RIDER COMFORT SHROUD KIT

Transcription

1 -J0 REV RIDER COMFORT SHROUD KIT GENERAL Kit Number M0A.AU, M0.AK, M0.AU, M0.AK Models For the most up-to-date model fitment information, See product label or (English only). Additional Parts Required When using this kit it is recommended that you have the latest calibration flashed into your ECM. See your dealer for the latest calibration. 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. (00a) This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Buell Dealer. Kit Contents See Figure 0 and Table. REMOVAL Remove Battery Pan. Remove the battery pan. a. Disconnect the ECM connectors [0] and []. b. Remove the ECM () screws and discard the front screw. It will be replaced with a new screw in the kit. c. Disconnect rear brake light switch connector []. d. Remove fuse block and relay center (). e. Remove main harness and plastic grommet () from battery pan. f. Remove fasteners () securing battery pan to left and right tail section. g. Lift the battery pan straight up and out.. See Figure. Remove the trunk pan. a. Remove the two fasteners securing the preload adjuster (on the left of the shock absorber) to the trunk pan. b. Remove the shock reservoir (on the right side of the shock absorber) fastener and retainer. c. Remove the remaining fasteners securing the front trunk pan to the side tail sections. d. Remove the remaining fasteners securing the rear trunk pan and remove the trunk pan. INSTALLATION Air Duct. See Figure. Cut the transmission vent hose () even with the shock absorber collar. is0 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. (000a). See Figure. Disconnect the battery cables from the battery, negative cable first.. Remove the battery. Figure. Trim Transmission Vent Hose -J0 of

2 is0. Install the trunk pan. a. Install the rear trunk pan fasteners and tighten to - in-lbs (- Nm). b. Install the front trunk pan fasteners and tighten to - in-lbs (.-0. Nm). c. Install the shock reservoir fastener and retainer and tighten fastener to 0- in-lbs (-0 Nm). d. Install the two fasteners securing the preload adjuster to the trunk pan and tighten to -0 in-lbs (.-. Nm). Foam strips Figure. Apply Foam Strips to Front of Air Duct is0a. Install the battery pan and tighten fasteners to - inlbs (- Nm). a. Install the ECM using existing rear screw and new front screw provided in kit. Torque rear screw to -0 in-lbs (.-. Nm) and front screw to 0-0 in-lbs (.-. Nm). b. Connect rear brake light switch connector. c. Install fuse block and relay center. d. Install main harness and plastic grommet to battery pan. Engine Shroud Kit M0A.AU keeps an existing right side engine shroud. Kit M0.AK installs an outer engine shroud only from the kit. All other kits use right side inner and outer engine shrouds.. Remove the existing right outer shroud and save the screws and washers to reuse.. See Figure. On 00 models connect the O sensor connector to the clip on the back of the right side inner engine shroud (except kit M0.AK).. Preload adjuster hose routing notches. Notch for gas reservoir hose. Air Duct. Adjuster hose retaining clip Figure. Air Duct Installed is0. See Figure. Cut and install foam strips () to the front lip of the air duct.. See Figure. Install the air duct () over the top front of the shock absorber. The shock gas reservoir hose is in the slot on the right side and the preload adjuster hose routes to the outside of the duct through two notches on the left side. Insert the preload adjuster hose into the clip () and close the clip to retain the hose You must install a new front ECM screw provided (part number AA00.CXZB).. Inner shroud. Inner shroud clip. O sensor connector Figure. O Sensor Connection to Inner Shroud -J0 of

3 is0 0. See Figure. Install right side outer engine shroud () to the inner shroud using three screws () from the kit and one saved previously () and tighten to - in-lbs (.-.0 Nm). Header Cover. See Figure. Insert plain end of clamps () through the mount clips on the inside of the header cover () and attach as shown in Figure. is0. Inner engine shroud. Screws () Figure. Install Right Side Inner Engine Shroud is0. Screw, previously saved. Screws from kit (). Outer engine shroud Figure. Install Right Side Outer Engine Shroud is0. O harness. Inner engine shroud Figure. O Harness Routing. See Figure. Install inner shroud () with two previously saved screws and washers () and tighten to - in-lbs (.-.0 Nm).. See Figure. Make sure that the O is harness () being routed outboard of the top rear tab on the inner shroud. This tab prevents the wire from being trapped between the cylinder head and the inner shroud... Clamps () Figure. Install Header Cover -J0 of

4 is0 0. Main harness. Battery positive cable. Electronic control module. Left rear and right rear tail section fasteners (). ECM connectors [0] and [] 0. Seat lock cable. Fuse block and relay center. Bank angle sensor (BAS) connector []. Main harness ground wire [GRD]. Auxiliary power outlet. Main harness with plastic grommet. Trunk pan. Battery ground cable. Left tail section Figure. Main Harness and Electrical Components Under Seat SERVICE PARTS is0a Figure 0. Service Parts: Rider Comfort Shroud Kits -J0 of

5 SERVICE PARTS Table. Service Parts Kit Kit M0A.AU Kit M0.AU Kit M0.AK Kit M0.AK Item Description (Quantity) Fan exhaust air duct (includes Item ) Clamp, header cover () Screw, /-0, ECM bolt (not shown) Fan exhaust air duct (includes Item ) Clamp, header cover () Screw, stainless, 0- x /, button head () (not shown) Shroud, inner right engine Screw, /-0, ECM bolt (not shown) Fan exhaust air duct (includes Item ) Clamp, header cover () Screw, stainless, 0- x /, button head () (not shown) Shroud, inner right engine Screw, /-0, ECM bolt (not shown) Fan exhaust air duct (includes Item ) Clamp, header cover () Screw, /-0, ECM bolt (not shown) : Generic inner and outer shrouds shown. Shrouds will vary according to kits. Part Number M00.AK C0.T C0.AM S0.AK S0. AA00.CXZB M00.AK C0.T C0.AM S0.AK S0. AN00.FSS M0.AU M0.AU AA00.CXZB M00.AK C0.T C0.AM S0.AK S0. AN00.FSS M0.AA M0.AA AA00.CXZB M00.AK C0.T C0.AM S0.AK S0. M0.AA AA00.CXZB -J0 of