HARLEY DAVIDSON HIGH OUTPUT ALTERNATOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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this kit is designed for use on 1980 and later FLT and FLTC models, 1982 and later FXR, FXRS, and FXRT models and 1984 and later FXRD, FLHT, FLHTC, FXRDG, FXRS-SP, FXLR, FLHS and FXRC model vehicles. This kit contains the following parts: QTY DESCRIPTION 4 Screw, sockethead torx 1 Ring terminal 6 Cable strap 1 Rotor assembly 1 Spacer, thick 1 Spacer, thin 1 Stator assembly 1 Regulator Installation 1. Refer to applicable Service Manual for detailed removal and installation procedures. 1 CAUTION Disconnect battery (negative cable first) before performing any electrical system servicing. 2. Observe the following guidelines to ensure proper operation. A. Do not drop or pound on the new rotor assembly. Permanent damage can result. B. Do not install a new style rotor with an old style rectifier. Permanent rectifier damage can result. C. Do not install a new style rectifier with an old style rotor. Permanent rectifier damage can result. D. Route the black rectifier wire away from hot or moving parts. Secure it to the frame with cable straps. Trim excess wire length, crimp on ring terminal and attach to positive battery terminal. 3. See Figure 1. When installing rotor and stator use thin spacer inside and thick spacer outside of rotor

HARLEY DAVIDSON DYNA GLIDE ADJUSTABLE HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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Installation 1. See Figure 1. Install setscrew (14) into lower hole on frame tube boss (2) leaving .20 in. of setscrew (or three threads) exposed. 2. Place highway peg mounting plate (1) into position. For a lower peg position, place bottom hidden hole in mounting plate over setscrew. For a higher peg position place upper hidden hole in mounting plate over setscrew. Attach mounting plate to frame tube boss using 1 in. long screw (3), lockwasher (4), and flat washer (5) from kit. Tighten screws to 33 ft-lbs. 3. Install footrest support (6) onto highway peg support plate using hex nut (7), lockwasher (8) and flat washer (9) from kit. Tighten nut (7) to 47 ft-lbs. 4. Locate spring washer (10) from kit. While holding spring washer in position on inside of footrest support (with square edge towards motorcycle), position footpeg (not included with this mounting kit) between footrest support mounting tabs, as shown. 5. Insert 1-1/2 in. long screw (12) from kit through footrest support mounting tabs, footpeg, and spring washer. Secure using locknut (13) from kit. 6. Repeat these steps for the other side of vehicle. 1 WARNING These footrest pegs must fold upward and toward the rear at about a 45°angle when retracted. If they do not, peg could contact ground while motorcycle is in a turn, causing loss of control or startling the rider, resulting in possible personal injury. If pegs do not fold up and back at a 45°angle, remove pegs and turn them over so the flat surface is facing forward.

HARLEY DAVIDSON FX SOFTAIL FRONT LOWERING SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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REMOVAL 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to the appropriate Service Manual and remove the front forks. 3. Move forks to bench area. Place suitable drain pan on floor beneath a vise. INSTALLATION Fork Disassembly 1. See Figure 6. Remove nuts (T), lockwashers (S), flat washers (R) and axle cap from studs at end of fork slider. 2. See Figure 1. Obtain FORK TUBE HOLDER (HD-41177) and proceed as follows: a. Clamp end of tool in vise (1) in a horizontal position with plastic knobs facing toward you. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 6 for Steps 3-17. 3. Remove fork cap bolt (A) and spacer (O) from fork tube plug (B). Remove quad ring seal (D). Save bolt and spacer but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug (B) from fork tube (G). Be aware that fork tube plug is under spring -J03923 1 of 4 pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring (1) from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove screw and washer (Q) from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring (1). 11. Remove dust cover (E). 12. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 13. Remove fork tube (G) from fork slider. Slide fork tube gently in a slide hammer motion against the slider to remove the seals and bushing from slider. 14. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). NOTE The lower stop (L) may come out with the damper tube or remain in the slider tube. Ensure that the lower stop is removed from the slider tube. 15. Remove the lower stop (L). 16. Remove damper tube (2) from fork tube. 17. Remove rebound spring (F) from damper tube. 18. Repeat Steps 1-17 for the opposite side fork assembly. Fork Assembly

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HARLEY DAVIDSON XL 2-UP CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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Additional Parts Required •XL883 and XL883L models require the separate purchase of Passenger Footpeg Kit 50203-04, which is available from a Harley-Davidson dealer. •XL1200N, XL883N and XL1200X models require separate purchase of guide washer 7487. Kit Contents See Table 1 and Table 2 for the kit number and corresponding grabstrap number. See Figure 7 and Table 3 for a list of the service parts. Table 1. Kit Contents Grabstrap Kit Number Grabstrap Kit Number 51312-07 52883-04A 51295-04 51686-05 51312-07 52907-04A 51295-04 52283-06 51312-07 52923-04B 51295-04 52299-06 51312-07 52859-04B Table 2. Kit Contents Grabstrap Kit Number Grabstrap Kit Number 51312-07 52849-04B 51295-04 51386-04 51312-07 52871-04A 51295-04 51684-05 51312-07 52884-04A 51295-04 51685-05 51312-07 52916-04B 51295-04 52176-06 51295-04 52184-06 INSTALLATION NOTE When installing this kit, be careful not to scratch painted surfaces (fender, tank, etc.) with the metal tabs on the seat. Models Originally Equipped With Solo Seat 1. Remove the seat according to the instructions in the owner’s manual. 2. See Figure 1. Remove and discard seat post washer (2) and screw (3) from the front fender hole. 3. For XL883 and XL883L models: See Figure 2. Remove plastic cap (1) from rearward fender hole and save. 4. Remove retention nut (2) and washer (3) from middle fender hole

HARLEY DAVIDSON NOSTALGIC BRAKE PEDAL PAD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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This kit is designed for use on the following model motorcycles: 1980 and later FLHT, FLT, FLHR, FLHS 1986 and later FLSTC, FLSTN, FLSTF, FLSTS. Each kit contains: QTY DESCRIPTION PART NO. 1 Brake pedal cover 44249-96 1 Rubber tread 44251-96 1 Bolt (with rubber H-D logo) 44229-95 1 Washer, 7/8 in. OD 6422 1 Washer, 5/8 in. OD 6316HW 1 Offset washer 6421 1 Acorn nut 7946 All Service Parts are listed above. Installation 1. Remove previously installed brake pedal cover from motorcycle. 2. Align and place brake pedal cover over rubber tread. 3. Insert bolt, with rubber logo properly aligned, into hole in combined new brake pedal cover and rubber tread. 4. Place 5/8 in. OD flat washer onto bolt first, followed by 7/8 in. OD washer. 5. Place new brake pedal cover and bolt/washer assembly on brake pedal. 6. Place offset washer on bolt. 7. Adjust and hold offset washer in position covering exposed slot under brake pedal and attach acorn nut to bolt. Tighten acorn nut to 25-29 ft-lbs

HARLEY DAVIDSON HIGH INTENSITY DISCHARGE (HID) DUAL BULB HEADLAMP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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REMOVAL 1. Remove seat according to the instructions in the service manual. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. 2003-Earlier Models: Disconnect battery cables, negative (-) cable first. Refer to the service manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 3. 2004-Later Models: a. Remove left saddlebag. Refer to the service manual. b. Remove left side cover and main fuse. Refer to the service manual. 4. Remove fuel tank according to the instructions in the service manual. 5. See Figure 1. Remove the Phillips screw (1) at the bottom of the bezel and remove the bezel. Save parts for installa- tion. 1 2 is03916 1. Phillips screw 2. Bezel Figure 1. Remove Bezel 6. See Figure 2. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle. 7. Gently pull headlamp assembly out far enough to disconnect wiring. Save short wire harness for installation. 8. Remove wire connector at the back of the headlamp bulb. 9. See Figure 2. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation

HARLEY DAVIDSON FLHT (Electra Glide Standard) FAIRING COMPARTMENT POUCH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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General This kit is designed for 1996 and later FLHT, Electra Glide Standard, model motorcycles Kit contents: QTY DESCRIPTION 1 Pouch 4 Velcro™strip Installation 1. Wash inside of fairing compartment with a clean, soft, nonabrasive cloth, water and mild soap. 1 CAUTION DO NOT use benzine, paint thinner, gasoline, powdered abrasives, alkaline cleansers, or any other harsh cleansers to clean the fairing compartment. They will damage the surface. Never scrape fairing surfaces with a razor blade or other sharp instrument because permanent damage will result. 2. Arrange pouch in compartment. 3. Align and attach velcro strips from kit to top, bottom and sides of compartment so they match the placement of velcro strips on pouch. 4. To secure pouch to fairing compartment, press pouch velcro strips against compartment velcro strips. Care of Pouch 1. When necessary, remove and wash pouch with mild soap and warm water

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HARLEY DAVIDSON FL SOFTAIL FOWARD CONTROL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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INSTALLATION Shifter Side, Left Block or jack vehicle under frame in a way that the vehicle will not fall over. Failure to properly block and/or raise the vehicle could result in death or serious injury. (00462c) 1. Block the motorcycle under the frame so that it is upright and level, with the weight off of the jiffy stand. 2. Remove footpeg. 3. Remove jiffy stand, shifter linkage and bracket per applicable Service Manual instructions, retaining hardware. 4. See Figure 5. Obtain the new left side shifter bracket (2), and three TORX® screws (3) from the kit. 5. Place washers previously removed on the screws. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 40 ft-lbs (54.2 Nm) . 6. See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9). If leg stop is incorrectly installed, excessive wear can allow vehicle to fall when rested on jiffy stand, which could result in death or serious injury. (00479b) 7. Install jiffy stand and attach the spring. When properly installed, the hook on the spring side connected to the bracket will face upward. 8. Verify that rubber bumper is in place on prong of jiffy stand. Without the bumper, the stand will make hard contact with the primary drive cover when retracted, which may result in damage to the cover. 9. Extend and retract the jiffy stand leg several times to verify proper operation. The stand should swing freely to the fully extended and fully retracted positions. 10. Refer to applicable Service Manual and re-attach the shifter linkage

HARLEY DAVIDSON PUSHROD COVER RETAINER INSTALLATION AND REMOVAL TOOL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Figure 1. Pushrod Cover Retainer Installation and Removal Tool There are no Service Parts available with this kit. REMOVAL 1. See Figure 2. Insert the pin of the pushrod cover retainer tool into the retainer loop with the back of the tool towards the cylinder fins. Rotate the tool towards the cylinder to remove the pushrod cover retainer. INSTALLATION 2. See Figure 3. Load the pushrod cover retainer into the tool as shown in figure 3. Place the top edge of pushrod cover against top edge of push rod. 3. See Figure 4. Place the tool on top of the spring cover. Pivot the tool upward to install the pushrod cover retainer is05892a Figure 2. Removing Pushrod Cover Retainer is05895a Figure 3. Loading Pushrod Cover Retainer in Tool is05893a Figure 4. Pushrod Cover Retainer Installation

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HARLEY DAVIDSON XL PULLBACK HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Installation Removing the Existing Front Brake Line To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) 2. See Figure 1. Open the bleeder nipple cap on the front brake caliper. Obtain a length of plastic tubing. Install one end of the tubing over the caliper bleeder valve (1). Place the free end of the tubing into a suitable container. Open the bleeder valve about 1/2-turn and pump the front-brake hand lever to drain the fluid out of the front brake system. Do not reuse brake fluid. NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch line are clean and undamaged before assembly. (00329a) 3. Disconnect the brake line from the front brake caliper and the front brake master cylinder assembly. Discard the brake line sealing washers, but retain the banjo bolts. The brake line kit contains all new sealing wash- ers. CAUTION 1 CAUTION 1 WARNING 1 WARNING 1 WARNING ® Kit Number 56021-04B 1 of 6 Figure 1. Draining Brake Fluid i01986 i05811.tif 1 1. Caliper bleeder valve NOTE Carefully compare the new brake line to the old line before removing the old linefrom the motorcycle. Make sure the banjo fittings on the new brake line will be oriented the same as the fittings on the old line. 4. Make note of the front brake line routing and the orientation of the banjo fittings, then unfasten the brake line clamps at the right side of the front fork upper bracket and the underside of the front fork lower bracket, and remove the brake line assembly from the vehicle. Save the upper clamp and all attaching parts, but discard the brake line.

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