Filed Under (Harley Davidson) by admin on 10-02-2011
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)
Filed Under (Harley Davidson) by admin on 25-02-2012
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
Filed Under (KTM) by admin on 26-01-2012
Remove the lower d bolt making sure you keep track of the order of the small parts for re-assembly. 2) Remove the lower in-frame bolt. 3) Install the supplied lower kickstand mounting bracket onto the frame at the lower chain roller boss. The counter bore should slide over and onto the frame boss. The chain roller should go back into place just how it came e supplied lower kickstand mounting bracket between it and the frame. Do not is bracket needs to pivot to align with the lower hole in the main . 4) Install the kickstand onto the bike using one of the provided M8x30mm flat head sub-frame to main-frame bolt location. Do not tighten yet. 5) Line up and install the other provided ad bolt thru the lower kickstand mounting hole into the supplied lower kickstand mounting bracket. 6) Now tighten all three bolts, two mounting bolts (front) and one lower kickstand mounting bracket 7) Periodically check the kickstand and all mounting bolts for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride! We recommend using a heavy-duty chain lube. If necessary, you can remove the back cover plate for additional cleaning. Never remove the kickstand leg pivot bolt!
Filed Under (Harley Davidson) by admin on 24-10-2010
1. Close the bag completely. Support the outside of the bag with a covered piece of soft material to prevent marring or scratching. 2. Position the template on the outside of the bag, centered between the buckles. Align the template along the gap between the seams as shown at right. Tape the template in place. 3. Drill all of the small holes on the template using a 1/4″ drill bit for the assembly holes. Drill or punch the 3/4″ hole for the lock. 4. Sandwich the lock. item 4, between items 3 and 5 as shown above in FIG.1. Fasten it to the bag with the black slotted blind screws (items 7). Sandwich the leather between the lock cover plate (item 6) on the outside and the lock assembly. It may be necessary to remove a section of excess overlapped leather. 5. Use the phillips head screws (item 7) provided to attach the spring loaded ratched bar assembly. 6. Lock operation. *a. rotate the locking bar down as the bag is closed * * so that it is started into the lock aseembly. *b. check that the bag straps are outside of the bag. *c. Press the bag lid down as your help to align the * * bag lock assembly with the locking ratched bar. the ratchet bar whill operate smoothly into the * * lock when properly aligned.
Filed Under (Harley Davidson) by admin on 01-03-2011
Removal (Left and Right Forks) 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 Touring Model Service Manual and remove front wheel, fender and brakes. 3. Refer to Touring Model Service Manual and remove headlamp nacelle. 4. Loosen fork cap bolt from fork tube plug at top of fork tube, but do not remove. 5. See Figure 1. Standing at front of vehicle, loosen pinch bolt (with lockwasher) on right side of lower fork bracket, but do not remove. 6. Spray glass cleaner on fork tube above the rubber fork stop. After lubricating surfaces, move fork stop up fork tube until it contacts bottom of upper fork bracket. 7. Holding fork slider to prevent fork from dropping, remove fork cap bolt from fork tube plug. Slide fork tube down and out of upper fork bracket, fork stop, lower fork bracket and slider cover. 1 WARNING 1 WARNING 1 WARNING 1 of 5 ® Kit Number 54614-05 Figure 1. Loosen Pinch Bolt on Lower Fork Bracket i04808 1 Fork cap bolt 2 Fork stop 3 Pinch bolt 8. Thread fork cap bolt back into fork tube plug to prevent loss of oil while handling. 9. Move forks to bench area. Place suitable drain pan on floor beneath vise. 10. Repeat Steps 2-6 to remove left fork. Left And Right Fork-Disassembly 1. Remove nuts, lockwashers, flat washers and axle holder from studs at end of fork slider. 2. See Figure 2. Obtain FORK TUBE HOLDER (Part Number HD-41177) and proceed as follows: a. Clamp end of tool in vise in a horizontal position with plastic knobs facing toward you. b. See Figure 3. With the fork cap bolt topside, clamp fork tube between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. 3. Remove fork cap bolt from fork tube plug. Remove quad ring seal. Save bolt but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug from fork tube. Be aware that fork tube plug is under spring pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring 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 6mm screw from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring. 11. Remove and discard damper tube. 12. Remove wear ring and rebound spring. Discard rebound spring. Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted. 13. Using pick tool, remove retaining clip between fork slider and fork tube. 14. Remove fork tube from fork slider. NOTE To overcome any resistance, use the fork tube as a slide hammer, that is, first push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. 15. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing. 16. Remove the lower stop. Right and Left Fork-Assembly Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. 1. See Service Parts Illustration. Obtain new Damper Tube (Item 7, Part Number 46532-04) from kit. Obtain new Rebound Spring (Item 8, Part Number 46273-02) from kit and install on opposite end. Install wear ring removed in step 12. 2. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube. Install lower stop at end of damper tube. 3. Install fork slider in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (14) (Part Number 45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube. 5. Slide slider spacer down fork tube until it contacts slider bushing.