Sportster Crashbar 2003 and earlier

Installation Instructions
03 & Earlier Sportster Crashbar

Tools Needed:

• Wrench set
• Torque wrench
• Welding equipment
• Marking tools
• Paint/powder coat removal tools

Step 1: Install Center Mount Bolt

• Begin by using the longer bolt with the 1/2" long spacer. This bolt will be used in the center mount of the crashbar, attaching it to the crossbar of the front section of the frame.
• Insert the bolt through the slotted hole in the crossbar welded onto the crashbar.
• Place the spacer between the crashbar and the frame.
• Tighten this bolt first to temporarily hold the crashbar in place, ensuring it is positioned correctly for setting up the bungs.

Step 2: Attach Coped Bungs to Crashbar

• Position the supplied coped bungs between the frame and the mounting holes on the crashbar side plates.
• Once the bungs are in place, mark their locations on the frame. This will indicate where paint or powder coat needs to be removed for welding.

Step 3: Prepare Frame for Welding

• Remove the crashbar to access the marked locations on the frame.
• Remove the paint or powder coat from the marked areas on the frame where the bungs will be welded. This will provide a clean surface for the welds.

Step 4: Reinstall Crashbar and Tack Weld Bungs

• After cleaning the frame, reinstall the crashbar and ensure it is level.
• Tack weld the coped bungs in place on the frame at the marked locations.

Step 5: Fully Weld Coped Bungs

• Remove the crashbar again and fully weld the coped bungs to the frame.
• Allow the welds to cool before proceeding.

Step 6: Final Installation

• Once the welds are fully cooled, reinstall the crashbar.
• Use the supplied hardware to secure the crashbar in place, ensuring all bolts are tightened to 35 ft-lbs torque specification.