INSTRUCTIONS
®
REV. 02-12-2003
-J02833
Kit Number 50181-04
WIND DEFLECTOR KIT
General
i04485c
5
This kit fits all 2003 and later FLHR/I/CI model motorcycles.
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1
1
1
1
4
4
4
DESCRIPTION
Wind deflector
Handlebar cover
Emblem, Bar-and-Shield logo
Screw, hex head, serrated flange,
1/4-20 x 1/2 in
Trim strip, nacelle
Screw, pan head, Posidriz,
#6-32 x 3/4 in
Flat washer, #6 (1 in. O.D.)
Hex nut, serrated flange, #6-32
Hex nut, Keps, #6-32
Screw, button head, Torx,
5/16-18 x 3/4 in (Chrome)
Flat washer, (Chrome, 0.69 in. O.D.)
Flat washer, (Chrome, 1.06 in. O.D.)
8
4
This kit contains the following items:
QTY
1
1
1
3
9
2
PART NO.
57000-04
67867-04
14448-94
6
1
3588
67899-04
NOTE
This instruction sheet references Service Manual information.
A Service Manual for your model motorcycle is required for this
installation and is available from any Harley-Davidson Dealer.
Installation
11
7
13
3
2806
6789
7888A
7889
94600-98
6330
6433
10
12
1
2
3
4
5
6
7
Headlamp
Nacelle trim strip
Flange nut
Handlebar cover
Pan head screw
Flat washer
Nut w/ washer
8
9
10
11
12
13
Fork-lock plate
Flat head screw (2)
Nacelle (left half)
Stud (4)
Bushing (4)
Acorn nut (4)
Figure 1. Nacelle, Headlamp, and Handlebar Cover
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect battery cables
(negative cable first) before proceeding. (00048a)
5. Carefully pry off the fork-lock label plate (8) at the rear
of the stock handlebar clamp cover (4). Remove the
entire plastic plate; do not remove the adhesive label
from the plate.
1WARNING
6. Remove and retain the two flat head Pozidrive screws (9)
underneath the fork-lock label plate.
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
1. Refer to the Service Manual and follow the instructions
given to remove the seat and disconnect the battery
cables, negative cable first.
2. Remove the windshield from the motorcycle, if installed.
See WINDSHIELD-REMOVAL in the Service Manual.
3. Remove the headlamp assembly from the headlamp
nacelle. See HEADLAMP ASSEMBLY-REMOVAL in
the Service Manual.
NOTE
Earlier models used a stamped metal speed nut instead of a
flange nut to fasten the nacelle trim.
4. See Figure 1. Reaching inside the headlamp nacelle
(10), remove the flange nut (3) to release the trim strip
(2). at the top of the nacelle. The nut and trim strip can
be discarded.
7. Loosen, but do not remove the pan head Pozidriv screw
(5), nut (7) and flat washer (6) holding the front of the handlebar cover.
8. Remove the four chrome acorn nuts (13) from the left
and right-side fork studs (11).
9. Remove the windshield grommets (12) and clutch cable
clamp from the left and right-side fork studs.
10. If the passing lamp bracket is to remain in use:
Cover the front fender with shop rags or other suitable
material to protect the fender paint. Remove the passing
lamps and bracket from the left and right side fork studs
and carefully set the assembly on the front fender.
If the passing lamp bracket and windshield will no
longer be used: Remove the passing lamp and bracket
assembly from the motorcycle. See PASSING LAMP
BRACKET-REMOVAL in the Service Manual.
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11. Raise the handlebar clamp cover slightly, and while
separating the halves of the headlamp nacelle, slide the
cover forward, running the shaft of the screw down the
gap until the cover is free of the nacelle. Discard the
cover along with the attached screw, nut and washer.
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12. If the passing lamp bracket is to remain in use:
a. Install the four windshield grommets (removed earlier) on the left and right side fork studs. Slide the
passing lamp and bracket assembly onto the fork
studs. Verify that the four grommets are in place on
the inboard side of the passing lamp brackets.
b. Install the clutch cable clamp, along with the cable, on
the upper left stud. Thread the acorn nuts onto the
fork studs and tighten to 72-108 in-lbs (8.1-12.2 Nm).
If the passing lamp bracket and windshield will no
longer be used:
a. Remove the upper left-side fork stud. Obtain a
chrome button-head screw and either the larger or
smaller diameter chrome flat washer from the kit.
NOTE
Select the chrome washer that best
covers the slot in the nacelle.
b. Place the washer onto the screw threads. Place the
clutch cable clamp, along with the cable, in position
and loosely assemble the screw into the fork. Do not
tighten at this time.
c. Continue, one at a time, replacing the three remaining fork studs with the chrome button-head screws
and chrome flat washers from the kit.
d. Using a T-40 TORX drive head, tighten all four
screws to 15-20 ft-lbs (20-27 Nm).
13. For ALL applications: Obtain the wind deflector,
handlebar clamp cover and three hex head serrated
flange screws from the kit. Fasten the cover to the wind
deflector with the screws, and alternately tighten to 1218 ft-lbs (16.3-24.4 Nm).
14. Position the deflector and cover assembly onto the
flange at the top of the headlamp nacelle.
15. Obtain the pan head Pozidrive screw, Keps nut and flat
washer from the kit, and loosely assemble them.
16. See Figure 2. Holding the screw assembly, reach inside
the headlamp nacelle and insert just the screw head up
through the opening to engage the slot in the tab at the
front of the wind deflector. The nut and flat washer
should remain inside the nacelle. Tighten the screw to
10-20 in-lbs (1.1-2.3 Nm).
-J02833
Figure 2. Wind Deflector Assembly to Nacelle
17. Install the two flat head Pozidrive screws removed in
Step 7 to secure the handlebar clamp cover to the fork
lock mechanism.
Press the stock fork-lock label plate into position on the
handlebar cover.
18. Obtain the chrome nacelle trim strip and serrated flange
nut from the kit. Insert the weld stud on the trim strip
into the hole at the top of the headlamp nacelle, and
reach inside the nacelle to install the flange nut. Tighten
the nut to 15-20 in-lbs (1.7-2.3 Nm).
19. Install the headlight into the nacelle. See HEADLAMP
ASSEMBLY-INSTALLATION in the Service Manual.
1WARNING
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
20. Connect the battery cables, positive cable first.
21. Refer to the Service Manual, and follow instructions to
install the seat.
1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat
can shift causing loss of control, which could result in
death or serious injury. (00070a)
22. Remove the adhesive backing from the Bar and Shield
emblem and install in the handlebar clamp cover
recess.
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