Harley Davidson J02994 (2003) Manual

Harley Davidson Motor J02994 (2003)

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Side 1/2

INSTRUCTIONS

-J02994 REV. 10-10-2003

SHIFTER LINKAGE COVER

General

This “Harley-Davidson script”-style shifter-linkage cover kit

fits 1997 and later FXDWG (Dyna Wide Glide®) model motor-

cycles. This kit also fits 1993 and later Dyna models

equipped with Forward Control Kit 49080-03.

NOTE

A Service Manual for your model motorcycle is available

from any Harley-Davidson dealer.

Installation

1. See the Service Parts illustration. Obtain an upper mount-

ing bracket (2), lower mounting bracket (3), two 1/2-inch

long screws and the Allen wrench (6) from the kit.

2. See Figure 1. Assemble the upper and lower mounting

brackets onto the shaft of the ball screw shell at one

end of between the ball screw (3) andthe shifter rod (1),

the jam nut (2) so the shaft passes above the three

holes in the brackets.

Insert the two screws in the outboard holes of the lower

bracket, and use the Allen wrench to thread them part

way into the holes in the upper bracket. Do not fully

tighten the screws at this time.

3. Repeat Steps 1 and 2 at the other end of the shifter rod.

4. Position the linkage cover (1) on top of the linkage and

examine the fit.

• If the cover fits properly, proceed to Step 8.

• If the center holes in the front and rear upper mounting

brackets cannot be adjusted to line up with the holes

on the inboard side of the cover, the linkage will need

to be adjusted to accept the cover. Proceed to Step 5.

5. See Figure 1 (below) and SHIFTER LINKAGE

ADJUSTMENT in the Service Manual. To adjust the

length of the linkage, remove the link attaching nut (5)

and flat washer at the forward ball screw.

6. Loosen the jam nut (2) at the front end of the shifter rod,

and remove the mounting bracket installed in Step 3.

Rotate the forward ball screw shell to achieve the prop-

er length to allow mounting of the cover.

7. Re-attach the ball screw to the shifter lever with the flat

washer and nut removed in Step 5. Torque the nut on

the ball stud to 70-90 in-lbs (7.9-10.2 Nm).

Torque the jam nut on the shifter rod to 20-24 ft-lbs

(27.1-32.5 Nm).

8. Fasten the rear of the cover (1) to the rear upper bracket

using a short screw (5) from the kit. Fasten the front of

the cover to the front bracket with the remaining screw.

Tighten the cover securely to the upper brackets.

Position the cover upright over the shifter rod, and tight-

en the four remaining screws to clamp the brackets

securely to the ball screw shells.

9. If the linkage needed adjustment (Steps 5 through 7),

the position of the shift foot lever (6) may have

changed.

To return the lever to the original position, loosen the

socket head screw (7) holding the lever to the shaft. Pull

the lever from the shaft, rotate to the desired angle and

slide the lever back onto the shaft.

Torque the screw to 18-22 ft-lbs (24.4-29.8 Nm).

Kit Number 33878-04

1 of 2

Figure 1. Stock Shifter Linkage

i02475

1. Shifter rod

2. Jam nut (2)

3. Ball screw shell (2)

4. Shifter lever

5. Link attaching nut

6. Shift foot lever

7. Socket screw

-J02994 2 of 2

Service Parts

Shifter Linkage Cover

Date 10/03

Part No. 33878-04

Item Description (Quantity) Part No.

1 Linkage cover Not sold separately

2 Mounting bracket (upper) (2) 33879-04

3 Mounting bracket (lower) (2) 33880-04

4 Screw, button head, hex socket,

#10-24 x 1/2 in (4) 94381-92T

5 Screw, button head, hex socket,

#10-24 x 1/4 in (2) 3339

6 Allen wrench, 1/8 in Not sold separately

i02476

Produkt Specifikationer

Mærke:	Harley Davidson
Kategori:	Motor
Model:	J02994 (2003)

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