1975 harley fl compensator nut torque

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HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

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HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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HARLEY DAVIDSON STEERING HEAD WASHER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. 1. See Figure 1. Remove the fork stem cap (1). Bend the lockwasher (2) tab away from the steering stem nut (3) and remove the fork stem nut and lockwasher. Discard the lockwasher. NOTE Always tighten the steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm) before measuring fall away. Lubricate threads of nut with a small amount of clean engine oil. Avoid applying oil to the mating surfaces of the steering stem nut (3) and the new hardened washer from the kit. 2. Install the new hardened washer from the kit (2) and steering stem nut (3). Tighten steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm). 3. Check fall away following the instructions in STEERING HEAD BEARINGS BEARING ADJUSTMENT (FALLAWAY) in an appropriate Service Manual, however, tighten the steering stem nut (3) to 70 – 80 ft-lbs . Adjust adjusting nut (5), if necessary per instructions. 4. Install fork stem cap (1).

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2000 & later Harley Davidson Softails Drag Specialties Shocks Installation Manual

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Filed Under (Harley Davidson) by admin on 31-03-2012

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1. Place motorcycle securely on stand or blocks so the rear wheel is slightly off the ground. 2. Per instructions in a authorized shop manual, remove your old shocks. Note location of the mounting hard- ware. 3. Before reinstalling a Drag Specialties adjustable ride height shock, spin the non-flanged nut all the way onto the stud mount, followed by a bushing-cup, bushing, and sleeve. Then install shocks as you would a stock unit, following an authorized shop manual. With the non-flanged nut spun all the way onto the stud, the stock ride height is achieved. Once you have installed the other bushing, bushing-cup, and flanged nut you can now install the safety E-clip. This E-clip is snapped into the groove near the end of the stud mount where the threads stop. This is to serve as a reference point ONLY – when the flanged-nut reaches it you have lowered your ride height the maximum 2 inches. DO NOT torque the flange-nut against the E- clip (see figure 1). 4. Tighten all shock mounting bolts to the proper torque specifications (see shop manual for specs). 5. Drag Specialties shocks have adjustable pre-load to compensate for varying weights. A Harley Davidson pre-load adjustment wrench is necessary to adjust the pre-load setting. Progressive Suspension, Inc. wrenches are available as Part # SW-784 from most Dealers and Accessory Stores and the Harley Davidson wrench is available as part #94455-89 from any Harley Davidson Dealer. Spring preload is set by us to the lightest setting. To increase preload for heavier riders/loads/passengers, loosen locknut with the inside portion of the supplied wrench or a 1 1/ 16 ” wrench and back it off several turns. Use the supplied wrench or a Harley

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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Harley-Davidson CHAIN DRIVE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 15-04-2012

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1) Assemble & install the chain tensioner assembly over the primary chain as shown in figure 1. 2) Install the compensator sprocket with extender & spacer (numbers 5, 6, & 7, FIG 2)(#7 is not included in this kit), primary chain, chain tensioner, and clutch basket simultaneously onto the motor drive shaft & transmission main shaft. Rotate the chain drive slightly as needed to allow the splines to line-up. 3) Install the chain tensioner nut loosely on the chain tensioner bolt. 4) Install the sliding cam onto the compensator sprocket, & slide the compensating sprocket cover-assembly (#3) over the cam. 5) Apply 2 drops of Rivera “Red” thread-lock on the threads of the motor drive shaft, & install the motor nut loosely with the fingers at this time. The hex spacer (#7) and spacer (#2) as seen in fig.2 are not provided in Rivera Engineering’s chain drive kit. These components are required with some applications, and can be purchased from your local Harley-Davidson dealer. FIG 2 6) Apply 2 drops of Rivera “red” thread-lock on the threads of the transmission main-shaft and loosely install the clutch hub nut (left hand threads). 7) Place the HD “Primary Drive Locking Tool” HD-41214 on the primary chain as shown in figure XXX and tighten the motor sprocket nut to 150-165 foot-pounds. 8)Turn the locking tool 180 degrees and move it to the clutch sprocket. Tighten the clutch hub nut to 70-80 foot pounds (left- hand thread). Adjust chain tension so that the top strand has 5/8″- to-7/8″ of up and down play (cold drive train). Tighten the center bolt nut to 21-29 foot pounds of torque.

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HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON HORN COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION 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) 1. Remove seat and disconnect wires from horn. 2. See Figure 1. Remove stock horn bracket nut (2) and the entire stock horn cover assembly (1). Remove the horn (3) and all hardware components from the stock cover including wire clamp, clips, and mounting bracket. Leave rubber mount and locknut on motorcycle. Note assembly order for kit installation. NOTE Do not over-tighten “horn to horn cover” nut. Over-tightening may result in permanent damage to the horn. 3. Apply Loctite 271 (Red) to threads of nut (4) fastening the horn to the horn cover. Tighten nut to 80-100 in-lbs (9.0- 11.3 Nm). Tighten screws fastening the horn cover to the horn bracket to 35-55 in-lbs (4.0-6.2 Nm). 4. Route wiring harness through the clamp (if present) and install the entire horn cover assembly to the mounting stud (5). 5. Tighten nut (2) fastening the horn bracket to the horn rubber mount to 80-100 in-lbs (9.0-11.3 Nm). Connect positive (+) 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. (00068a) 6. Connect wires to terminals and reconnect battery. NOTE Horn is not polarity sensitive. Ground and power wire may be connected to either terminal. 2 4 1 5 3 is03958 1. Horn cover assembly 2. Bracket nut 3. Horn 4. Nut 5. Mounting stud Figure 1. Horn Cover Installation 7. Test horn. NOTE Test the horn only when mounted on the vehicle. The sound may be muffled if tested when hand-held. A muffled sounding horn that is mounted to a vehicle may indicate permanent damage to the horn by over-tightening the horn to horn cover nut (Figure 1, Item 4). Attempt to adjust nut torque. Replace horn if necessary. 8. Reinstall seat

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