Harley-Davidson feuling Adjustable Pushrods Installation Instructions

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Filed Under (Harley Davidson) by admin on 22-04-2012

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1. Refer to the proper factory service manual for your model and year of engine, for removal of existing pushrods. 2. The Feuling pushrods are designed with a small adjustment parameter for rigidity creating maximum lift – These are not quick install pushrods and may require the removal of the lifter blocks and or loosing of the breathers/rocker arms supports. When loosening the rocker arm supports always remove the breather bolts first. 3. Clean and inspect each new Feuling pushrod including center oil hole 4. Feuling pushrods are marked Intake and Exhaust. The shorter pushrods are Intake and the longer pushrods Exhaust 5. Feuling recommends using new O-rings and gaskets where applicable to prevent oil leaks
6. Always pump up hydraulic lifters before installing them. Use an oil squirt can to fill the lifter with oil through the feed hole on the side of the lifter, push oil through the feed hole until the air bubbles are gone. If needed work the oil back and forth through the feed hole and pushrod seat with the squirt can. Light weight oil can be helpful. 7. Assemble and adjust one cylinder at a time, the servicing cylinder needs to be on TDC of compression stroke so the cam lobes are at their lowest point 8. Install pushrods into proper locations with the adjusting side of the pushrod down, towards the lifter. Slide the pushrods through the pushrod covers up into the rocker housing and set the pushrod on the seat of the lifter. We recommend filling the pushrods with oil then maneuver the pushrod up into the rocker arm seat. 9. Torque rocker arm housings and breathers to factory torque spec’s 10. See the instructions for your lifters for the proper adjustment. All Feuling hydraulic lifters run best at . 090″ – . 100″ of crush.

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WEGO IV Wide-Band Exhaust Gas Oxygen Sensor System Installation Instructions

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Filed Under (Harley Davidson) by admin on 21-04-2012

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO IV unit where the display will be visible during testing. The unit is not sealed and must be mounted in a dry location away from sources of heat. We recommend underdash mounting or use in a dyno lab environment. The unit is not intended for underhood mounting. The unit can be secured by means of Velcro tape strips. Use nylon tie wraps to secure the wire harness near the unit. 5. Working with clamping terminal blocks . All connections to the WEGO IV terminal block must be clearly identified either by means of distinct wire colors (such as shown in Figure 1) or wire labels. If you use different wire colors, mark up Figure 1 for future reference. All connections can be made with 18-20 AWG wire. Wire should be stripped back

CYCLE SOUNDS T-TAP POWER HARNESS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-04-2012

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This t-tap plug is designed to work with Cycle Sounds audio systems. However it can be used to wire many add on 12 volt accessories to you Harley Davidson motorcycle. This plug is rated for 6-8 amps of power and should not be used for adding any product that is rated for more than the t-tap plug is rated for. Take the time to check the products power rating for which you want to install to make sure it is compatible with the t-taps amperage rating. Failure to do so couldlead to electrical failures, which could result in serious injuries or even death. it is possible to overload your motorcycles charging system by adding too many electrical accessories. U se amp meter to verify all power connections. Also check product power ratings for anything you are trying to install. Exceeding the maximum amperage can lead to electrical failures, which could result in serious injuries or even death. INSTRUCTIONS: Step 1: remove seat on bike and locate the wire harness under the seat that matches the plugs on the t-tap harness (2120-0026.) Location may vary between bike models. Step 2: unplug bike harness and snap each end of t-tap harness in correct plug opening. When finished connect power wires to the male plug.(all Cycle Sounds audio systems come pre wired with correct wire colors and terminals). When using this t-tap for any other 12 volt accessory, make sure the red and black wires are snapped into their proper pin connectors. Kit does not come with power terminals for the accessories device. See your local bike dealer for purchase of terminals

Harley-Davidson DETACHABLE SISSY BAR SIDE STRAPS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 20-04-2012

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1. Remove factory sissy bar upright. Save upright if to be reused. Remove the two factory buttonhead screws and washers from the fender support on each side. Remove factory side plates. Discard side plates and factory hardware. 2. Cement the Plastic Sliders (item #1) into the brackets on the Khrome Werks Side Straps (item #2), using contact glue. 3. Install the special buttonhead screws through the flanged spacers (items #7, 8), then through the fender supports, frame, and into the fender. 4. Assemble the Knurled Knob (item #6) to the Side Strap, using the 1⁄ 4 “-20 x 1⁄ 2 ” screw, chrome washer and compression spring (items #3, 4, 5). The spring goes under the washer and into the counterbore of the knurled knob. 5. Install your sissy bar upright into the Side Straps, using the 1 ⁄ 4 “-28 x 3⁄ 4 ” screws provided (item #9).

HARLEY DAVIDSON ADJURE'S BIG CITY LED LIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 20-04-2012

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ADJURE OFFERS DOT COMPLIANT LED REPLACEMENT TURN SIGNALS TO FIT BOTH THE FLAT AND FOOTBALL HARLEY DAVIDSON TURN SIGNAL HOUSINGS. STOCK HARLEY DAVIDSON HAS 3-WIRE AMBER (RUN/TURN) IN FRONT AND 2-WIRE AMBER (TURN ONLY) IN THE REAR. IF YOU WANT TO CHANGE YOUR REAR TURN SIGNALS INTO RUN/TURN/BRAKE, YOU MUST CHANGE THE LENS COLOR TO RED AND THE BEST WAY TO DO THIS IS TO ALSO ORDER AND INSTALL OUR P/N# K48590 (RUN/TURN/BRAKE CONTROLLER). NOTE: WHEN USING LED’S AS A TURN SIGNAL YOU MUST ALLWAYS USE A “LOAD EQUALIZER” P/N#K48100 TO MAKE THEM WORK PROPERLY. INSTALLATION: COVERS BOTH FLAT AND FOOTBALL HOUSINGS 1) REMOVE THE LENSES FROM YOUR STOCK TURN SIGNALS BY REMOVING THE 2 SCREWS ON EACH SIDE OF THE LENS. 2) REMOVE THE BULB BY PUSHING IN AND TURNING COUNTER CLOCKWISE. 3) INSERT INTO THE LIGHT SOCKET THE PLUG ON YOU NEW LED’S BY PUSHING IT IN AND TURNING IT CLOCKWISE. 4) SET THE LENS ON THE HOUSING AND REPLACE THE SCREWS. TO CONNECT THE LOAD EQUALIZER: 1) THERE ARE 3 WIRES CONNECT THE BLACK TO A GOOD GROUND AND ONE OF THE WIRES TO ANYWHERE IN THE LEFT SIDE TURN SIGNAL SYSTEM AND THE OTHER WIRE TO ANYWHERE IN THE RIGHT SIDE TURN SIGNAL SYSTEM.

Harley-Davidson wheel installation kits

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Filed Under (Harley Davidson) by admin on 19-04-2012

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ReAcToR Five-SPoKe cuSTom wheel The five slim spokes of this custom wheel dramatically change the look of the VRSC™ motorcycle. Available in mirror-chrome or gloss black, the “ball-milled” spokes radiate from the unique center hub to blend with the machined rim, opening the bike for a light, sporting profile. The smooth curving rim, highlighted with machined grooves, adds to the true custom look without compromising strength or performance. The raised bosses on the hub carry the Original Equipment floating brake rotors, and add to the clean appearance of the installed wheel. 19″ Front Fits ’02-later VRSC models. Requires separate purchase of model-specific Wheel Installation Kit. ’07 VRSCX, ’08 VRSCAW Anniversary models, and other models equipped with laced front wheels also require additional purchase of (2) Front Brake Rotors P/N 44553-06A. 43219-08 Chrome. $1,119.95 43501-08 Gloss Black/Orange Stripe. $1,119.95 18″ Rear (240 Tire) Fits ’07-later VRSC models (except ’07-’08 VRSCD and ’07 VRSCR). Requires separate purchase of model-specific Wheel Installation Kit. 43728-08 Chrome. $1,399.95 43616-08 Gloss Black/Orange Stripe. $1,399.95 18″ Rear (180/55 Tire) Fits ’02-’06 VRSCA and VRSCB models, ’06-’08 VRSCD and ’05-’07 VRSCR models. Requires separate purchase of model- specific Wheel Installation Kit. 43215-08 Chrome.

Harley-Davidson BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-04-2012

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1) Remove the primary chain case cover. Refer to your Factory Service Manual for this procedure. 2) Remove the compensating sprocket nut with a 1-1/2″ socket. A ½” impact gun is best for this task. *) Remove the 1-3/16″ clutch nut. This is a left handed nut so loosen it by turning it in the clockwise direction (as viewed from the left side of the motorcycle). 4) With one hand on the compensating sprocket and one on the clutch assembly, remove the primary drive assembly (compensating sprocket, primary chain, tensioner assembly, and clutch as shown in figure a and set it on a clean surface. 5) Flip the adjuster shoe bracket on the chain tensioner assembly. figure b shows the stock orientation of the adjuster show and bracket. Figure C shows the adjuster show bracket flipped 180°. To flip the shoe bracket, remove the two ¼-28×2 bolts that hold the bracket assembly together. This will allow you to separate the chain tensioner assembly components from the primary chain. Flip the bracket around as shown in figure c . PAGE 4 Figure B Figure A BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS 6) install the new compensating sprocket, chain, and clutch onto the motor sprocket shaft and the transmission input shaft. The flipped chain tensioner assembly (as shown in figure c ) is not ‘captured’ on the primary chain like the stock configuration. Loosely install the chain tensioner assembly onto the anchor plate bolt. Tighten the compensating sprocket nut to 157+ 7 ft-lbs and the clutch hub nut to 75+ 5 ft-lbs using red Loctite on the threads.

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Harley Davidson HOGPRO DEUCE 200 TIRE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 18-04-2012

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1. Remove the seat 2. Remove the rear wheel. 3. Drain and remove the primary covers and drive belt. 4. Install the new supplied 13/16″ drive belt. 5. Re-install the primary covers, gasket, seal, and fluid. 6. Remove chrome fender strut covers. 7. Remove the plastic license plate mount and un-plug the turn signals 8. Remove the rear fender 9. Discard the long gold colored wiring covers from both sides of the inner fender. 10. Wash the inside of the fender thoroughly with soap and water. 11. Clean the inner fender along the wiring path with supplied alcohol. 12. Locate the wiring harness at the top right of the fender. 13. Firmly affix the 5 supplied zip holders along the wiring path. 14. Attach the harness using the supplied zip ties. Leave enough slack so that you can adjust the position of the harness once the fender is re-installed. 15. Re-install the fender using the supplied hardware. (The curved fender mounting brackets will be re-installed from the inside out using the 4 thin supplied nyloc nuts and washers. 16. Install the front license plate mount bolts inside out using the 2 supplied nylocs and washers. 17. Tighten the fender. Using a hack saw or cut off wheel, remove the remaining threaded studs flush with the nyloc nut on each of the fender brackets. 18. Re-install your chrome fender struts. 19. Adjust the wiring harness and tighten the zip ties. Cut off the excess zip tie. 20. Install the new Hogpro wheel, pulley, and the 200 tire of your choice. 21. Have Fun!

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Harley-Davidson touring bikes WHEELDOCK EZ-UP Center Stand Installation Instructions

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Unlike other center stands, the WHEELDOCK EZ UP stand requires very little effort to operate and can usually be done while still on the bike by simply pushing down on the foot lever with your left foot. Once you feel both feet of the center stand in contact with the ground, transfer your weight up off of the seat and onto the foot lever of the center stand. The stand should rotate under the bike and a bit forward lifting the bike quite easily. CAUTION: Never attempt to raise the bike with a passenger on board, as you will damage the foot lever. You can also raise the bike on the center stand by using the following traditional method: Place the bike on the side stand and step off to the side. From the left side of the bike, push the bike up to the vertical position and press down on the foot lever until both feet of the stand are in contact with the ground. Now apply weight to the foot lever while lifting up on the bike. For cleaning the rear wheel: first place a ½-inch piece of plywood under the stand and use this (beside the bike) method for placing the bike up on the plywood spacer; this will allow the wheel to rotate freely for cleaning. Do not try this while on the bike, as it will require too much foot pressure on the lever. You now have two options to get the bike off of the stand: You can simply rock the bike forward, or put the bike in gear and drive off in most cases as long as you are parked on a flat, level surface. Tips for solving common problems: If you have the correct height stand and you still have difficulty getting the bike up on the stand check the following: the bike must be in neutral, the wheel should be straight forward and not cocked, do not hold the front brake lever and make sure you have 15 lb or more air pressure in the rear suspension. These are the most common problems we encounter.

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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