Instructions
Sportster 200 Wide Tire Kit
(2004-2010 model)
Before beginning
installation of your Fat Tire Kit, we strongly advise acquiring a Harley Davidson
Service Manual to assist you in the tear down and reassembly of your
motorcycle. Important torque specification, clearance and alignment
specifications are listed in the manual. If you are not an experienced mechanic
or doubt your own ability to perform these basic tasks, we suggest that you may
want to take your bike to a reputable shop for the work.
Take time to familiarize
yourself with the parts included in the kit before beginning.
1. Offset pulley
2. rear axel, washers (2) and nut
3. rear axel adjuster plates (2)
4. 1/4" x 2-1/2" Allen bolt (1)
5. 1/4"x 2 -3/4" Allen bolt
(1)
6. 3/8" x3" Allen bolt (1)
7. 1/4 x 3/4"spacer (2) [pulley
cover]
8. 1/2"x3/4" spacer (1) [pulley
cover]
9. 1/2" x 7/16" spacers (2) [upper shock
mount]
10. swing arm
11. fender
12. tire.
13. instructions
1. The
motorcycle should placed on a lift, stand or jack and secured with straps or
other locking devices, to keep the bike stable while the rear wheel is removed.
Disconnect the battery before beginning disassembly. Remove the seat, rear
fender, rear exhaust pipe, rear shocks, wheel /tire and swing arm as outlined in
your service manual.
2.
Remove the front pulley cover and pulley [remember the pulley nut is
left-handed], and install the new offset pulley according to instructions in
your service manual.
3.
Remove the bearings from your old swing arm and install them in your new
Fat Tire swing arm. Again, refer to your service manual and install the new
swing arm.
4. With
the axel provided in your kit, attach the rear wheel with brake rotor and
pulley attached to the swing arm.
Use a straight edge or laser line to line up the front and rear pulley. Then,
measure the distances between the wheel hub and the swing arm on either side to
determine the length of spacers needed, [helpful hint: pvc pipe be used for trial purposes. Once
alignment is achieved, pull the pvc out and cut your steel or aluminum spacers to
match.]
5. The
slot on the rear brake caliper mounting bracket where it mounts to the swing arm
must be machined to 2 1/16" total width, using the axel hole as center line, to
fit the larger swing arm. If you don't have a machine shop close by, ship us
your bracket and we'll machine it for you, free of charge.
6. To
mount the fender, the inside surface must be ground down on either
side to achieve a minimum 8 3/4"
[or more] clearance between the two frame rails where the upper shock mounts are seen [arrows].
Be careful not to get into the oil tank while grinding.
7. To gain more clearance with less grinding the fender rails can be spread apart to
achieve a minimum 8 3/4" clearance between the two rails. A hydraulic jack or
"port-a-power" will do the job. As a. precaution, a piece of all-thread can be inserted in one of the
frame rail holes, with a nut and washer on each side and set to stop the rails
from bending too far or getting out of square. Take your time and test fit the fender
frequently while you work.
8. Set
your fender between the rails to determine how much will need to be taken off
the front in order to achieve the
desired clearance between the fender and tire [ stock fender clearance is 3-3/4"
". You can check this by drilling a small hole in the fender under the seat area
and stick a piece of stiff wire through the fender until it touches the top of the tire]. In order to
achieve the desired profile, and allow clearance in the front for the oil tank, the
front portion of the fender may have to be trimmed similar to what is shown in photo 2.
Test your work frequently until clearance is achieved.
9. Mark
and drill your mounting holes for the fender and for the turn signal wiring.
Check fit and alignment again with
mounting bolts in place and tightened. Mount your seat using the front mounting stud and mark
the location for the rear mount
10. If you want to use the plastic front splash
guard [skirt] from the stock fender, drill out the rivets and remove the skirt.
Then use the skirt as a pattern to drill holes in the new fender. The skirt can
be re-attached after it's painted.
11. Cut the hole for your tail light and mount
it. When using the stock tail light assembly, the main supply connector will
have to be cut off and the wires run through the steel wire loom on the underside of
the new fender. Then use solder joints and cover them with heat shrink to
re-attach the connector. This can be done before or after the fender is
painted.
12. Make sure your mounting bolts clear the rear
tire when the shocks are fully compressed.
13. Remove the fender and swing arm and it's
ready to paint!
14. When the paint dries, mount your new painted
swing arm, fender, tail light, and license plate bracket, just like you did the
first time.
15. Mount shocks using spacers provided in the
kit, to maintain proper shock alignment
16. Mount rear wheel and tire using axel and nut
supplied with the kit Adjust belt tension and alignment as per Service Manual
instructions.
17. Mount the front pulley cover with the bolts
and spacers included in the kit.
18. Re-connect battery and battery
cover.