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HARLEY DAVIDSON 80-SPOKE REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Additional Parts Required This kit includes the custom wheel only. Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley-Davidson dealer: •Wheel Bearing Remover and Installer (HD-44060) •Wheel Installation Kit (See Service Parts Tables for part number) The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning: •Harley® Bright™ Chrome Cleaner (94683-99) •Harley® Glaze™ Polish and Sealant (99701-84) •Harley®Wheel and Spoke Brush (43078-99) •Harley-Davidson®Wheel and Tire Cleaner (94658-98) 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. Kit Contents See the Service Parts section for kit contents. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. NOTE Remove the rear brake caliper before removing the wheel. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. Install the tube and tire on wheel. Refer to REAR WHEEL in the Service manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. 4. Install rear wheel (1), stock axle and stock axle nut. Refer to REAR WHEEL in Service Manual

Steering Stem Nut Installation Instructions & Owners Manual

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Filed Under (Tips and Review) by admin on 26-11-2010

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Sport Bike Damper Kit Installation Instructions DISCLAIMER: All GPR Sport Bike damper kits are manufactured to be used ONLY w/ the stock top triple clamp and frame. If either is modded, aftermarket or crash damaged, the kit will not install properly and GPR will not be held responsible for the consequences of improper installation due to this or any other improper mounting or modifying. The provided instructions must be followed precisely, as failure to do so can result in the GPR damper kit being installed incorrectly. An improper installation may lead to a variety of undesirable steering problems. Please take your time and carefully follow the installation instructions. As always, give us a call if you have any questions, we’re more than happy to assist you in getting the damper kit mounted on your bike properly 1. Remove the stock Steering Stem Nut (SSN) and washer from the stock top triple clamp steering stem. Carefully set the stock nut aside, as you may be using it later. Bikes requiring a specific GPR SSN to replace the stock SSN are listed at the end of this installation sheet. If your bike is on the chart, throw you stock SSN in the toolbox along w/ the washer, as you may need it at a later date if for any reason you need to remove the GPR kit from your bike. Stock SSN’s that are either ‘domed’ at the top or ‘flanged’ at the bottom will definitely NOT work, may lead to problems and should NOT be reinstalled during the baseplate installation. See #2 below for further instructions about both SSN/Steering stem and arm clearance issues 2. With the stock SSN and washer removed, place the GPR Baseplate over the steering stem on the top triple clamp and reinstall either the stock SSN or the GPR SSN provided. Torque SSN down to the recommended specs as per the owner’s manual for your particular bikes make and model. NEVER reinstall the stock washer that came on the bike! The baseplate is now your new washer. If you do accidentally use the stock washer, the arm on the stabilizer will most likely ‘rub’ on the nut. It will be too high, potentially locking the steering and handlebars, thus making your bike un steerable and unridable. DO NOT ride your bike until all installation steps have been completed and you can visually verify that there is clearance between the arm of the stabilizer and the steering stem and/or SSN. Once the installation is complete, at the #1 setting you

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HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required 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. Kit Contents See Figure 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

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

HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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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. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 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. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

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Harley-Davidson MOBILE RADIO & CONTROL UNIT Installation Manual

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Filed Under (Harley Davidson) by admin on 22-03-2012

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Installation of the ORION mobile radio and control unit consists of: •Assembling and installing the weather resistant motorcycle case assembly, including the adapter bracket, case/antenna mounting bracket, and bottom case (previously assembled) to the motorcycle mounting bracket (user supplied). •Installing the radio in the radio mounting bracket located inside the weather-resistant case, •Installing the control unit, microphone, and speaker •Installing the antenna •Routing the power, control, and option cables •Connecting all cables including: power, control, and option cables. •Installing the Headset Option •Operational check All mounting hardware consists of stainless steel screws, locknuts, nuts, and lockwashers to resist corrosion. TOOLS REQUIRED •Socket wrench set U.S./metric with 3″ extender •Open end wrench, adjustable •Wire clippers •TORX BIT set, small metric 13
EQUIPMENT INSTALLATION Assembling & Installing The Weather Resistant Case As- sembly The motorcycle Weather Resistant Case Assembly may be installed on almost any motorcycle. Installation instructions provided here include information for the Harley-Davidson Dyna and Road King models and the Kawasaki K1000. Figure 5 illustrates installation on Harley-Davidson motorcycles while Figure 6 illustrates installation on a Kawasaki K1000. Refer to these diagrams during installation. Installation on other motorcycles is at the discretion of the installer. Harley-Davidson Installation 1. Unpack the weather resistant motorcycle case, remove the key taped to the top cover and open the case. 2. Refer to Figure 5 and verify that all components shown in the diagram are available. 3. Mount the adapter bracket onto the Dyna or Road King radio mounting bracket (user supplied) using the 1/4-20 x 5/8 screws provided

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HARLEY DAVIDSON CUSTOM FOOTPEG KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 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 A Service manual for your motorcycle is available at your Harley-Davidson Dealer. 1. See Figure 1. The footpeg shown in Figure 1 is different from the footpeg in the kit, however the installation is identical. Remove the locknuts and screws that hold the existing footpegs in place. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. NOTE When performing Step 3, make sure the spring washer is position inside the footpeg support with the square edge toward the inside of the support as shown in Figure 2. 3. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer, along with the mount end of the footpeg, inside the slots of the footpeg supports. 4. Secure each footpeg and spring washer with the screw and locknut removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm) . 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) 5. For each footpeg, loosen the adjusting screw in the recessed hole until the footpeg rotates. Position the footpeg as desired, then tighten the adjusting screw to 21 ft-lbs (29 Nm)

BMW R1200GS Exhaust System Installation instructions

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Filed Under (BMW) by admin on 26-10-2010

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The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury or any other damages caused by improper installation or operation of the Akrapovič exhaust system. When installing the Akrapovič exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature. 2. Akrapovič makes no representation or warranties with regard to damage caused by the improper installation, use and maintenance of the Akrapovič exhaust system. The warranty is limited to defects recognized by our technical department and due to normal use, and excludes items subject to normal wear (gaskets and damping wool). The guarantee is void in case of accident, modification, improper or competition use. 3. Do not attempt to install the Akrapovič exhaust system on a vehicle model for which it was not made or tested by Akrapovič. 4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust system or parts which are in direct contact with it, even when the engine is not running. Also protect other people, especially children, from the injuries mentioned above. 5. In some cases Akrapovič exhaust system kits contain chemical products (ceramic anti-seizing grease; bolt sealant). Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous membranes. Keep out of reach of children. 6. Technical specifications of Akrapovič exhaust systems and related products are subject to change without notice. 7. Before removing the original exhaust system from your vehicle, please compare the parts you received with the list of materials provided in the installation manual in order to assure that you have all the parts necessary for the installation of your new Akrapovič exhaust system. 8. Although this manual consists of instructions for installation in written form, as well as photographs and pictures representing individual steps of the installation, please note that the photographs and pictures are symbolic and are intended for representation of general overview only. The photographs and pictures contained herein should serve as a guideline only and actual installation of the exhaust system may not correspond with the photographs and pictures entirely.

Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

HARLEY DAVIDSON CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT GENERAL Kit Number 56032-08 Models For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only). This kit does not fit models equipped with a hydraulic clutch, handlebar mounted gauges or the Road Tech® Radio. Additional Parts or Accessories Required Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on this model motorcycle. Please see the P&A retail catalog or the Parts and Accessories section of for a list of required parts or accessories for this model. For Australia, Brazil, England, Europe and Japan, two special screws (Part Number 2935A) will also be required. Tools and Supplies Required Loctite® 271 Threadlocker and Sealant – Red (H-D Part Number 99671-97) is required for the proper installation of this kit. Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed. Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) For models that retain the original brake line, the two brake- line gaskets found at each banjo fitting must be replaced . Refer to the appropriate parts catalog or see a Harley-Davidson dealer for the correct part numbers. Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the parts catalog for replacement stock hand grips. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available. 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 this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 6 and Table 1. INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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 the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills)

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