80-SPOKE REAR WHEEL KIT - Harley
Contents
1. rim must be trued both laterally and radially If new bear ings were installed wheels may be trued with only the bearings and center spacer installed See Figure 9 and Table 2 for the proper offset dimensions for your wheel 3 of 7 1S02624 1 Cast in marking or groove side of hub Table 2 Wheel Offset Dimensions Kit Number A B 42959 08 1 29 inch 1 13 inch 33 6 mm 28 6 mm 42962 08 1 41 inch 1 05 inch 35 7 mm 26 6 mm 40750 08 1 86 inch 1 05 inch 47 3 mm 26 6 mm J04243 Figure 9 Offset Dimension See TRUING LACED WHEELS the Service Manual for your model motorcycle MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to ensure that they keep their original shine and luster 1 Clean heavily soiled wheel surfaces using Harley Davidson Wheel and Tire Cleaner applied with the Harley Wheel and Spoke Brush 2 Thoroughly clean chrome with a good quality chrome cleaner such as Harley Bright Chrome Cleaner 3 After cleaning and polishing seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant 4 of 7 SERVICE PARTS is04588 l 1 1 bed S Figure 10 Service Parts 80 Spoke Rear Wheel Table 3 Wheel Assembly Service Parts Table Item Description Part No 42959 08 Part No 42962 08 Part No 40750 08 12. ORX bit for removal and installation is02615 KTS OD ISS SC a N Figure 1 Spoke Wheel Components The 80 spoke wheel uses two lengths of spokes installed in the inner and outer rows on the hub See Figure 2 is02617 1 Inner spoke row 2 Outer spoke row 3 Machined directional groove Figure 2 Spoke and Directional Groove Location on Hub See Figure 3 and Table 1 Measure distance A outer to determine outer and inner spoke lengths Separate outer and inner spokes in preparation for installation to hub and rim J04243 is02693 TTT Figure 3 Spoke length Table 1 Spoke Lengths Spoke Length A Outer spoke 5 19 inch 132 mm Inner spoke 5 59 inch 142 mm 1 See Figure 4 Place the hub on table with machined groove side up Insert a spoke in each hole of the outer row as shown Angle the spokes clockwise 2 Center the rim over the hub assembly with the valve stem hole facing up See Figure 5 3 See Figure 4 Using any outer row spoke insert the first spoke into the rim hole to the left of the valve stem hole on the upper half of the rim centerline Loosely assemble the spoke nipple is02618 Figure 4 Install Outer Spokes on Hub 20f7 is02619 Fee eek ae ZEEE MALASON aces RO QS 1 Outer spoke location on rim 2 Valve stem hole Fig
3. Wheel assembly consists of items 2 3 4 and 5 Not Sold Separately 2 Rim strip not shown 43147 40 43147 40 43147 40 3 Rim 43087 04 43087 04 43087 04 4 Hub 41137 04A 41137 04A 40752 08 5 Spoke and nipple kit contains 20 inner spokes 20 outer 41899 05 41899 05 41899 05 spokes and 40 nipples Table 4 Service Parts Table Kit Installation Kit Item Description Quantity Part Number 42959 08 1 Wheel Not sold separately Items requiring separate purchase J04243 5 of 7 Table 4 Service Parts Table Kit Installation Kit Item Description Quantity Part Number 2000 2005 _ Kit 43854 08 A Bearing 2 9267 oe oe Rear B Sleeve bearing spacer 43608 00 2000 2002 C Disc screw 5 43567 92 Softail D Sprocket screw 5 Dyna and Softail models 3737A pea and Sprocket screw 5 XL and Touring models 3899 2000 2001 F Washer 5 6516HW Touring NOTE Discard the following components which are provided with this installation kit but Models are not required for this fitment Sprocket screw 5 3109 Sleeve bearing spacer 43618 06 Sleeve bearing spacer 43618 07 Valve stem 43206 01 Valve stem 43157 83A 2002 2007 Kit 43861 08 A Bearing 2 9247 Dee AE Rear B Sleeve bearing spacer 43517 00 XL Models C Disc screw 5 43567 92 D Sprocket screw 5 2004 2006 Touring m
4. cMOTOR HARLEY DAVIDSON WY J04243 INSTRUCTIONS REV 2007 04 19 80 SPOKE REAR WHEEL KIT GENERAL Kit Number 42962 08 42959 08 and 40750 08 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only NOTE Accessory hub caps are not compatible with this wheel Additional Parts Required This kit includes the custom wheel only Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley Davidson dealer e Wheel Bearing Remover and Installer HD 44060 e Wheel Installation Kit See Service Parts Tables for part number The following Harley Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning e Harley Bright Chrome Cleaner 94683 99 e Harley Glaze Polish and Sealant 99701 84 e Harley Wheel and Spoke Brush 43078 99 e Harley Davidson Wheel and Tire Cleaner 94658 98 IWIN NIN 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 J04243 NOTE This instruction sheet references Service Manual information A S
5. er primary bearing 43904 08 H Bearing ABS Red side of bearing must face inward 9252 NOTE Discard the following components which are provided with this installation kit but are not required for this fitment Valve stem 43157 83A Valve stem 43206 01 Sprocket screw 5 7039 Sleeve bearing spacer 43704 08 Shim bearing 41447 08 Screw TORX 4552 Table 5 Service Parts Table Kit Installation Kit Item Description Quantity Part Number 40750 08 1 Wheel Not sold separately Items requiring separate purchase 2008 and Kit 43878 08 A Bearing 2 9267 eee Bs ae Rear B Sleeve bearing spacer 41696 08 C Disc screw 5 43567 92 D Sprocket screw 5 3109 NOTE Discard the following components which are provided with this installation kit but are not required for this fitment Valve stem 43157 83A Valve stem 43206 01 Sprocket screw 5 3899 Sprocket screw 5 3814 Sleeve bearing spacer 41900 08 Shim bearing 43904 08 Washer 5 6516HW J04243 7 of 7
6. ervice Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See the Service Parts section for kit contents INSTALLATION 1 Remove existing rear wheel assembly Save axle axle nut brake disc and wheel spacers for kit installation NOTE Remove the rear brake caliper before removing the wheel CAUTION Do not re use sprocket mounting screws Re using sprocket mounting screws can result in torque loss and damage to the sprocket and or belt assembly 00480b 2 Install the tube and tire on wheel Refer to REAR WHEEL in the Service manual CAUTION Do not re use brake disc screws Re using disc screws can result in torque loss and damage to rotor and or brake assembly 00319b NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER INSTALLER 3 Assemble wheel installation kit components and brake disc s to wheel using the appropriate service parts table Refer to REAR WHEEL in Service Manual R Install rear wheel 1 stock axle and stock axle nut Refer to REAR WHEEL in Service Manual 1 of 7 WHEEL LACING PROCEDURE NOTE If only the rim is to be replaced tape the spokes together to hold the position on hub and remove spokes from rim Install taped hub spoke assembly to the new rim and tighten spokes Then remove the tape and true wheels The nipple fitting of the spoke uses a standard T 30 T
7. odels 3737A Sprocket screw 5 2007 Touring models 3109 Sprocket screw 5 XL and 2002 2003 Touring models 3899 F Washer 5 XL and 2006 and earlier Touring models 6516HW NOTE Discard the following components which are provided with this installation kit but are not required for this fitment Valve stem 43157 83A Valve stem 43206 01 Sprocket washer 5 7039 Sprocket bolt 5 4552 Sprocket bolt 5 40439 01 Sprocket screw 5 3873 Sleeve bearing spacer 43704 01 2008 and Kit 43878 08 A Bearing 2 9276 ae ae Rear B Sleeve bearing spacer 41900 08 ABS and C Disc screw 5 43567 92 2008 and D Sprocket screw 5 Touring models 3814 a oe Sprocket screw 5 XL models 3899 F Washer 5 XL models 6516HW G Shim bearing install under primary bearing 43904 08 NOTE Discard the following components which are provided with this are not required for this fitment installation kit but Valve stem 43157 83A Valve stem 43206 01 Sprocket screw 5 3109 Sleeve bearing spacer 41696 08 J04243 6 of 7 Table 4 Service Parts Table Kit Installation Kit Item Description Quantity Part Number 2008 and Kit 41453 08 A Bearing 9276 sneer ee Rear B Sleeve bearing spacer 41900 08 ABS C Disc screw 5 43567 92 D Sprocket screw 5 3814 G Shim bearing install und
8. ure 5 Install Outer Spokes 4 Install the rest of outer row spokes in every fourth hole Loosely assemble the spoke nipples 5 See Figure 6 Insert the first inner row spoke into the hub Angle the spoke counterclockwise crossing four outer row spokes Loosely assemble the spoke nipples is02622 Gag DARE SS RON G LN Z 2 Ke gt 9A DOES lt 7 E Nae NA Figure 6 Install Inner Spokes 6 Install the inner row spokes into every fourth remaining hole above the rim centerline Loosely assemble the spoke nipples 7 See Figure 7 Turn rim over so brake disc side faces down Place any outer row spoke into hub Angle spoke counterclockwise and insert into rim hole angled to accept it Loosely assemble the spoke nipple J04243 is02621 SARANA SS et ORN RN fi gt SS N Figure 7 Install Outer Spokes 8 Insert the remaining outer row spokes angled counter clockwise into hub and rim Loosely assemble the spoke nipples 9 Insert inner row spoke into hub and angle spoke clock wise crossing over 4 outer row spokes Place spoke into appropriate rim hole Loosely assemble the spoke nipples 10 See Figure 8 Install remaining inner row spokes Loosely assemble the spoke nipples 11 Tighten spoke nipples to 19 35 in Ibs 2 2 4 Nm is02623 Ye 0 N AS E a Figure 8 Remaining Inner Spoke Installation TRUING LACED WHEELS The
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