Figure 6 Tighten all fender mounting hardware in the following sequence a Tighten the screw B and seat post C to 96 156 in Ibs 10 9 17 6 Nm b Tighten the forward D and rearmost G fender support screws on both sides of the fender to 132 216 in Ibs 14 9 24 4 Nm c Tighten the rear lamp stalk flange nuts 6 to 132 216 in tbs 14 9 24 4 Nm d Tighten the rear fender brace screw 3 to 132 216 in lbs 14 9 24 4 Nm 15 See Figure 3 if installing side mount license plate 60318 07 Disregard if installing 60947 10 Feed the license plate lamp harness 1 up through the harness channel 2 Insert the harness into the upper license plate bracket harness clips 3 and the wire trough 6 above the rear fender extension 30f7 License plate lamp harness Harness channel Upper harness clip 5 Left rear lighting harness Lower harness clip 3 Rear fender extension oa Peps Figure 3 Rear Lamp Harness Routing 16 2007 2009 models Install the ECM to the ECM caddy on the fender per service manual instructions 17 ALL models See Figure 6 Obtain the reflector mounting block 9 and rear reflector 10 from the kit 18 Clean the rear underside of the new fender and
11. ter rear chopped Black with hole A for ECM 59865 07DH 2007 2009 Black Kit 60236 10DH 1 Fender Sportster rear chopped Black no hole A for ECM 59865 10DH 2004 2006 Black 2010 Black J04940 6of7 Table 1 Service Parts Kit item Description Quantity Part Number Parts common 2 Brace rear fender 59727 07 to ALL kits 3 Machine screw truss head Phillips 3085 4 Clip rear fender threaded 2 10323 5 Tailstop turn signal stalk 2 5531 6 Flange nut 2 7531 7 Grommet fender isolation 11474 Spacer 7882 9 _ Mounting block reflector with tape 68724 07 10 Reflector rear red 59359 06 11 Bracket reflector mounting right 68704 07 12 Bracket reflector mounting left not used in this application 68857 07 13 Refiector side red 2 69490 07 14 Pop rivet 5 8692 18 Plain washer 6 6192 16 Refiector bulb socket assembly 2 68497 07 17 Socket terminal 10 including spares 72991 01 18 Socket housing four way 2 72914 01BK 19 Bulbytail stopiturn signal 198 2 68168 89A 20 Lens tail stopturn signal red 2 68559 07 21 Converter modul and interconnect harness talllstop tumn signal 68278 07 22 _ Holder tal stopiturn signal converter module 68299 07 23 Rear fender extension 59502 09A 24 Socket housing two way 73152 96BK For license lamp wire Not used in this application It
12. the fender support cover and the lamp support and thread the stalk into the lamp housing Tighten to 96 156 in lbs 10 9 17 6 N m e Using the thumbs of both hands apply even pressure around the outer edge of the reflector assembly until fully seated tdi Liberally apply electrical contact lubricant H D Part No 99861 02 of equivalentito the contacts 11 12 inthe reflector socket and at the base of the new bulb 3 Push n the bulb and rotate clockwise to install g Install the new red lens 2 to the lamp housing and gently apply thumb pressure until it snaps into place Rotate the lens to position the slot at the bottom of the lamp 9 Repeat Steps 2 through 8 for the remaining lamp Rear Fender Assembly and Mounting NOTE Test fit the prime coated fender prior to painting but have the fender painted before assembly and final installation Protect the painted fender from scratches and damage during assembly steps 4 See Figure 6 Obtain the new painted chopped rear fender 1 five pop rivets 14 and five washers 15 and the rear fender extension 23 from the kit Line up the holes in the extension with the holes in the fender Secure the extension to the fender with the pop rivets and washers Line up the holes in the extension and wire troughs with the holes in the fender Secure the extension and troughs to the fender with the pop rivets and washers 2 2007 through 2009 models install the ECM cadd
13. the screw threads but do not fully tighten at this time Install a new flange nut 6 from the kit onto the tail stop turn signal stalk 5 sorew threads but do not fully tighten Position either the license plate bracket assembly H or left side reflector mounting bracket 12 if installing accessory side mount license plate kit 60947 10 against the inside of the fender on the left side Line up the holes in the bracket with the holes in the fender Feed the left side tail stop turn sigfial lamp wiring through the holes the fender and license plate bracket assembly Insert the remaining OE 1 38 inch 35mm screw and washer through the forward mounting hole in the support cover the fender suppart the mounting hole in the rear fender and the mating slot in the license plate bracket assembly Install the OE flange nut onto the screw threads but do not fully tighten Install the remaining new flange nut onto the tail stop turn signal stalk screw threads but do not fully tighten Position the rear fender brace 2 to the underside of the fender and align the center hole with the hole in the fender Loosely fasten with the Phillips head screw 3 See Figure 2 Make certain that the tab 3 on each nut plate 2 fits into the slot 4 in the fender brace 1 when securing the nut plates with the rearmost fender mounting screws and washers 5 Do not fully tighten NOTE If installing accessory side mount license plate ki
14. y into the large hole in the fender 3 ALL models Obtain the new license plate bracket assembly ltem purchased separately or left side reflector mounting bracket 12 if installing accessory side mount license plate kit 60947 10 right side reflector mounting bracket 11 rear fender brace 2 Phillips head screw 3 two fender clips 4 two flange nuts 6 grommet 7 and spacer 8 from the kit and the OE fender mounting hardware removed earlier 2087 10 n 12 13 Install the grommet 7 into the seat mounting hole in the fender Place the new spacer 8 onto the threads of the OE hex head seat mounting bolt B With an assistant holding the new fender in place between the fender supports insert the bolt from the underside through the fender grommet and the frame tab Place the OE washer and seat post C onto the screw threads and tighten finger tight at this time Position the right side reflector mounting bracket 11 against the inside of the fender Line up the holes in the bracket with the holes in the fender Feed the right side tail stop turn signal lamp wiring through the holes in the fender and reflector mounting bracket Insert an OE 1 38 inch 35 mm screw and washer D through the forward mounting hole in the support cover E the fender support the mounting hole in the rear fender and the mating slot in the reflector_mounting bracket Install an OE flange nut F onto
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