Sportster Crashbar 2004 and Up

 

 

 

Front Highway Crash Bar Installation Instructions
2004 and Up Sportster Models

 

---

 

Tools Needed:

 

• Wrench set
• Torque wrench
• Blue Loctite (optional)

 

---

 

Step 1: Prepare the Frame

 

• For mid-control Sportster models (2004 and up), locate the front control mounts where the crash bar will be attached.
• If there are any bolts holding wire clips in place, remove them to clear the mounting area.

 

---

 

Step 2: Position the Crash Bar

 

• Slip the crash bar into position, aligning it with the mounting points on the frame.

 

---

 

Step 3: Apply Blue Loctite and Torque

 

• For added security, apply Blue Loctite to the threads of each bolt

 

---

 

Step 4: Attach the Crash Bar

 

• Use the supplied hardware to secure the crash bar to the frame, start all bolts before tightening them fully.
• Tighten the bolts to a torque specification of 30-35 ft-lbs.