Harley-Davidson Hard mount installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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1. It is recommended that you create a template from cardboard or heavy paper (not included) of the back of the bag to assist in proper placement on the motorcycle. The template can be used for both bags simply by flipping it over horizontally 180 degree for slant style bags. For all other saddlebags transfer template to other bag making sure that the hole pattern corresponds with the bolts pattern on the opposite fender strut. 2-Assemble the saddlebags support 2. Remove your existing fender strut mounting bolts. 3. (A*) Install replacement 8mm x 70mm or 10mm x 70mm bolts. (Most Harley-Davidson models will utilize the 8mm bolts. Please determine which bolts will fit your specific application prior to assembly. Your make and model of motorcycle may require additional hardware. (See your motorcycle owner’s manual). 4. Install 2 upright and secure tight enough to maintain position and secure with the lock nuts (Metric applications do not require lock nuts). Ensure that bracket angles are away from the bike. 5. Lightly apply a dab of engine oil and lightly coat the exposed bolts(C or D) and barrel bolt Hex- head (E) assemblies (Mark at 4 points for each saddlebag). You can also use a marker or pen to mark. Take the template or bag and place against the brackets. Hold and press firmly to transfer the oil to the bag or template. The oil will leave a mark on the bag or template. If you are not satisfied with the position of the bag wipe the oil off and repeat as many times as necessary. Note: Position according to your specific setup, ensure the bag will not contact hot engine or exhaust components. If planning on carrying a passenger, ensure that there is enough clearance for the passenger’s legs between the bags and the foot pegs. Make sure that the uprights DO NOT contact moving parts, including but not limited to suspension components. 6. Place the Saddlebag on a firm surface and drill 4 holes (make sure you drill holes according to the size of the bolt to be passed) into the back of the bag only, according to your oil drop pattern. Also be careful not to damage the large mesh pocket inside the saddlebag. If a template was utilized cut the corresponding holes into the template and place temple on the back of the bag and drill following above directions. The template can be utilized for both sides of the bag

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FLH Harley-Davidson Bikes/ Trikes Steering Damper Installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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First, we’re going to install the upper Bracket. (#8 in Fig. 1) Start by placing a clean towel or other protective material over your front fender to protect it from falling objects. Remove the 5/16-18 Allen head bolt and washer holding the top of the crash bar to the frame. Use a ¼” Allen wrench. Access is easier if you crank the forks over to one side. Line up the hole in the new bracket with the crash bar, orienting the bracket to the crash bar as shown in Fig. 1, and re-install the bolt with a drop of blue loc-tite. Torque the bolt to 15-20 ft. lb. If you don’t have a torque wrench, well, you should have one, but if not, 15-20 ft. lb. is a bit tighter than a spark plug torque, which is 12-18 ft. lb. If you are not sure, snug it down tight, but don’t try to break it. Note than on a couple of these, I had to slightly elongate the hole in the bracket to re-install the upper crash bar bolt. (Side mount bracket installation) Next, the side bracket install. (#6 in Fig. 1) You’ll need a #35 Torx driver to remove the two screws holding the LEFT passing lamp/turn signal bar to the bike/trike. Carefully remove the upper and lower screws, holding the bar to prevent it from falling, possibly jerking the attached wiring. Once you have removed the screws, you can let the bar hang, while you orient the side bracket as per Fig. 1. Re-install the two screws you just removed, capturing the damper side bracket under the light bar. Use a drop of blue loc- tite here as well. Hand tighten the two screws, aligning the lamp bar and damper side bracket. Using your torque wrench, (you did find one didn’t you?) Tighten the two screws to 15-20 ft. lb. Ok the easy part is out of the way.

2007 Harley Davidson Sportster 1200 Installation Manual

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Filed Under (Harley Davidson) by admin on 11-04-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Remove the ECM from the tray and remove the tray from the fender. You can reach underneath the fender to gain access to the release tabs for the tray. 4 Install the Dynojet tray into the rear fender . Make sure that all 3 location tabs are underneath the fender. 5 Lay the PCIII in the tray (Fig. B). 6 Install the stock ECM on top of the PCIII making sure that it is secured by the tray locking tabs. 7 Plug the GREYconnector from the PCIII into the ECM. 8 Route the PCIII harness on top of the GREY connector (Fig. C) and route towards the front of the bike. Fig. A Fig. B Fig. C 2007 Harley Davidson Sport ster 1200 – PCIII USB – 2 i817-51 1 www .powercommander .com Unplug Tray 9 Plug the BLACK connector from the PCIII into the stock wiring harness. Secure this connection with one of the supplied zip ties (Fig. D). 10 Run a zip tie behind the wiring harness (Fig. E). 11 Route the stock wiring harness as shown in Fig. E. Due to the lack of room on this bike this step needs to be exact or the install will not fit properly . Make sure that the harness coming from the GREYconnector is flush against the battery box. Acouple inches of this harness will be tucked underneath the frame

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Harley Davidson Twist Gear and Wide Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 11-04-2012

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Assemble triple lip output seal 705002 and output spacer 280001 together. The seal is shipped with high performance grease packed into the seal lips to ensure lubrication and exclude dust & water. (Caution: Only high temperature grease should be used, grease is better than oil, never install the seal dry.) Slide the quad ring and seal/spacer assembly onto the transmission output shaft, then slide tool JE300001 ( TwistGear TM ) or JE300002 ( WideGear ) onto the shaft and finally tighten the nut until the tool drives the seal flush with the case. Do not attempt to install the main drive seal without the JE tool or the seal will be damaged, and the seal performance will be compromised (the JE seal is wider around the shaft for the third sealing lip, which will be damaged if a tool is pressed against it.) It is best that a new JE spacer be used each time a new seal is installed for quick break-in of the main lip seal surface. Counter Shaft Assembly Note the order and orientation of the gears on the counter shaft when it is removed from the trapdoor. Disassemble the counter shaft and transfer the parts to the TwistGear TM counter shaft. Note that the TwistGear TM counter shaft assembles in different order than the OEM counter shaft. Two washers are required in the position as shown in figure 1 (see arrow) before the retainer ring is installed. The second washer is included in the kit.

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harley davidson oil filter cooler installation instructions

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Filed Under (Harley Davidson) by admin on 10-04-2012

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2000 cH ROME 99 – 07 SOFTAIL MODELS #2001 CHROME 99 – 07 DYNA MODELS #2002 CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2005 black CHROME 99 – 07 SOFTAIL MODELS #2006 BLACK CHROME 99 – 07 DYNA MODELS #2007 black CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2020 REPLACEMENT OIL FILTER #’S: 2000, 2001, 2002, 2005, 2006, 2007 1. See Figure 1 to verify all Feuling components and the proper mounting bracket for your model 2. Wash, clean and inspect all new Feuling hardware, Including – off-set sandwich oil filter adapter, filter cooler housing and oil lines, use compressed air to blow dry the oil lines, fittings, threads and bolt holes. Use a tap and die if needed to clean threads. (On installation use lubrication on all fasteners and fittings) 3. Refer to the proper service manual for your model motorcycle & engine, for removal of engine oil and spin-on oil filter. Dispose of these items properly. 4. Clean engine case oil filter spigot and sealing surface thoroughly. 5. Install the clean Feuling off set oil filter sandwich adapter; both O-ring and gasket need to be assembled dry. 6. First install the inside half of the off-set oil filter adapter, O-ring side towards engine case filter mount. We recommend using a dab loctite on the 1″ lock nut. (See figure 2) It is recommend to mock up the sandwich adapter before torquing nuts and bolts to obtain desired orientation and proper clearance to engine case and frame rails. 7. Install the fittings and oil lines onto the outer half of sandwich adapter torque fittings to proper specs using thread sealant on the 1/8 NPT threads and engine oil on the -4 AN oil line fittings. 8. Complete installation of sandwich adapter, including the inner gasket. Finger tight the allen head bolts in an alternating sequence on both sides before final torque. Re-Torque the allen head bolts after the first heat cycle after installation and during every oil change.

Harley Davidson Touring Bikes 2009 Installation Manual

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Filed Under (Harley Davidson) by admin on 10-04-2012

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LegUp has developed a new, stronger attachment system which replaces the Harley-Davidson® center stand previously included in the kit! You will need to remove most all of the exhaust system, in order to install the support stand. Remove the right front floorboard the entire right exhaust pipe, and the left rear floorboard. These need to be removed to allow access to the swing arm pillow block lower bolts, which attach the support stand to the motorcycle. Leg Support Stand If you haven’t already done so, install the uprights (Blue above) to the plate. These uprights bolt to the plate on the bottom with (4) 3/8″ bolts and lock washers. The taller upright goes on the right side of the plate (the far side in this picture). Remove the bottom bolts from the swing arm pillow blocks and set them aside. The right one may have a cap rather than a bolt. These bolts are the ones under the big chrome circles where the swing arm meets the frame. Once this is done, use a helper and gently slide the plate (red above) under the bike. It gets located under the transmission, and below the cross-brace that has two large holes in it. Lift the stand until the holes in the uprights align with the holes in the pillow block. Re-install the pillow block bolts, but leave them loose. Find the 3/8″ Strap (green above) and the (2) 5/16″ bolts and lock washers. Place the strap above the cross-brace that is under the transmission, and align one of the bolts (the bolts go through the non-threaded holes in the plate) with the threaded hole in the strap, through the cross-brace. Just start the first bolt, and then repeat the process on the other side

HARLEY DAVIDSON FORK MOUNTING KIT INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 10-04-2012

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1. Insert two additional screws into the rear of the extrusion of the light head. See instruction sheet packaged with light head for details. 2. See figure 1. Secure the mounting brackets to the directional Cuda TriOptic light head using the #8-32 KEPS nuts and screws supplied with this kit and light heads. Ensure that drain holes in the light head will be pointing down when installed on the motorcycle. Refer to instructions packaged with light head for details. 3. See figure 2. Remove and retain the top screw from the fork as shown. Attach the assembled bracket to the fork using the previously removed screw and hand tighten the screw. 4. See figure 3. Remove and retain the bottom screw. Rotate the bracket assembly to align with the bottom hole. Replace the previously removed screw. Tighten all hard he Model 350213-03 is a kit for mounting Cuda TriOptic light heads 351012 & 351023 devices to the side of the forks on a Harley Davidson motorcycle. This kit uses hardware supplied with Cuda TriOptic light heads. B. UNPACKING. After unpacking the kit, inspect it for damage that may have occurred in transit. If the unit has been damaged, do not attempt to install or operate it. File a claim with the carrier, stating the extent of damage. Carefully check all envelopes, shipping labels, and tags before removing or destroying them. Ensure that the parts listed in the KIT CONTENTS LIST are included in the package.

1990 Harley Davidson ULTIMA 6 SPEED BUILDERS KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-04-2012

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For 2000 & later models removal of approximately 1/4 of an inch off of the shifter arm bushing is likely required. Doing so will allow installation of the retaining clip & washer onto the shifter arm. It is good practice to double check how much material should be removed before cutting the bushing. See fig. 1 & 2 Install supplied Main drive gear bearings & countershaft needle bearings using special tool # 97-164 NOTE: Lightly coat bearings with assembly lube or gear oil for easier installation. Install supplied Main drive gear retaining clip & verify that it is fully seated and cannot come out. Do not re-use old bearings or retaining clip. Install supplied Main drive gear into bearings using special tool # 97-166 See fig. 3 Install supplied trap door gasket & verify that it is on correctly. Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly. Slowly slide in gear set until the mainshaft & countershaft will not slide in any further. Lightly tapping on the trap door (while verifying that there is no interference) with a soft blow hammer will then fully seat the shafts & trap door. See fig. 4 Once gear set is installed use the supplied 5/16-18×1-1/2 & 1/4-20×1-1/2 bolts to secure the trap door. Torque the 5/16 bolts to 15 ft-lbs w/ red loctite (high strength) Torque the 1/4 bolts to 9 ft-lbs w/ red loctite (high strength) See fig. 5 FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 2 FIG. 6 At this time check to make sure all gears rotate freely & that all slider gears slide with no interference. Lightly lube & install supplied quad seal onto main drive gear. See fig. 6 Install Main seal using special tool # 97-164. See fig. 7 Install original spacer onto mainshaft. NOTE: Beveled side goes in towards quad seal. See fig. 8 Install supplied transmission drain plug & supplied speedo sensor plug with gasket. Install supplied shifter forks onto appropriate slider gears. See fig. 9 Lightly lube & install supplied shift fork shafts. NOTE: Short shaft is installed from the right side with the threaded hole facing out. Long shaft is installed from the left side & should not protrude from the right side of case. See fig. 10 Install supplied shift fork shaft allen head plugs. (Use red loctite to prevent movement of plug & to aid in sealing)

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Harley Davidson AIR INTAKE SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-04-2012

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1. Preparing Vehicle a. Make sure vehicle is parked on level surface. b. Set parking brake. c. If engine has run in the past two hours, let it cool down. d. Disconnect negative battery terminal. e. Do not discard stock components after removal of the factory system. 2. Removal of stock system a. Stock air box configuration system. b. Release the four clips on the air box. c. Loosen the hose clamp on the turbo inlet pipe. d. Vehicle equipped with MAF sensor. Unplug the mass air flow (MAF) sensor. 4 d) Clamp removal. e. On vehicles equipped with IAT, unplug the IAT sensor and remove from the housing. f. Pull the air filter status meter from the grommet. g. Remove the rear section of the intake system. h. Remove the remaining stock air box system. 5 3. Installation of AEM® intake system. a. When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed to do so. i. Use the supplied torx key to remove the MAF sensor. Save screws for later use. b. Install the supplied coupler as shown. c. Place the aluminum stand in the plastic member as shown.

HARLEY-DAVIDSON TOURING TRUE DUAL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-04-2012

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1. Remove both saddlebags and side covers from the motorcycle 2. Remove seat and place it away from the work area; disconnect battery. 3. Cover the primary housing, transmission top, and end cover near the head pipe to prevent damage. 4. Remove the bolt for the passenger floorboard that attaches it to the frame. 5. Remove the right side rider floorboard and support brackets. Loosen muffler clamps; remove the support bolts located at the rear upper portion of the mufflers. Remove mufflers from the head pipes. Unscrew clamps on the factory heat shields, and remove heat shields from the head pipes. 6. Unplug both O² sensors. Cut and remove the ZIPSTRIP that holds the front O² sensor wire to the frame. Loosen clamp on the rear exhaust pipe; remove the left side pipe, while leaving the split pipe in place. 7. Loosen clamp on crossover pipe and remove leaving right side exhaust intact. 8. Remove nuts on the flanges located at the cylinder heads. Remove the right side pipe as one unit. 9. Use snap ring pliers to carefully remove the circlips on each pipe inlet; remove

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