180 MM WIDE TIRE KIT - Harley
Contents
1. 7 Remove screw 4 and washer 3 from inside of the fender 1 and remove the rear turn signal and mount assembly 9 NOTE The washer 5 between the fender strut and fender is held in place with an adhesive Do not remove 8 Remove screw 8 and stock rear fender bracket 2 Save the screw and discard rear fender bracket 9 Install rear fender bracket from kit 6 loosely with screw 8 from previous step 10 See Figure 9 Apply 2 3 drops of Loctite 243 blue to the screw 3 from the kit route the turn signal wire into the fender and loosely install turn signal using the screw 2 Fender 2 Turn signal wire isO07 1 Figure 3 Keep Turn Signal Wire Flat To Rear Fender Wall NOTE See Figure 3 Keep the turn signal wire flat to the fender to ensure the bracket seats properly against the fender See Figure 4 Ensure loop of the wire 1 that routes around the turn signal mounting screw and bracket stud is a maximum of 3 8 in below the bottom of the rear fender bracket 4 11 See Figure 4 Route turn signal wire down around the fender bracket stud through the channel 3 towards the rear of the motorcycle Ensure that the wire is flat to the fender in the channel Continue to route the wire flat against the fender up to the rear of the wire clip as shown then rearward to the tail light 12 See Figure 4 Tighten turn signal mounting screw 5 to 14 ft lbs 19 Nm J038312. Turn signal wire flat to fender Cable strap from kit Rear fender bracket wire channel 3 8 in to bottom of wire Turn signal mounting screw from kit Stock wire clip O21 a Figure 4 Turn Signal Wire Routing 13 See Figure 2 Tighten fender strut cover screw 8 to 18 ft lbs 24 Nm 14 See Figure 4 Secure the turn signal wire 1 to the rear of wire clip 6 using a cable strap 2 as shown Ensure the clasp of the cable strap locates in front of forward of the wire clip as shown Cut off excess cable strap 15 Repeat Steps 7 15 for the opposite side of the motorcycle 16 See the appropriate Service Manual and remove the rear tire from the wheel and replace with the tire from the kit Also inspect the tire check radial and lateral runout and balance the wheel 17 See the appropriate Service Manual Install the rear wheel and verify axle swing arm alignment and belt deflection Clearance Check 1 Remove upper shock bolts and spacers from both sides of the motorcycles 2 Using the jack lower the motorcycle until the rear fender strut almost rests on the belt guard 3 Obtain a 24 in length of straight cold drawn 3 16 in round bar or square bar to use as a gauge 4 See Figure 5 Lay gauge across the tire s radial ridge 2 and check that the gauge 1 can pass through the fender without touching the turn signal mounting screw or the rear fender bracket Repeat for opposite side of motor cycle
3. the frame and T bracket 2 Move the rear wheel to the left or right as necessary to provide clearance for the gauge Tighten the T bracket bolts while maintaining pressure on the tool Tighten bolts to 25 30 ft lbs 34 41 Nm Repeat Clearance Check procedure Figure 6 Rear Leverage Points Right Side Shown Left Side Similar 1 Front rubber mount adjustment 2 T Bracket adjustment is00702 Rear mount bolt 2 Rear mount T bracket mount bolt 2 T bracket mount Front mount bolt 2 Front mount 1 2 3 4 5 6 Figure 7 Front Leverage Points Left Side Shown Right Side Similar J03831 Figure 8 Vehicle Alignment Return Motorcycle to Service 1 Apply 2 3 drops of Loctite 243 blue to the upper shock bolts Install upper shock bolts and spacers Tighten upper shock bolts to 75 85 ft lbs 102 115 Nm 3 of 4 4 See Figure 1 Connect turn signals connectors 2 and 3 power in connector 4 and tail light connector 1 Route wires as shown Install tail light to rear fender using two tail light mounting screws removed previously Connect battery negative cable WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a Verify turn signal brake and tail light operation See the appropriate Service Manual and perform the Vehicle Alig
4. 5 If gauge passes proceed to the Return Motorcycle to Service section below If gauge contacts screw or bracket perform the Hori zontal Adjustment procedure below 2 of 4 j 4 1 Gauge 2 Radial ridge Figure 5 Gauge Clearance Horizontal Adjustment The following adjustment procedure is meant to center the tire between the rear fender brackets It requires two people 1 See Figure 8 Loosen the two front 5 and two rear 1 mount bolts J S aA O 6S989 978 See Figure 6 Using a suitable tool wrapped in a clean soft cloth between the swingarm and frame as indicated by the arrow move the rear wheel to the left or right as necessary to provide clearance for the gauge Tighten the rear mount bolts while maintaining pressure on the tool Tighten bolts to 22 27 ft lbs 30 37 Nm See Figure 7 Using a suitable tool wrapped in a clean soft cloth between the front mount and frame 1 move the rear wheel to the left or right as necessary to provide clearance for the gauge Tighten the front mount bolts while maintaining pressure on the tool Tighten bolts to 22 27 ft lbs 30 37 Nm Repeat Clearance Check procedure If further adjustment is necessary proceed with the following step If further adjustment is not necessary proceed to RETURN MOTORCYCLE TO SERVICE section See Figure 8 Loosen the two top bolts 3 of the T bracket 4 See Figure 7 Use a suitable tool between
5. NIN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a J03831 3 Disconnect battery negative cable 4 Refer to the appropriate Service Manual and remove the rear wheel is00773 LID ii Tail Stop Connector Left turn signal connector Right turn signal connector Power in connector sono ky Figure 1 Remove Connectors is00705 Rear fender Stock rear fender bracket Stock washer Stock hex screw Stock washer Rear fender bracket from kit Stock fender strut cover Stock screw Stock turnsignal and mount assembly 1 2 3 4 5 6 7 8 9 Figure 2 Replace rear fender bracket 1 of 4 NOTE If a Dyna Saddlebag Kit has been previously installed proceed to Step 16 Discard rear fender brackets screws and cable straps from the 180 MM Wide Tire Kit If Dyna Saddlebag Kit is being simultaneously installed install the saddlebags according to the Instruction Sheet included with that kit then proceed to Step 16 Discard rear fender brackets screws and cable straps from the 180 MM Wide Tire Kit 5 See Figure 1 Remove two screws and tail light lens from the tail light base Disconnect the tail light connector 1 and set the tail light aside 6 See Figure 1 Disconnect the turn signal connectors 2 and 3 and power in connector 4 NOTE See Figure 2 for Steps 7 10
6. cMOTOR HARLEY DAVIDSON WY J03831 INSTRUCTIONS REV 2009 08 11 180 MM WIDE TIRE KIT GENERAL Kit Number 43768 06 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 This kit will fit models equipped with the following e Saddlebag Kits e Detachable Sideplate Kit only when installed with a Saddlebag Kit Additional Parts Required A Dunlop tire must be purchased for the front wheel when using the wide tire kit on the 2010 model year Dyna Motorcycles equipped with laced wheels also require inner tube 40502 06 and tire rim flap 43101 06 for proper install ation Proper installation of this kit requires the use of Loctite 243 Threadlocker and Sealant Blue 99642 97 AWARNING Dealer installation is required Proper installation of this kit requires specific alignment procedures to ensure proper tire clearance Tire contact with chassis components can lead to tire failure which could result in death or serious injury 00428c NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation Kit Contents See Figure 9 and Table 1 INSTALLATION Install Wide Tire 1 Place motorcycle on a lift and secure front tire 2 Place a scissor jack under the frame so that the rear wheel can be raised and lowered IWIN
7. nment procedure and verify rear wheel to front wheel parallelism Verify that belt and belt guard are clear of the rear tire To prevent excessive vibration check for loose hardware and re tighten as necessary SERVICE PARTS is00712 Figure 9 Service Parts for Wide Tire Kit Table 1 Service Parts Table Item Description Quantity Part Number 1 Tire 180 60 B17 75V 43197 04A 2 Bracket rear fender 2 59514 06 3 Screw 2 4592 4 Cable strap 2 10065 J03831 40f 4
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