Front Highway Crash Bar Installation Instructions
For 1997-2008 Bagger Models
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Remove the Factory Crash Bar
Begin by removing any existing factory crash bar from the bike. -
Position the New Crash Bar
Position the new crash bar in place, using the same mounting points as the factory crash bar. The upper tab of the crash bar should be positioned to the outside of the frame, unlike the OEM crash bar, which slips into a slot. -
Install Lower Mounting Bolts
Attach the crash bar at the lower two mounting points on the frame using the provided 3/8" x 16 x 1" long bolts and washers. Do not tighten these bolts yet; leave them loose to allow for adjustment, if needed. -
Install Upper Tab Bolt
For the upper tab, use the longer 3/8" x 16 allen bolt with a nyloc nut. The nyloc nut should be placed inside the frame.- Tip: If access to this location is difficult, place the nyloc nut into the end of a 9/16" open-end wrench and secure it with tape on the back side of the wrench to hold it in place. Slip the wrench up the frame slot to align the nut with the hole in the crash bar, then start the bolt.
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Attach the Crossbar Bolts
Install the two button-head bolts through the center crossbar of the crash bar into the matching holes in the bike’s chassis. -
Tighten All Bolts
Once all bolts are in place, tighten them. The lower 3/8" mounting bolts should be torqued to 30-35 ft-lbs.