2007 harley sportster 1200 low exploded view off primary assy

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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

HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

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HARLEY DAVIDSON SPORTSTER LOW REAR SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION NOTE Internal shock absorber components are not repairable beyond the Service Parts listed on this instruction sheet. Consult your Harley-Davidson dealer if further service is required. The installation procedures for this kit are the same as the original equipment (OE) installation procedures in the Service Manual. Refer to the appropriate Service Manual for the rear suspension system removal and installation procedures. The OE hardware will be re-used in the kit installation. Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) SHOCK PRELOAD (SPRING) ADJUSTMENT Refer to the appropriate Service Manual for spring adjustment. Spanner wrench (94700-52L) is required for spring adjustment. SERVICE PARTS 1 is04854 Figure 1. Service Parts: Sportster Low Rear Suspension Kit Table 1. Service Parts: Sportster Low Rear Suspension Kit Part Number Description (Quantity) Item 54734-04 Rear shock (2)

2007 Harley-Davidson Softail Family Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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frame Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Swingarm Mild steel, round tube sections, forged junctions, MIG welded Mild steel, round tube sections, forged junctions, MIG welded Mild steel, round tube sections, forged junctions, MIG welded Front Fork 41.3 mm telescopic, “beer can” covers 41.3 mm telescopic, “beer can” covers 41.3 mm telescopic, “beer can” covers Rear Shocks Hidden, horizontal-mounted, coil-over Hidden, horizontal-mounted, coil-over Hidden, horizontal-mounted, coil-over Caliper Type 4-piston front and rear 4-piston front and rear 4-piston front and rear Rotor Type: (diameter x width) Patented, uniform expansion rotors Patented, uniform expansion rotors Patented, uniform expansion rotors Front 292 mm x 5.08 mm 292 mm x 5.08 mm 292 mm x 5.08 mm Rear 292 mm x 5.84 mm 292 mm x 5.84 mm 292 mm x 5.84 mm Front (mm) 130 130 130 Rear (mm) 109 109 109 Engine Torque (EU standard EC95/1)5 86 ft. lb / 117 Nm @ 3200 rpm 89 ft. lb / 120 Nm @ 3300 rpm 89 ft. lb / 120 Nm @ 3300 rpm Right 29° 30° 28° Left 26° 28° 26° Battery Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating) Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating) Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating ) Charging Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Starting 1.2 kW electric with solenoid shift starter motor engagement 1.2 kW electric with solenoid shift starter motor engagement 1.2 kW electric with solenoid shift starter motor engagement Headlamp Headlamp Headlamp Quartz Halogen, 55-watt low beam, 60-watt high beam Quartz Halogen, 55-watt low beam, 60-watt high beam Quartz Halogen, 55-watt low beam, 60-watt high beam Tail/Stop Lights Tail/Stop Lights Tail/Stop Lights 8W/28W (5W/21W) 8W/28W (5W/21W) 8W/28W (5W/21W) Turn Signal Lights Turn Signal Lights Turn Signal Lights 28W (21W) self-canceling 28W (21W) self-canceling 28W (21W) self-canceling Indicator Lamps Indicator Lamps Indicator Lamps High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6-speed (overdrive), low fuel warnings High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6- speed (overdrive), low fuel warnings High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6-speed (overdrive), low fuel warnings Passing Lamps Chrome Vivid Black Vivid Black Vivid Black Black Cherry Pearl Black Cherry Pearl Black Cherry Pearl Deep Cobalt Pearl Black Pearl Black Pearl Pewter Pearl Fire Red Pearl Deep Cobalt Pearl White Gold Pearl Deep Cobalt Pearl Olive Pearl & Vivid Black Suede Blue Pearl & Vivid Black Suede Blue Pearl White Gold Pearl & Vivid Black Black Cherry Pearl & Pewter Pearl Olive Pearl White Gold Pearl & Deep Cobalt Pearl Fire Red Pearl & Black Pearl Pacific Blue Pearl Deep Cobalt Pearl & Pewter Pearl Pewter Pearl Yellow Pearl White Gold Pearl

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HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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HARLEY DAVIDSON BLADE FRONT WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. 2. See Figure 2. Install valve stem assembly (L) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. • For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. • For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. • For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08: • Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side. • For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. 4. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. 5. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that 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

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Harley-Davidson Sportster 883/ 1200 Straightshot HS Exhaust system REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Remove the two head pipe mounting nuts from each flange, located at the cylinder head. 3. Remove the two bolts from each muffler body which attach the muffler bodies to the mounting bar. 4. Remove the clamp bolt which mounts the rear head Page 1 of 4 D445N Rev. 1.0 Sportster 883/1200 Straightshot HS Exhaust system Part #17815 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: 3/16″ & 5/16″ Allen wrenches 3/16″ & 5/16″ Allen & 1/2″ sockets 3/8″ Ratchet & Extensions T30 Torx driver 1/2″ Wrench 5/16″ nutdriver/flat blade screwdriver Ft/lb. & In/lb. Torque wrenches Snapring pliers pipe to the belt drive cover bracket and carefully remove both exhaust pipes from the motorcycle. 5. Remove the drive belt cover and take the bracket off the rear cover bolt, it will not be re-used. 6. Loosen the brake rod at the rear eyelet using a T30 Torx driver. 7. Remove the exhaust mounting bar, saving the three mount bolts and washers for re-use. 8. Using snapring pliers, carefully remove the flanges and circlips from the stock exhaust system. Save for re-use. NOTE: If circlips look bent or twisted replace them with new circlips. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. Vance & Hines recommends you replace your gaskets with Screamin’ Eagle gaskets part number 17048-98. 2. Install and tighten supplied mounting bracket (stamped 356-P) using stock bolts and washers (Figure 1). Torque to 30-33 Ft/Lbs. NOTE: Support the rear of the bracket during tightening to insure it is aligned with the bottom edge of the frame. 3. Re-install drive belt cover. Torque to 1 x 3/8″ bolt 30-33 Ft/Lbs. 2 x 1/4″ bolts 80-120 In/Lbs. 4. Re-install brake rod eyelet using blue thread locking compound (Loctite® 243). There is a 1/2″ clearance hole in the bracket to allow access for tightening brake rod eyelet. Torque to 120/180 In/Lbs. (Figure 1). 5. Remove header pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips where hose clamps will loop through (Figure 2). 6. Install circlips and flanges from the stock system onto both new head pipes.

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2008 Harley-Davidson XR 1200 Specifications

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

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Quartz Halogen, 55-watt low beam, 60-watt high beam Tail/Stop Lights…………………………………………………………………………5W/21W Turn Signal Lights ……………………………………………………… 21W self-canceling Instruments ………………………………..Unique compact instruments with prominent ……………………. white faced tachometer, digital speedo, dual trip meter and clock Indicator Lamps ……………. Hazard warning lights operated by turn signal controls; …………………………………………. high beam, neutral, low oil pressure, turn signals, ………………… engine diagnostics, low fuel warnings, low battery, security system5 Colour Options6 Vivid Black; Mirage Orange Pearl; Pewter Denim Model Features Styling and Ergonomics • Styling and livery inspired by the legendary XR 750™ flat track racer • Wide, black handlebars for dirt track looks and superb control • Rear-set footrests for excellent cornering clearance • Ergonomics designed around average height European male rider • Standard passenger footrests Powertrain and Intake • Isolation-mounted high torque 1200cc Evolution® V-Twin engine finished in silver powdercoat • Downdraft Electronic Sequential Port Fuel Injection (ESPFI) and electronically controlled active intake system Wheels, Brakes and Tyres • Unique, lightweight cast wheels with flat track inspired 3-spoke design, finished in black • Powerful Nissin® dual front brakes with 4 piston calipers and 292mm patented uniform expansion rotors • Dunlop® Qualifier D209 tyres developed specifically for the XR 1200. 180mm rear tyre. • Sport-tuned Showa® suspension featuring 43mm inverted front forks and pre-load adjustable twin rear shock absorbers Other Features • Aircraft style aluminium alloy fuel filler • Hands-free Harley-Davidson® Smart Security System5 Warranty Warranty7 ……………………………………………………… 24 months (unlimited mileage) Service Interval8 ………………………………………………. First 1,000 miles (1,600 km), ………………………………………………………. every 5,000 miles (8,000 km) thereafte

2008 harley- davidson sportster specifications

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Filed Under (Harley Davidson) by admin on 01-11-2010

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diMensions Length 89.10 in. (2263.14 mm) Overall Width 35.20 in. (894.08 mm) Overall Height 46.80 in. (1188.72 mm) Seat Height: *•*Laden2 26.30 in. (668.02 mm) *•*Unladen* 28 in. (711.20 mm) Ground Clearance 4.40 in. (111.76 mm) Rake (steering head) 29.6° Fork Angle 29.6° Trail 4.70 in. (119.38 mm) Wheelbase 59.70 in. (1516.38 mm) Tires (Dunlop® Harley-Davidson® Series, blackwall) : *•*Front*-*D401F* 100/90-19 57h *•*Rear*-*D401* 150/80B16 71h Fuel Capacity (warning light at approximately 1 gal.) 4.5 gal. (17.03 L) Oil Capacity (w/filter) 3.60 qts. (3.41 L) Transmission Capacity 1 qts. (0.95 L) Weight: *•*As*Shipped** 557 lbs. (252.65 kg) *•*In*Running*Order* 581 lbs. (263.54 kg) *•*Gross*Vehicle*Weight*Rating* 1000 lbs. (453.59 kg) Gross Axle Weight Rating: *•*Front** 335 lbs. (151.95 kg) *•*Rear* 665 lbs. (301.64 kg) enGine Engine3 Air-cooled, Evolution® Valves* Pushrod-operated,*overhead*valves*with*hydraulic, ** self-adjusting*lifters;*two*valves*per*cylinder Bore x Stroke 3.50 in. (88.90 mm) x 3.81 in. (96.77 mm) Displacement3 73.20 cu. in. (1200 cu. cm) Compression Ratio 9.7:1 Fuel System4* Electronic*Sequential*Port*Fuel*Injection* (ESPFI) Air*Cleaner* Paper*cartridge*type Lubrication*System* Dry-sump drivetrain Primary*Drive** Chain,*57/38*ratio Final*Drive* Belt,*68/29*ratio Clutch** 9-plate,*wet Transmission 5-speed Gear Ratios (overall) : U.s.** HDI* JPN 1st 9.315 9.004 9.004 2nd 6.653 6.432 6.432 3rd 4.948 4.783 4.783 4th 4.102 3.965 3.965 5th 3.517 3.400 3.400 chassis Frame Mild steel, tubular frame; circular sections; cast junctions wing*Arm*Mild*steel,*rectangular*tube*sections,*stamped*junctions;*MIG*welded* Front Forks 39 mm Rear Shocks Coil-over; preload dual-adjustable Wheels5 (Chrome, Laced Steel option) : Black, 13-Spoke Cast Aluminum 105th Anniversary Wheels5 (Chrome, Laced Steel option) Gloss*Black*Painted*Cast*Aluminum *•*Front* 19 in. x 2.15 in. (482.60 mm x 54.61 mm) *•*Rear** 16 in. x 3 in. (406.40 mm x 76.20 mm) Brakes: *•*Caliper*Type* Dual-piston*front,*single-piston*rear* *•*Rotor*Type* (diameter x width) :** Patented,*uniform*expansion*rotors** *•*Front* 11.50 in. x .20 in. (292.10 mm x 5.08 mm) *•*Rear** 11.50 in. x .23 in. (292.10 mm x 5.84 mm) Suspension Travel: *•*Front*Wheel* 4.12 in. (104.65 mm) *•*Rear*Wheel* 2.12 in. (53.85 mm) perforMance Engine Torque6 (per SAE J1349) : *•*North*America* 79 ft. lbs. @ 4000 rpm* (107.12*NM*@*4000*rpm) *•*World** 75 ft. lbs. @ 3500 rpm* (101.70*NM*@*3500*rpm) *•*Japan* 66 ft. lbs. @ 3500 rpm* (89.50*NM*@*3500*rpm) Lean Angle (per SAE J1168) : Right: 31° Left: 30° Fuel Economy7 (EPA urban/highway test) : 42/57 mpg (5.60/4.13*L*/100*km) electric Battery** Sealed,*maintenance-free,*12V,*12-amp/hour,*200*cca (per Battery Council International Rating) Charging Single-phase, 30-amp system (357W*@*13.5V,*2000*rpm,*405W*max*power*@*13.5V) Starting* 1.2*kW*electric*with*solenoid*shift*starter*motor*engagement Lights (as per country regulation) : *•*Headlamp* (quartz halogen) * 55-watt*low*beam,*60-watt*high*beam* **•*Tail/Stop*Lights* 8W/28W* (5W/21W)* *•*Turn*Signal*Lights** 28W (21W) self-canceling *•*Indicator*Lamps* High*beam,*neutral,*low*oil*pressure,*turn*signals,** **

Harley-Davidson Softail Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 02-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the fasteners that secure the seat. Remove seat. 6. Disconnect negative Battery Terminal. 7. Remove the Saddle Bags. And their hardware. If equipped. 8. Loosen Muffler Clamp on both Mufflers and other attaching hardware. Remove and discard both Mufflers. 9. Loosen the 4 exhaust stud nuts and save. Remove and discard head pipes and exhaust gaskets. 10. Disconnect the Rear Lamp Wiring Harness. 11. Remove any fasteners from Electrical Box. 12. Remove and discard Rear Fender, Fender Support and fasteners. NOTE: 2008-Current various models. Remove ECM from Fender and save nuts. 13. Drain all Brake Fluid from the Rear Brake System. 14. Un-clamp Rear Brake Line from the frame and Rear Fork. 15. Remove and discard both Banjo Bolts and Crush Washers from the Rear Brake Caliper and the Rear Brake Master Cylinder. 16. Remove Brake Light Switch from the Brake line, Save for reassembly. 17. Remove the Torx screw from the Brake Line bracket, Save the Torx screw for reassembly. 18. Remove and Discard Brake Line. 19. If Lower Controls option. Remove and Discard right and left floorboards/foot pegs, brake pedal, shifter, and shift linkage. Remove and Discard Passenger Foot pegs or Floorboards and their mounts. Then skip to step 24. 20. If Lower Controls Not purchased. Continue. 21. Remove acorn nut from Shift Linkage. 22. Remove 3 fasteners from Drivers Floorboard and remove. 23. Remove and discard Jiffy Stand. 24. Remove the Primary Cover by first removing the top and rear inspection cover screws. 25. Continue by removing remaining fasteners. 14 total. 26. Remove and discard Primary Cover Gasket. 27. Clean residual gasket material from both surfaces. 28. Loosen the Top Center Nut on the Primary Chain Adjuster. Lower the Primary Chain Adjuster until it rests flat on the Inner Primary Cover. 29. Remove the Clutch Lifter Retaining Ring from the Clutch Basket. Remove Clutch Lifter Assembly. 30. Using the Primary Drive Locking Tool. Loosen the Compensating Sprocket Nut. 31. Using the Primary Drive Locking Tool. Loosen the Clutch Hub Main shaft Nut. WARNING: This nut is LEFT HAND threaded. 32. Remove the Primary Drive Locking Tool, Compensating Sprocket Nut, and Clutch Hub Main shaft Nut. 33. Remove the Sprocket cover and Sliding Cam from the Crank Shaft Extension. 34. Remove the Clutch Assembly, Primary Chain, Compensating Sprocket, and Crank Shaft Extension in one assembly.

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