Front Highway Crash Bar Installation Instructions
For 2006 to 2017 Dyna Models
Tools Needed:
- 3/8" x 16 tap (if necessary)
- Allen wrench set
- Torque wrench
- Blue Loctite (recommended)
1. Locate Mounting Holes
- Begin by locating the four mounting holes at the bottom front corner of the frame where the crash bar will be installed (two on each side of the bike).
- Some bikes may have plastic plugs installed in these holes. If present, remove the plugs.
- Inspect the threads inside the mounting holes to ensure they are free from dirt and debris. As the holes are open from the backside, material can accumulate in the threads. If necessary, clean the threads using a 3/8" x 16 tap.
2. Remove Voltage Regulator
- Locate the voltage regulator on the front of the bike and remove it by loosening the two allen head bolts that secure it to the frame.
- Save the two bolts as they will be reused later.
- Once the bolts are removed, allow the voltage regulator to drop downward, but keep all electrical connections intact.
3. Install Crash Bar
- Position the crash bar in place.
- Start the lower supplied bolts into both sides of the crash bar.
- Once the lower bolts are started, pivot the crash bar upwards to align the upper mounting holes. Install the upper bolts as well.
- Once all four bolts are started, tighten all four mounting bolts securely. While tightening, make sure the main bar of the crash bar is held or rotated so it is in contact with or very close to the down tubes of the chassis.
4. Reinstall Voltage Regulator
- After the crash bar is securely mounted, install the voltage regulator onto the relocation tab on the crash bar.
- The relocation tab with the crown logo cut into it should face outward. The upper profile of the tab will match the top edge of the voltage regulator and should face the same direction as the stock position.
- Use the factory allen bolts that previously held the regulator in place, along with the supplied 1/4" x 20 nyloc nuts for attachment.
5. Final Steps
- Recommended: Apply Blue Loctite to all bolts before installation.
- Torque all 3/8 x 16 mounting bolts to 30-35 ft-lbs.