2008 harley softail tool box mounting bracket

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HARLEY DAVIDSON SOFTAIL LEFT SIDE LEATHER TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Installation While handling and installing tool box, be careful not to scratch surface. 1. See Service Parts Illustration. Install tool box (1) to mounting bracket (6) using button head screws (2) and washers (5). Screws (2) should be inserted through mounting holes on inside of tool box (1) and then inserted through bracket (6) holes and threaded into weld nuts attached to bracket. 2. Remove and save the two screws that secure left rear fender support to motorcycle frame. 3. Remove two bolts, nuts, and washers that secure debris deflector to motorcycle frame. This will allow you to move debris deflector out of the way when installing new passenger footpeg support bolt. Save hardware for reinstallation. 4. For 1990 to 1999 Softails: If tool box is being installed with passenger footpeg, remove the hex head bolt and left passenger footpeg. Retain footpeg and lockwasher for reinstallation. Discard bolt . If tool box is being installed without passenger footpeg, remove hex head bolt and left passenger footpeg. Discard footpeg. Retain bolt and lockwasher. For 2000 and later Softails: See page 3 . Remove footrest from clevis. Remove clevis from frame by removing cap screw from center of clevis. If tool box is installed with footpegs, keep all hardware. If toolbox is to be installed with footboards, discard hardware. 5. Slide top of mounting bracket (6) between rear fender support and frame. Align top holes in bracket with fender support holes. Align lower bracket hole with footpeg mounting hole in frame. Install the two screws, removed in Step 2, in fender support. Do not tighten screws at this time. 6. For 1990 to 1999 Softails: Place lockwasher retained in step 4 on footpeg support hex head bolt (3) from kit. CAUTION 1 of 3 For 2000 and later Softails with footpegs: Install kit 49352-00 according to instructions included in this kit. Footpeg must fold up at a 45°angle (from vertical) toward rear of motorcycle. This angle allows footpeg to fold up if, by accident, it strikes the ground surface when making a sharp turn. Failure to set footpeg to the proper fold-up angle could result in death or serious injury. 7. For 1990 to 1999 Softails: Position footpeg so it folds up and back at a 45°angle. Install bolt (3) from kit through frame, tool box bracket (6), and spacer (4), into footpeg, as shown. NOTE If vehicle is equipped with saddlebag support bracket, Part No. 90346-90 or 90346-94, position saddlebag support bracket between tool box bracket and spacer.

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HARLEY DAVIDSON RIDER BACKREST MOUNTING HARDWARE KIT INSTALLATION INTSRUCTIONS

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

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INSTALLATION 1. Remove seat according to the instructions in the service manual. 2. Remove the ECM caddy/battery cover by removing two screws. 3. See Figure 1 and Figure 2 for the mounting locations of the brackets. NOTE Some seats may limit the fore/aft mounting location of the backrest bracket. 4. See Figure 3 and Table 1. Remove plastic protective cap and locknut from stud. Leave the small plastic washer in place or the stud plate will fall out. With the backrest mounting bracket tab facing forward, attach the backrest mounting bracket (1) to stud plate with stock locknuts from the stud plate. 5. Tighten locknuts to 5-8 ft-lbs (6.8-10.8 Nm) . 6. Attach the front mounting bracket (6) to the frame cross- member using using two flange screws (8) and flange nuts (7). Tighten screws to 72 in-lbs (8.1 Nm) . 7. Attach the bracket support (2) to the front mounting bracket (6) with screw (8) and nut (7). 8. Install screw (5) and nut (9) to bracket support and backrest tab and tighten to 15 ft-lbs (20.3 Nm) . 1 2 is05475 1. Backrest mounting bracket 2. Front mounting bracket Figure 1. Bracket Mounting Locations 3 2 1 is05476 1. Backrest mounting bracket 2. Front mounting bracket 3. Bracket support Figure 2. Backrest mounted After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) -J04733 1 of 2
9. Install the ECM caddy/battery cover using two screws previously removed and tighten to 6-8 ft-lbs (8.1-10.8 Nm) . 10. Install seat according to service manual instructions. 11. Hold slit between rider and passenger seat open. On rider backrest, compress backrest rods and spring. Insert rods into backrest mounting bracket. Backrest Pad Adjustment 1. Adjust fore/aft position of backrest pad. Use 3/16 inch hex wrench to adjust set screw that is accessible through eyelet opening on rear of pad. If possible, do not remove set screw because it is difficult to install.

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HARLEY DAVIDSON MOUNTING BRACKET SERVICE MANUAL

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Filed Under (Harley Davidson) by admin on 12-04-2011

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INSTALLATION 1. See Figure 1. Note position of mounting brackets (1). Remove old mounting brackets and discard. NOTE On 1997-2000 models, the air fittings are installed to the two mounting holes on the right-hand right side bracket. On 2003 and later models, the single air fitting is installed to mounting hole on the left-hand side bracket. 2. See Figure 2. Install new mounting brackets from kit on each side of the motorcycle using new locknuts as follows: a. Use the 5/16-18 x 1 inch screws (5) in the upper two holes with 2 chrome washers (3) placed between the mounting bracket and the saddlebag support at each of the two locations. Install a 5/16-18 flange locknut (2) behind the screw that does not screw into a weld nut. Tighten to 15-19 ft-lbs (20-26 Nm). b. On each side, install a 1/4-20 x 7/8 inch screw (9) through the bottom hole of the mounting bracket and the saddlebag bracket as shown, with a chrome washer (3) placed between the mounting bracket and the saddlebag bracket. Tighten to 10-14 ft-lbs (13.5- 19.0 Nm). On 1997-2002 models, install the air line fittings to the lowest two holes drilled in the right side bracket. On 2003 and later models, install the single air line fitting to the lower front hole drilled on the left side bracket. c. See Figure 2. On each side, attach docking points (6) in their proper location on mounting bracket with 3/8- 16 x 1-1/2 in. buttonhead screws (7), washers (3) and locknuts (8) but leave locknuts slightly loose so docking points can be adjusted for proper fit. On 1997and later models, the docking point will attach through the front hole of the mounting bracket as shown. On 1994-1996 models, the docking point will attach through the rear hole of the mounting bracket. d. Place detachable passenger backrest into docking points as described in the Backrest Instruction Sheet. Make sure that the forward notches of the sideplates are pushed completely into the forward docking points, then tighten the rear docking points securely to 45-47 ft/lbs (61.0-64.0 Nm

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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 SPORSTER, DYNA AND SOFTAIL LICENSE / TURN SIGNAL RELOCATOR INSTALLATION INSTRUCTIONS

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

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1. Remove the license plate. Remove the license plate mounting bracket from the fender. Remove the two screws from the tail light lens and pull the light outward, unplug the wire connector and set aside. Unplug the turn signal wire connectors from the tail light base and push them out thru the hole in the fender. Looking up underneath the rear fender remove the wires from the clips that secure them to the bottom side of the fender. Cut the wires 2″ from the plugs as shown in photo 1. 2. Unscrew the signal housings from their mounting stems while rotating the wires on the inside of the fender so as not to twist them off while unscrewing the signal from the stem. Remove the signals pushing the wires thru from the inside while pulling the signal outward. Remove the nuts from the backside of the fender that secure the stems and remove the stems. 3. Assemble the license/turn signal bracket, turn signals. Place the smaller reinforcing bracket inside the license plate bracket. Locate the two supplied 5/16″ X 1″ bolts with holes drilled thru the center and the two supplied 5/16″ long spacers. Place the bolts thru the brackets from the inside, threads facing outward followed by the spacers. Thread the wires of the signals thru the bolts and thread the bolts into the signals and snug the bolts. 4. Mounting the LED lights a. Locate the supplied LED tail/brake lights. NOTE: this license plate holder is designed for the new U.S. standardized 7″ wide license plate. If you have an old style wider plate call us at the phone number below and we will send you a separate set of chrome brackets to work with your larger plate at no charge. b. Install the lights as shown in photos 2 & 3. Thread the wires of the LED lights thru the lower holes in the license bracket, peel the adhesive backing and press them firmly in place. Cut the wires off at about 18″ long. c. Install the license plate bracket with signals and LED lights onto the rear fender as shown in photos 2 & 3. Place the two supplied 1/4″ X 1″ flat head screws thru the license plate mounting block. Notice that the thicker half of the mounting block goes toward the top of the fender. d. Next route all the wires from the right turn signal and LED into the slot or notch on the backside of the mounting block followed by the rubber mounting gasket. Install the two nuts from the underside of the fender (Removed from the original license bracket.) onto the two flat head screws and snug them being sure the wires are all in the slot of the mounting block. Run all of the signal and LED wires thru the hole in the fender to the left of the mounting block. e. Install the license plate assembly onto the mounting block using the two supplied 1/4″ X 1/2″ flat head screws. Check the slack from all the wires and again be sure the wires are not pinched between the mounting block and the fender. Tighten all four flat head screws securely. Align the turn signals and tighten their mounting bolts securely.

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Triumph Bonneville America And Speedmaster The Freak Installation Instructions and Parts List

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Filed Under (Triumph) by admin on 29-10-2010

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INSTALLATION In order to install The Freak, the factory air-box must be removed. Because of it’s design, the factory air-box is not an item that is easily removed. There are several parts that must be removed in order to get the air-box out of the bike in one piece. We recommend using the following method to remove your air box without having to cut it into smaller pieces in order to get it out of the frame. 1. PARTS REMOVAL In order to gain access to the air-box, it is necessary to remove certain parts of the motorcycle to gain access to the air-box area of the frame. Removing the following parts should be the first steps you take. A. Seats – Remove both seats starting with the passenger pillion, if applicable. B. Side cover and grommets – Remove the plastic side cover on the right side (throttle side) of your motorcycle. This is the faux oil-tank cover that has the name of your bike on it. Underneath the side cover there are three rubber grommets (1 on the frame tab, and two on the air-box) that support the side cover. Remove the two that are on the air-box and leave the one on the frame. You will attach the two that you removed to the right side bracket in Section 4C . C. Faux air filter covers – On the right side of the bike, remove the chrome faux air filter covers, by removing the one allen head screw that holds it onto the air-box. On the left hand side (clutch side) remove the faux air filter cover in the same manner, you removed the one on the right. D. Plastic shrouds – on the left side, remove the black plastic air-box shroud, by removing the two allen head screws holding it in place. Then remove the plastic shroud covering your fuse box (this is the piece that surrounds your ignition terminal next to the battery). E. Battery – Remove the battery by unscrewing the torx-head bolt that holds the chrome bracket in place. Remove the chrome bracket and the black plastic cap. Tilt the battery out of the box with the top towards you. Disconnect both battery terminal connectors, negative (-) terminal first. Remove the battery. F. Battery box – Remove the two bolts that hold the battery box to the frame. Pull the battery box out as far as you can, then remove the the ignition terminal from the battery box, by removing the two allen screws that hold it in place from the back. Next, remove the fuse box from the battery box, by pushing it out from the back. It is not necessary to disconnect any of the wiring going to the fuse box, or the ignition terminal. G. Rear fender – Remove the rear fender, by first disconnecting the taillight wires. Follow the wires from the tail light assembly on the inside of the rear fender (left side) towards the front of the bike until you come to the box connector. Disconnect the tail light wires at this connector, being careful not to break it. Once the wiring is disconnected, remove the 6 bolts that hold it to the struts. Have someone hold the fender for you while you are removing all of the bolts so that it does not drop once the bolts are removed. Slide the fender out the rear of the bike. 2. PREPARE THE MOTORCYCLE FOR AIR-BOX REMOVAL To remove the factory air-box without damaging it, it is necessary to lift the bike. We recommend the use of a multi-position ATV/motorcycle jack with a minimum lift height of 10″. A. Setting up the lift – Place the lift under your bike and secure your bike to the lift according to the lift manufacturer’s instructions. B. Raise slightly – Lift the motorcycle to the point where the rear springs are without tension, but NOT to where the rear tire is off the ground. C. Remove the rear springs – Take off each of the rear springs by removing the the two bolts on each spring. Once all the bolts are removed gently pull the springs out off of the studs. If they do not pull off easily, you can raise or lower the bike slightly with the lift to ease tension on the spring. Remember, you should not have the rear tire off the ground at this point. The bike should only be raised enough to relax the tension in the springs. D. Remove the mufflers – Remove the mufflers by loosening the clamp at the exhaust header, and by removing the rear foot peg hangers. If the mufflers are not removed, they can become damaged by the axles in Section 2H . E. Disconnect the carburetors – With a small flathead screwdriver, pull the retainer springs out of the channel of the carburetor intake tubes (the two large black tubes coming from the air box into the back of each carburetor), and simply push them towards the air box off of the carbs

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LED Motorcycle Power Box Installation Instructions

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Filed Under (Tips and Review) by admin on 29-01-2011

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This box requires the presence of a mounting plate secured to the motorcycle’s luggage rack. If the bike in question is not equipped with a mounting plate, one must be fabricated prior to installation of this box. Five mounting holes (.281″ dia.) are required to mount this box. If the motorcycle is already equipped with a mounting plate, it may be necessary to drill the 5 mounting holes required for this installation. Use the diagram shown to determine the precise location of these holes. 1. Position the box onto the mounting plate. Align the 5 vibration dampeners with the 5 mounting holes in the mounting plate. 2. Using the illustrations shown, secure the box to the mounting plate using the provided hardware. Note: Your luggage rack may already have the correct mounting holes drilled. Check the measurements below and if these holes already exist at the proper distance, remove any existing mounting hardware from the holes and secure the box with the supplied mounting hardware. 3. Place the box into its mounting position on the deck and secure it with the supplied mounting hardware as shown in the diagram. Wiring: Diagrams for optional equipment are found below. Refer to the diagram on the following page for general motorcycle box wiring information

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HARLEY DAVIDSON ROAD TECH XM SATELLITE RADIO RECEIVER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) -J03989 1 of 8
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. Refer to Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Receiver Mounting Bracket Installation When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. ALL models: See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 3. Using a T-27 TORX drive head, remove the two screws that retain the clutch-lever clamp to the handlebar. 4. See Figure 4. Obtain the correct mounting bracket (2) for your vehicle, and two button-head screws (3) and spacers (4) from the kit. Insert the button-head screws into the mounting bracket, through the holes above and below the slot. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the clutch lever clamp removed earlier. 5. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) . Receiver and Antenna Bracket Installation 6. Obtain the satellite radio receiver (1), antenna bracket (6), and four lock nuts (8) from the kit. Insert the four studs on the back of the receiver through the four holes in the receiver mounting bracket. 7. See Figure 4 for mounted position of the antenna bracket to the receiver mounting bracket. Assemble a lock nut to each of the bottom two studs. Install the antenna bracket onto the top two studs, and assemble a lock nut to each top stud. Tighten the locknuts securely. Antenna Installation 8. Obtain the XM radio antenna (5) and two-sided adhesive tape (7) from the kit. 9. Use isopropyl alcohol to clean the horizontal antenna mounting surface of the antenna bracket, and the bottom (mounting) surface of the antenna. 10. Peel the liner from one side of the tape, and apply the tape squarely to the bottom surface of the antenna. 11. Peel the liner from the exposed side of the adhesive tape on the antenna base. 12. Position the antenna over the bracket without touching the adhesive to the bracket. Center the antenna over the bracket with the antenna cable toward the center of the vehicle. 13. Press the antenna squarely and firmly onto the bracket, and hold pressure for about 60 seconds. After releasing pressure, avoid direct contact with the antenna for about 20 minutes. HARNESS ROUTING AND CONNECTION

HARLEY DAVIDSON LEFT SIDE TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION NOTE While handling and installing tool box, be careful not to scratch surface. 1. See Figure 1. Attach the toolbox (4) to the toolbox mounting bracket (1) using the three pan head screws (2) and Nylock nuts (3) from the kit. 2. Remove the two button head screws (I) which secure left rear fender support (B) to motorcycle frame (C). Retain screws for reassembly. 3. On models with passenger footpegs: a. For FLSTN models: Remove button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E). b. For all other models: Remove the locknut (G), hex head bolt (J), spring washer (H) and footpeg (E). Remove the socket head cap screw (K) that secures the footrest support (F) to the frame (C). c. Remove the two bolts, nuts and washers which secure the bottom of the splash guard to the swingarm. This will allow you to move splash guard when installing the new passenger footrest bolt. d. Retain all removed components. 4. On models with passenger footboards: a. Remove the screw securing the passenger footboard assembly to the frame. Remove the footboard assembly. b. Retain all removed components. 5. Slide the top of mounting bracket (1) between rear fender support (B) and frame (C). Align top holes in bracket with fender support holes. Align lower bracket hole with footrest mounting hole in frame. Install the two screws (I), removed in Step 2, in fender support. Do not tighten screws at this time. Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) 6. On models with passenger footpegs: a. For FLSTN models: Install button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E) on top of the toolbox bracket (1). Tighten screw to 35-45 ft-lbs (47.5-61.0 Nm). b. For all other models: Refer to instructions in footpeg extension kit, Part Number 49352-00 for installation, and install the extention kit, footrest support and footpeg on top of the toolbox bracket (1). c. Install the two bolts, nuts and washers and secure the bottom of the splash guard to the swingarm. 7. On models with passenger footboards: a. Position footboard assembly, in the same orientation as removed, on top of tool box bracket. b. Install screw removed in Step 4. Tighten to 35-45 ft- lbs (47.5-61.0 Nm)

HARLEY DAVIDSON XL SPRING SEAT MOUNTING KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to service manual and remove the existing seat, seat post, washer and screw. Do not remove grommet or T-spacer from rear fender. Save the washer and screw for later installation. 2. See Figure 1. Clean the frame surface where the hook- and-loop strip will be attached with a 1:1 mixture of isopropyl alcohol and water. Let it dry completely. 3. Install the frame cover to the frame as follows: a. Remove the loop side of the hook-and-loop (3) from the bottom of the frame cover (1). b. Remove the protective tape from the hook-and-loop strip and attach it to the frame as shown. Wrap it under the frame or trim excess length, if necessary. c. Orient the frame cover so that it covers the seat pan and secure the cover to the frame with the hook-and- loop strips. 4. See Figure 3. Install two springs (2) to the mounting bracket (1), oriented as shown, with screws (3). Tighten screws to 25-30 ft-lbs (34-41 Nm) . 5. See Figure 3. Install mounting bracket to frame tab a. Install mounting bracket (1) over frame tab. Orient it so that the two retaining tabs on the mounting bracket will hold down and be fully seated on the frame cover. b. Secure mounting bracket with screw (B), washer (C) and nut (4). Do not tighten. c. Center the frame cover and mounting bracket to the motorcycle frame. d. Tighten mounting bracket screw and nut to 15-20 ft- lbs (20-27 Nm) . 6. Install seat pivot bracket (15), washers (14) and screws (13) to the seat. Tighten screws to 48-72 in-lbs (5.5-8.0 Nm) . 7. Remove the rear fuel tank mounting screw, washers, nut and thread protector. Save washers for later installation

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