2009 harley electraglide classic problems

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HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

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Harley-Davidson FL Models (1993-2009) HARLEY PASSENGER FLOORBOARD COMFORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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1. Using your 5/16″ allen wrench, unscrew the Cap head allen bolts attaching the stock passenger floorboard mount to the frame and remove the assembly. You will reinstall this assembly once the mounts have been installed. STOCK MOUNT FEATURES: Notice the floorboard mount has a locating pin that protrudes from the rear surface. This pin is what keeps the mount from swiveling on the frame. The frame has three threaded holes and one unthreaded hole on each side. These holes provide the three different floorboard heights the bike offers stock. HEIGHT POSITIONS: The Comfort Kit mounts provide you the ability to raise the stock floorboards height 1-1/4″ or 2″ higher than the highest stock position. This is accomplished by attaching the mounts to the specific combinations of the threaded holes on the frame. POSITION #1 – Raises the floorboards 2″ by attaching the mounts to the #1 & #2 threaded holes from the top. NOTE: You must use the rectangular spacer block in order to use the 2″ rise position in order to clear the right exhaust pipe. POSITION #2 – Raises the height 1-1/4″ by attaching the mounts to the #2 & #3 thread holes from the top. TILTING: You will notice one threaded and one unthreaded hole towards the top of each mount and directly between these holes is an engraved L & R. These mounts are Left and Right side specific. The locating pin mentioned in the stock mount features paragraph inserts into the unthreaded hole and locks the floorboard into its tilted position.

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 BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings 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. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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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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2009 Harley-Davidson FLH Series Independent Suspension Trike Conversion Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Important Safety Precautions a. Make sure you have a clear understanding of all basic shop safety practices and that you wear appropriate clothing and use safety equipment. Be especially careful of the following: · Read all directions before you begin, and make sure you have the tools, the parts and the skills required to perform the tasks safely and completely.Harley-Davidson® FLH 2009 & Up Independent Suspension CHAMPION TRIKES Installation Guide Page 5 of 18 Revision 8 · Protect your eyes by using proper safety glasses, goggles or face shields anytime you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. · Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. · Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported. b. Make sure the engine is turned off and battery disconnected before you begin work. · Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine. · Burns from hot parts: Let the engine and exhaust system cool before working on those areas. · Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts. c. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries. d. Use only nonflammable solvent, not gasoline, to clean parts. e. Never drain or store gasoline in an open container. f. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts. 1.6 Specifications Overall Length: 103″ Overall Width: 57.25″ Wheel Base: 53″ Max Load Capacity: 600 Lb Max Tire Size (15″): 205 / 70 / R15 Wheel Size (15″) (4 lug) Offset +35 mm 15x7JJ 4 on 4.5 Tire Pressure: 24-26 PSI Suspension: Double A-arm Independent Rear Differential: Custom-built rear differential utilizing OEM drive belt. Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 5.75 cubic feet. Two full-face helmets and additional storage. *Champion does not change certain components that will affect EPA, CARB, or any laws that will change the emission characteristics of the motorcycle.

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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Harley Davidson Touring Bikes 2009 Installation Manual

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Filed Under (Harley Davidson) by admin on 10-04-2012

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LegUp has developed a new, stronger attachment system which replaces the Harley-Davidson® center stand previously included in the kit! You will need to remove most all of the exhaust system, in order to install the support stand. Remove the right front floorboard the entire right exhaust pipe, and the left rear floorboard. These need to be removed to allow access to the swing arm pillow block lower bolts, which attach the support stand to the motorcycle. Leg Support Stand If you haven’t already done so, install the uprights (Blue above) to the plate. These uprights bolt to the plate on the bottom with (4) 3/8″ bolts and lock washers. The taller upright goes on the right side of the plate (the far side in this picture). Remove the bottom bolts from the swing arm pillow blocks and set them aside. The right one may have a cap rather than a bolt. These bolts are the ones under the big chrome circles where the swing arm meets the frame. Once this is done, use a helper and gently slide the plate (red above) under the bike. It gets located under the transmission, and below the cross-brace that has two large holes in it. Lift the stand until the holes in the uprights align with the holes in the pillow block. Re-install the pillow block bolts, but leave them loose. Find the 3/8″ Strap (green above) and the (2) 5/16″ bolts and lock washers. Place the strap above the cross-brace that is under the transmission, and align one of the bolts (the bolts go through the non-threaded holes in the plate) with the threaded hole in the strap, through the cross-brace. Just start the first bolt, and then repeat the process on the other side

HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. 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. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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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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