2001 harley road king quick connect o ring replacement

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY DAVIDSON FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT INSTALLATION INSTRUCTIONS

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

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1. Remove stock gas cap from fuel tank. 2. Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. 3. See Figure 1. Install gas cap into fuel tank. is00407 Figure 1. Screw in Gas Cap is00466 Figure 2. Note Position of Arrow on Trim Ring 4. Push down on gas cap and rotate clockwise one-eighth of a turn to lock. To unlock, push down on gas cap and rotate counterclockwise one-eighth of a turn. 5. See Figure 2. Before removing adhesive backing, note position of arrow on inside diameter of chrome trim ring. NOTE As you rotate trim ring, you will see gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. Rotation of trim ring should be minimal. 6. See Figure 3. With the arrow pointing toward front of motorcycle, rotate chrome trim ring slightly to determine best position of bottom chrome trim ring to contour of the fuel tank 7. See Figure 4. Mark position of chrome trim ring with masking tape or grease pencil. 8. Carefully cut masking tape with a hobby knife making sure not to scratch chrome trim ring or paint surface on fuel tank. 9. Peel off adhesive backing from chrome trim ring. 10. Using gas cap to center and masking tape (or grease pencil mark) to align, press chrome trim ring firmly into position for about ten seconds. 11. Peel off masking tape (or remove grease pencil mark) from chrome trim ring and fuel tank. 2 1 is00414a 1. Masking tape 2. Cut masking tape Figure 4. Align Trim Ring and Press into Place NOTE Allow adhesive trim ring to cure for about 5-7 minutes before you continue with kit installation. Install Flush-Mount LED Fuel Gauge 1. Remove the seat following 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) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 2. Disconnect battery cables, negative (-) cable first. 3. Remove stock fuel gauge. Refer to service manual for instructions. 4. Insert wires down tube of fuel tank from LED fuel gauge. 5. See Figure 5 and Figure 6. Insert LED fuel gauge in the fuel tank cup

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2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

HARLEY DAVIDSON PASSING LAMP TRIM RINGS INSTALLATION INSTRUCTIONS

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

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1. Loosen the screw from one original equipment passing lamp trim ring and remove the ring. 2. See the Service Parts illustration. Remove the screw (3) and nut (2) from the accessory trim ring (1) and set aside temporarily. 3. If not already installed, place the rubber strip (4) inside the trim ring. Align so the gap in the rubber strip is opposite the split in the trim ring as shown. 4. Insert the passing lamp sealed unit (C) inside the new trim ring and rubber strip assembly. NOTE Rotating the lamp unit may help insertion. 5. Position the bottom of the lamp unit to line up with the split in the trim ring. 6. For 2002 and later models Install the adapter ring (D) onto the passing lamp housing, lining up the tab on the ring with the notch in the lamp housing. Install the trim ring and lamp assembly onto the adapter ring, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the adapter ring. For 1962 through 2001 models Install the trim ring and lamp assembly onto the passing lamp housing, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the passing lamp housing. 7. Assemble the screw and nut to the trim ring and tighten securely. 8. Perform steps 1 through 7 for the second passing lamp. SERVICE PARTS 4 2 B C F H 3 G E 1 A D

2000 Harley-Davidson FLHRCI Road King Classic

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Filed Under (Harley Davidson) by admin on 03-11-2010

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the Road King® Classic is a motorcycle with enough traditional styling to drop jaws throughout the continent. The Road King® Classic boasts laced wheels, fat white-walls and gorgeous leather saddlebags with hard inserts so they keep their shape across the long miles. Slightly narrower new handlebars provide improved ergonomics. Fender tips, tank and seat valance all boast a metal emblem. The model is available with a fuel-injected, chrome-and-black Harley- Davidson® Twin Cam 88 engine. Specifications: Engine Type: 1449 cc, 4-Stroke, Air Cooled, V-Twin Engine Bore and Stroke: 95.3 mm x 101.6 mm Valves 2 valves/cylinder Claimed Horsepower: 67 hp (50 kW) @ 5200 rpm Maximum Torque: 110 Nm (81.1 ft. lbs) @ 3100 rpm Transmission type: 5 speed Final Drive: Belt Tire – Front: 130/90-16 Tire – Rear: 130/90-16 Brakes – Front: dual 292 mm discs with 4-piston calipers Brakes – Rear: single 292 mm disc with 4-piston calipers

HARLEY DAVIDSON HEADLAMP VISORS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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These kits fit all motorcycle models equipped with 7-inch headlamps. These kits do not fit models equipped with Headlamp Trim Ring Kits part numbers 69626-99, 69627-99, 69733-05, and 69734-05.INSTALLATION 1. See Figure 1. Remove original equipment bottom screw (1) and trim ring (2). Save parts for later use. 2. See Figure 3 and Table 2. Install headlamp visor (1) from kit and trim ring (A) previously removed. NOTE Make sure the screw holes in the trim ring and the headlamp assembly are aligned as it is difficult to rotate the trim ring when it is fully seated. 3. Loosely install bottom screw (C) previously removed on trim ring. Do not tighten at this time. 4. See Figure 2. Visually check to ensure that rubber bumpers on inside face of headlamp housing are not caught. 5. Snug bottom screw on trim ring and headlamp visor. 6. Rotate visor from side to side around headlamp assembly (B) if ring is caught on face of headlamp. 7. Push down on top of trim ring and push in on the bottom of the trim ring to fully seat the headlamp visor. 8. While tightening the bottom screw, continue to maintain inward pressure on bottom of headlamp visor, until screw is tight and trim ring is fully seated. 3 2 1 is00923 1. Bottom screw 2. Trim ring 3. Headlamp Figure 1. Original Equipment Headlamp Trim Ring

Harley Davidson Dakota Digital HLY-6000 Road Star Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The Road Star wiring is split into 2 different bundles with black connectors on the ends that were used to plug into the stock gauge cluster. Cut off both connectors. They are no longer needed The speed sensor wires on the HLY-6000 have a connector on the end that allows you to plug it directly into Harley Davidson speed sensors by using an appropriate adapter (sold separately). Luckily for us, the Road Star’s stock speed sensor will work just fine without an adapter so go ahead and cut off that connector, you don’t need it.
Ideally, the best location for the “brain box” unit of the HLY-6000 would be under the left side cover. Unfortunately, mine is full of other stuff so I had to improvise the location and decided to mount it to the back portion of the under-seat area. I would recommend that you mount yours under the left side cover though. The wires are the perfect length for that location. The brain box and wires could fit under the right side cover, but I don’t believe that the main gauge connector would reach. Using the wiring scheme on the last page of this guide, match up the wires on the Road Star with the corresponding wires on the HLY-6000 wiring harness and solder them together. Important Wiring Information: Both BLACK wires on the brain box need to be connected directly to the (-) terminal on the battery. Don’t connect them to anything else. The following wires from the Road Star are not used and can be taped off: • BLACK • RED / GREEN • BROWN The following wires from the HLY-6000 are not used and can be taped off: • GRAY • WHITE/ BLUE • WHITE (on main harness) • BROWN (*optional) The HLY-6000 has a “dimmer” function which is controlled by the BROWN wire. If you want the gauge to be bright all the time, then leave this wire disconnected. If you want the gauge to dim for night driving, then connect this wire to the GREEN Low Beam (+12v) wire

HARLEY DAVIDSON 5-3/ 4 INCH HEADLAMP TRIM RING INSTALLATION INSTRUCTIONS

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

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely. 1 2 is 01501 1. Trim ring 2. Rubber strip Figure 1. Installed Rubber Strip SERVICE PARTS See Figure 2 and Table 1

2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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