XL (Sportster) Engine Guard Instruction Sheet - Harley
Contents
1. 6 and flat washers 7 on screws 8 Insert screws 8 through upper engine guard bracket through upper engine mount and thread into tapped holes in steering head Insert original screw 11 through frame downtubes and bracket 5 Place new locknut 2 on screw 11 and tighten to 33 ft lbs 44 7 Nm Tighten screws 8 to 19 ft lbs 25 7 Nm SERVICE PARTS 20f3 is08107 Figure 4 Service Parts Table 1 Service Parts Item Description Quantity Part Number 1 Engine guard 2 Washer 5 16 x 15 16 x 3 16 2 6336B 3 Screw 3 8 24 x 5 1 2 in 4413 4 Locknut 3 8 24 x7 16 x 9 16 7775 5 Bracket 49014 86A 6 Screw 3 8 24 x 5 in 4333 7 Spacer 3 4 x 1 8 5789 8 Screw 5 16 18 x 1 1 2 in 2 4816A 9 Screw 5 16 24 x 1 1 4 in 2 45999 81A 10 Screw 3 8 16 x 1 3 4 in 2 3554 11 Washer 3 8 x 13 16 x 5 32 Not 6474 Shown J01290 3of32. controls in which case DO NOT USE SPACER through the offset end of bracket 10 and with large offset toward jiffy stand side of vehicle through the other motor mount Place kit supplied washer 3 on end of screw 14 and secure with locknut 4 Be sure bracket does not pinch wiring On 1986 and later models be sure bracket does not contact oil pressure switch 4 See Figure 1 Position engine guard 11 upper mounting bracket under the steering head 1 of 3 Please dispose of materials responsibly is08105 Locknut 3 8 24 Bracket Engine Guard Screw 3 8 24 x 5 in Screw 3 8 24 x 5 1 2 in OP ONS Figure 2 Hardware Positions Late 1984 and Later Models 5 Place flat washers 6 on screws 7 8 or 9 a Use 5 16 18 x 1 1 2 in screws 7 and 5 16 in washers 6 from kit on 1985 and earlier models b Use 3 8 24 x 1 1 4 in screws 8 and 5 16 in washers 6 from kit on 1986 through early 1994 models c On late 1994 and later models reuse the stock 3 8 16 x 1 1 4 in screws and washers d Use 3 8 16 x 1 3 4 in screws 9 and 5 16 in washers 6 from kit on 1996 and later XL 883 models Insert screws 7 8 or 9 through upper bracket on engine guard 11 and thread into nut plate Attach bracket 10 to engine guard 11 using screw 12 and locknut 4 Tighten nut 4 on screw 12 to 33 ft lbs Tighten screw 7 8 or 9 to 19 ft lbs Tighten nut 4 on
3. screw 14 to 33 ft lbs On 1986 models remove clutch cable from clutch hand lever and route cable through engine guard Install cable at hand lever and adjust freeplay according to procedure outlined in the 1986 XLH Service Manual Turn handlebars fully to the right and left and check for interference of clutch and brake cables from engine guard J01290 is08106 Frame Locknut 3 8 24 Upper mounting bracket guard Engine guard Bracket Lockwasher original Washer flat original Screw 5 16 18 x 1 1 2 original Screw 3 8 24 x 5 in 10 Spacer 11 Screw original OHNAARYONS Figure 3 Installation Generator Models INSTALLATION 1982 TO EARLY 1984 XL AND XR 1000 MODELS EQUIPPED WITH GENERATOR NOTE Cover front fender with a clean rag to protect it from scratches during installation procedures 1 6 See Figure 3 Remove screws 8 lockwashers 6 and flat washers 6 from underside of steering head Discard original screws 7 Retain washers for reassembly Do not remove shim washers between frame and motor bracket Remove screw 11 spacer 10 and nut 2 at frame downtubes Attach bracket 5 Part number 49014 85 to engine guard 4 using screw 9 and locknut 2 Tighten screw 9 to 33 ft lbs 44 7 Nm Position engine guard 3 upper mounting bracket under steering head with bracket 4 aligned with holes in frame downtube Place original lockwashers
4. 2 to early 1984 vehicles are on Page 2 Cover front fender with a clean rag to protect it from scratches during installation procedures INSTALLATION LATE 1984 AND LATER XL MODELS EQUIPPED WITH ALTERNATOR NOTE Late 1994 and 1995 XL vehicle nut plates have 3 8 16 threads Reuse original screws on late 1994 and 1995 XL models J01290 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Installing the 3 8 24 x 1 1 4 in screws from kit will damage nut plate and screw threads is08497 Nut plate Frame Washer 3 8 in flat Locknut 3 8 24 Upper mounting bracket guard Washer 5 16 in flat Screw 5 16 18 x 1 1 2 in Screw 3 8 24 x 1 1 4 in Screw 3 8 16 x 1 3 4 in 10 Bracket 11 Engine guard 12 Screw 3 8 24 x 5 in 13 Spacer 3 4 x 1 8 Do not use if equipped with forward controls 14 Screw 3 8 24 x 5 1 2 in 15 Motor mounts 1 2 3 4 5 6 7 8 9 Figure 1 Disassembly Installation Alternator Models 1 See Figure 1 From underside of steering head remove screws 7 8 or 9 and flat washer 6 Discard original screws and washer 2 Remove and discard the two top motor mount screws washers and nuts 3 See Figure 1 and Figure 2 Place washer 3 on 5 1 2 in long screw 14 Insert screw 14 through one motor mount through spacer 13 unless engine guard is being installed on a vehicle equipped with forward
5. MOTOR HARLEY DAVIDSON WY J01290 INSTRUCTIONS REV 2013 11 01 XL SPORTSTER ENGINE GUARD GENERAL Kit Number 49018 88C 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 AwARNING 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 references Service Manual information A Service Manual for your model motorcycle is reguired for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 4 and Table 1 AwARNING Front and or rear guard s can provide limited leg and cosmetic vehicle protection under unigue circumstances Fall over while stopped very slow speed slide It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object 00022b NOTE This kit can also be installed on 1982 through early 1984 XL and XR 1000 models eguipped with generator with the pur chase of short engine guard support bracket Part Number 49014 85 Part 49014 85 is not included with this kit Installation procedures for 198
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