Installation Instructions for Model #4

This model fits the 2008 and earlier touring bikes without factory installed King tour packs. Includes FLHR, FLHRC, FLHRS, FLTR, and FLHX.

Kit consists of:

• A powder-coated mounting-bracket assembly with custom pressure gauge, push-to-check valve, air-fill Schrader valve, length of air line with Y-fitting attached
• One  ¼” X 7/8” long hex head bolt
• Stick-on label for recording your personal air-pressure settings
• Instructions

Tools Needed:
7/16” combination wrench
 
Steps for Installing Model #4

 Step 1: Remove both saddle bags, which expose the H-D air-fill valve and the air lines going to each shock. Fasten your H-D pump, part number 54630-03A or equivalent, to the air-fill valve on your bike. Add 3-5 psi to clear the lines of any oil, but do not exceed 50 psi. Release all the air pressure from the system. Press the pressure relief valve on the pump or depress the center of the Schrader valve.

Step 2: Using a 7/16” wrench, remove the bolt holding the rear quarter-turn fastener bracket located between the right side saddle bag and the frame. Slide the mounting tab of the EZ-Air™ bracket down between the two flat surfaces of the frame and quarter-turn bracket. Using the longer bolt provided (1/4” x 7/8” long), line up the holes in the quarter-turn bracket and the EZ-Air™ bracket and install the bolt -- finger tight only at this time. (See Figure #1).

Step 3: Remove the original air line from the air fitting on the right side shock absorber. To remove this line, push in on the red locking collar and pull out on the air line at the same time - (See Figure #2). The included new air line assembly has a Y-fitting with a short piece of air line installed into one port of the Y-fitting and a longer line to plug into the unit. Press the short air line into the original air fitting on your shock and press the original air line (removed above) into the front port of the Y-fitting - (See Figure #3).  Route the longer air line for best appearance and plug line into the open fitting on the EZ-AIR™ unit - (See Figure #4).

Step 4: Once the EZ-Air™ assembly is positioned, you can set the saddle bag back on the lower mounting rail and reinstall the front quarter-turn fastener. Manually position the rear-quarter turn bracket to line up with the quarter-turn push pin. Lock the pin into the quarter-turn receiver and level the EZ-Air™ bracket and tighten the mounting bolt. (See Figure #5).

Step 5: Add air to the system with a suitable air pump such as the H-D part number 54630-03A. Never use high-pressure sources to fill your suspension system. For 2009 and later bikes, use 50 psi as a maximum setting. Your owner’s manual will give pressure guidelines based on total weight load. Experiment with the pressure setting until you get a comfortable ride without bottoming out the shocks on the more severe dips and bumps. We provide a stick-on label so that you can write down your personal air settings for solo, two up, and completely loaded (MAX).

You can now check your current pressure setting anytime by pushing the black push-to-check valve and reading the pressure directly on your new gauge. It is normal for the gauge to read zero until the button is pressed. If air is required, just attach your pump to the fill valve on the EZ-Air™ assembly and add air. The original H-D fill valve is also still fully functional.

You have successfully added the EZ-AIR™ management system to your bike. To remove this system or transfer it to another bike, just remove the Y-fitting  and the EZ-AIR™ assembly and replace the original air line back into the shock absorber air fitting.

Figure #1	Figure #2 Figure #3
Figure #4	Figure #5