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TRIUMPH ROCKET III HEEL / TOE SHIFTER INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Loosen the 10mm nuts at the ends of the shifter linkage rod (notice one end is a left hand thread). Remove the 10mm nut from the shifter arm & disengage the linkage. Remove the shifter pivot bolt using a 8mm hex key wrench. Remove the washer on the threaded side of the shifter pivot bolt. 2. Place one of the wave washers supplied onto the pivot bolt. Place a small amount of grease on the shifter pivot bolt shank and the Heel / Toe shifter pivot hole, insert the pivot bolt into the pivot hole of the toe heel shifter. Use a drop of blue loctite on the shifter pivot bolt threads and install the Heel / Toe shifter, tighten the pivot bolt securely. Check to see that the shifter pivots freely. If the side play is excessive (this is a result of variances in manufacturing tolerances of the stock and supplied components) remove the pivot bolt and install the second wave washer supplied. 3. Unscrew the linkage rod and replace it with the longer rod supplied (NOTE the rod has a left hand thread on one end and right hand threads on the other). Insert the shifter linkage stud into the desired hole in the new shifter being sure the flats on the stud engage the slot on the backside of the bolthole. Install the nut and finger-tighten only at this time. 4. While seated on the motorcycle first find the height setting you prefer for the toe shifter. Using one of the three boltholes for the linkage can set this. You can also gain some adjustment by exposing more or less threads of the new longer shifter linkage rod; however be sue that you have a minimum of 4-5 threads still engaged in the linkage ends. After setting the height, tighten all three 10mm nuts (the two at the ends of the linkage rod and the one which attaches the linkage to the toe/heel shifter) securely. After you have the toe shifter adjusted to your liking you can select the heel shifter height by moving the button head cap screw that secures the toe shifter to the heel shifter (Using a 5/32″ hex key wrench) next to the 10mm linkage nut to any of its three holes

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HARLEY DAVIDSON ALUMINUM SHIFTER LINKAGE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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REMOVAL 1. See Figure 1. Remove stock shifter rod (D). 2. Adjust new shifter rod in kit to match the length of the removed shifter rod by loosening locknuts (3), adjusting the length of the rod, then tightening locknuts to 20-24 ft- lbs (27-32 Nm) . 3. For models with a straight rear shifter rod lever: Discard spacer (7). Place cover (1) over the shifter rod lever (C). For models with an offset rear shifter rod lever: Place spacer (7) and cover (1) over the shifter rod lever (C). INSTALLATION 1. Apply Loctite® 243 to threads of capscrew (5) and install cap screw through the rear of the shifter rod and into the shifter rod lever. Tighten cap screw to 13-16 ft-lbs (18-22 Nm) . 2. For 1999 and later FLHT, FLHX, FLHR, and FXDWG models: Place the rod end on the outside of the shifter lever, then apply Loctite® 243 to the threads of capscrew (5). Attach the front of the shifter rod (6) to the shifter lever with capscrew (5) and acorn nut (4) (with acorn nut facing out). Tighten acorn nut (4) to 13-16 ft-lbs (18-22 Nm) . For all models except 1999 and later FLHT, FLHX, FLHR, and FXDWG: Place the rod end on the inside of the shifter lever then apply Loctite® 243 to the threads of cap screw (5). Attach the front of the shifter rod (6) to the shifter lever with cap screw and acorn nut (4). Tighten acorn nut (4) to 13-16 ft-lbs (18-22 Nm)

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HARLEY DAVIDSON DYNA FLOORBOARD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-03-2011

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Installation SHIFTER ASSEMBLY (LEFT SIDE) 1. Remove highway footrest assembly, if equipped. Discard bracket, plate and mounting hardware. 2. Remove stock footrest assembly. 3. Remove stock (chrome) shift lever. Retain shift lever, peg, bolt and washer. 1 WARNING ® 1 of 5 Kit Number 50601-01 -J01921 2 of 5 Figure 1. Shifter Assembly (Left Side) Item Description Part No. 1 Bolt, 5/16-18 x 5/8 hex HD 2882W 2 Hex cap screw, 5/16-18 x 2.00 (2) 3023 4 Set screw, shaft cover 3231B 6 Assembly,shift lever 33704-01A 7 Assembly,adjustable shifter rod 33719-79B 8 Lever, shifter, machining, polish 33706-01 9 Assembly, shifter plate, polish 33700-01 10 Cover, shifter lever, rubber (2) 34619-85 11 Retainer,shift lever for 1996 to 2000 models 34639-93 Item Description Part No. 11ARetainer bracket, shift lever for 2001 and later models 34639-01 12 Cover, shifter shaft 34640-93 13 Washer, wave, overlap type (2) 34641-01 17 Socket head cap screw 4740A 25 Washer, 5/16″ (2) 6016 28 Washer. 5/16″ 6702 30 Nut, hex, locking, 5/16-18 7710W 32 Acorn nut, 5/16-24 7736 33 Hex jam nut, 5/16-24 7744 30 11 1 12 7 32 28 6 13 9 25 2 17 25 2 10 8 i03110.eps 33 4 11A ’96-2000 models 2001 and later models 4. See Figure 1. 1996 to 2000 models. Bolt shifter lever shaft retainer bracket (11) to the stock shifter lever with bolt (1) and nut (30). Do not tighten bolt at this time. 2001 and later models. Bolt shifter lever shaft retainer bracket (11A) to the stock shifter lever with bolt (1) and nut (30). Do not tighten bolt at this time. 5. Loosen the left rear crankcase bolt (at bottom of cylinder) and slide the slotted end of shifter lever shaft retainer bracket (11) onto the bolt, but beneath the washer. Tighten crankcase stud to 15-17 ft-lbs (20-23 Nm). 6. Place chrome cover (12) on shifter lever shaft (at primary case) and secure with set screw (5). NOTE Small wave washer (13) goes between foot shifter and bracket. 7. See Figure 1. Place small wave washer (13) on shifter lever (6) shaft. Coat shaft with Loctite Anti-seize and slide into bracket. 8. Install foot shift bracket (9) using screws (2). Tighten screws to 25-30 ft-lbs (34-41 Nm). 9. Place shifter rod (2) and washers (25) in position. Use short stud on shifter rod to secure shifter rod at the transmission end. Use Loctite 242 (blue) on stud before installing. 10. Install acorn nut (32) and washer (28) at foot shift end. Use Loctite 242 (blue) on acorn nut before installing

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HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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harley- davidson DYNA BLACK FORWARD CONTROL KIT installation Manual

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Filed Under (Harley Davidson) by admin on 15-03-2012

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1. Disconnect battery cable, negative (-) cable first. 2. Remove the left side rider footrest assembly. Save the footrest and fasteners for installation. Discard the remaining hardware. 3. From the kit, press hole plugs (8) into the screw holes on the frame where the stock footrest assembly was mounted. 4. Remove plugs from forward control frame mount (I) and discard. 5. Remove the foot shifter lever (A) and shifter peg (D). Discard the old foot shifter lever (A). Save the foot shifter lever hardware and shifter peg (D) for future use. 6. See Figure 2. Remove the primary chaincase cover (6) and primary chaincase housing (1). Refer to your model motorcycles Service Manual for removal procedures. NOTE See Figure 1. Before removing the gear shifter lever (1) ((H) in Table 1), it is necessary to mark the correct orientation of the lever. Using a marking tool, draw a location marking (4) on the end of the splined shaft (2) across from the casting split (3). This will allow the new gear shifter lever to be installed in the same orientation as the old lever. 5 3 4 1 2 is 02083 1. Gear shifter lever 2. Splined shaft 3. Casting split 4. Location marking 5. Lever bolt Figure 1. Gear Shifter Lever Orientation 7. After marking the gear shifter lever orientation, loosen the lever bolt (5) and remove the old shifter lever. Discard the old gear shifter lever but keep the lever bolt. From the kit, install the new gear shifter lever onto the splined shaft in the same orientation as the old shifter lever. Tighten the lever bolt to 18-22 ft-lbs (24.4-29.8 Nm)

HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION INSRUCTIONS

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

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit

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HARLEY DAVIDSON CHROME TRANSMISSION HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cable, negative (-) cable only. NOTE The starter does not need to be removed to install this kit. 2. Remove exhaust system only if needed to access transmission top cover hardware. Refer to Service Manual for instructions. NOTES Replace existing zinc hardware with chrome-plated hardware one at a time so the transmission top and side covers do not need to be replaced. 3. Remove and discard existing six 1/4-20 x 1 in. hex socket- head screws and washers from top transmission cover. Install six chrome hex socket head screws (1) and washers (2) on top transmission cover (3). Tighten to 84-108 in-lbs (9.5-12.2 Nm). 4. Remove and discard existing two 1/4-20 x 1 in. hex socket head screws and washers from side transmission cover. Install two chrome hex socket head screws (1) and washers (2) on side transmission cover (5). Tighten to 84- 108 in-lbs (9.5-12.2 Nm). 5. Remove and discard existing four 1/4-20 x 1-1/2 in. hex socket head screws and washers from side transmission cover. Install four chrome hex socket head screws (4) and washers (2) on transmission side cover (5). Tighten to 84- 108 in-lbs (9.5-12.2 Nm). 6. Install exhaust system if previously removed. Refer to Service Manual for instructions. 7. Connect negative (-) battery cable

HARLEY DAVIDSON ENGINE/TRANSMISSION INTERFACE AND TOP COVER INSTALLATION MANUAL

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

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 1 4 3 2 is03621 1. Transmission top cover screw (3) 2. Upper and lower rear bearing housing screw (2) 3. Upper front bearing housing screw 4. Lower front bearing housing screw Figure 1. Interface Cover Installation 2. See Figure 1. Remove the two rear bearing housing screws (2) from the side of the transmission case. 3. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 4. See Figure 2. Obtain the rear interface mounting bracket (1) from the kit. 5. Apply a few drops of Loctite 243 (Blue) to the threads of the two bearing housing screws removed in Step 2. Install the rear interface mounting bracket to the bearing housing with the screws, and tighten to 13-18 ft-lbs (17.6-24.4 Nm) . 6. See Figure 1. Remove the upper front bearing housing screw (3) from the side of the transmission case. Loosen the lower front bearing housing screw (4). 7. See Figure 2. Obtain the front interface mounting bracket (2) from the kit. 8. Apply a few drops of Loctite 243 (Blue) to the threads of the upper front bearing housing screw removed in Step 6. Hook the slot in the front interface mounting bracket under the loosened lower screw head. Install the bracket to the bearing housing with the upper screw, and tighten both screws to 13-18 ft-lbs (17.6-24.4 Nm) . 9. See Figure 1. Remove and retain the three socket head cap screws (1) that fasten the right side and left front corner of the transmission cover. 10. Remove and retain the screw fastening the rear brake line P-clamp to the rear fork bracket. 11. See Figure 2. Obtain the right rear interface cover (3), two chrome 1/4-20 screws (6) and two flat washers (7) from the kit. 12. From the rear of the motorcycle, bring the right rear interface cover into position behind the rear exhaust pipe, over the bearing housing. The hole in the top surface of the cover should be positioned over the right rear transmission top cover hole. 13. Loosely fasten the interface cover to the rear interface mounting bracket with the two chrome screws and flat washers. 14. Obtain the chrome top interface cover (4) from the kit. 15. Position the top interface cover over the transmission top cover, overlapping the tab at the top front of the chrome right rear interface cover

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