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Harley Davidson Softail Drive Side Brake System Installation Manual

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Filed Under (Harley Davidson) by admin on 30-03-2012

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Removing The Stock Components Although the PM Drive Side Brake System can be installed with the swing arm bolted to the frame, we recommend removing it for better access as well as repainting. Begin by removing rear wheel,stock brake components and belt guard from swing arm. Photo #1 Using supplied 3/4 x 2″bolt,position Drive Side BrakeAssembly on swing arm. Slide assembly to center position of tab and axle spans. Making sure brake mounting tabs are flush with swing arm,snug 3/4 x 2″ bolt to hold assembly and mark swing arm area to be ground Photo #2 . Remove entire assembly from swing arm and thoroughly grind paint away from marked areas Photo #3 . Photo #4 Re-mount assembly to swing arm and slide to rear-most position of both axle and brake mounting tabs. Confirm that brake tabs are flush with swing arm and parallel to each other. Snug 3/4 x 2″bolt and 5/16″socket head cap screws in tabs to hold assembly during welding process. Warning Center the motorcycle on the lift so that it will not fall while you are working on it. Photo #6 Photo #5 Photo #7 Photo #9 Welding Tabs to Swing Arm Note PM recommends all welding be done by a certified welder. Photo #5 Tack weld rear of tabs to swing arm. Avoid excessive welding near brake as- sembly as heat can mar finish. Loosen socket head cap screws and 3/4″bolt,Slide entire assembly to forward most position and re tighten bolts Photo #6 (movement should require minimal effort if tabs are aligned properly) and tack front of tabs to swing arm. Remove brake assembly from swing arm. Weld tabs to swing arm.Verify alignment of tabs, as they must remain parallel to each other. Repaint swing arm and re-install on bike to factory torque specs. Installing Brake Assembly Remove primary bracket from tower assembly (this allows bracket to be installed without having to line up caliper on disc) by removing the three 5/16″socket head cap screws (commonly called allen bolts). Photo #7 Mount rear tire and bolt pulley to rear wheel. Place disassembled bracket against pulley using smaller of two supplied spacers between bracket and pulley. Slide wheel/brake assembly into swing arm. Place large spacer on right side and slide axle in. Do not tighten axle at this point . Photo #8 Slide caliper/tower assembly over disc and install 5/16″x 1″socket head cap screw in center hole to position assembly Photo #9 . Snug, but do not tighten bolt at this point.

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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

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1987 to Current Harley Davidson Softail (FLST Only) Motorcycle Trike Conversion removal and Installation Guide

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

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Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Seat (to be re-installed without modification). • Left and right saddle bags (if so equipped). • Left and right rear crash bars, saddlebag rails (if so equipped). • Left and right passenger foot rests (to be re-installed without modification) • Complete exhaust system (to be replaced with new system). • Rear wheel NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake caliper is removed • Remove Rear Caliper (disconnect brake line at caliper) NOTE: Cap line to prevent introduction of dust / debris into line. Remove caliper. • Rear Drive Pulley (1987-99 models to be re-installed without modification). • Rear Fender (2000 and newer models, fender mount plates to be reused). • Swing Arm NSTALLING TRIKE CONVERSION KIT 3.1 Sprockets and Drive Belts Specifications See following table for belt installation (1987-99 will use a 4 tooth longer belt) Note : See OEM manual for belt replacement procedure. Year Drive Sprocket OEM Belt New Belt / Sprocket 1987-92 70 T 132 T 136 1993-94 61 T 128 T 132 1995-99 65 T 130 T 136/70TOEM 2000-06 Champion Sprocket, 70 T 135 T Use OEM 2007 Up Champion Sprocket, 66 T Use OEM 3.2 Install Swing Arm É Noting size and location of bolts, remove Cross Assembly from Champion Swing Arm. Do not discard hardware. Figure 1 3.2.1 1987-99 Model Years • Remove bearings from OEM Swing Arm using OEM shop tools and hydraulic press. Note : Although original bearings can be re-used, it is HIGHLY recommended that NEW bearings be installed to Champion Swing Arm a. b. Press bearings into Champion Swing Arm in the same way as the OEM Swing Arm. Using OEM Spacer Tube and supplied washers (four ¾” flat washers), install Champion Swing Arm using OEM bolt, outside washers and nut. Do not torque pivot bolt nut at this time. Figure 2 Note : Insure belt path is over and under Swing Arm pivot. c. d. Replace cross assembly and hardware (previously removed in step 3.2) to Champion Swing Arm. Note that the 2 upper left hand side bolts are countersunk. Torque pivot bolt to OEM specification

TRIUMPH ROCKET III SWING ARM COVER INSTALLION INSTRUCTIONS

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

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1. Locate and remove the 6mm screw which secures the rear brake hose clip to the top of the swing arm (just in front of the lower right shock absorbers mounting point. 2. Notice the double faced adhesive tape on the inside of the cover and where it will contact the swing arm when installed, clean this area with rubbing alcohol and remove the backing from the adhesive tape on the inside of the cover. 3. Place the º” washer provided on the top of the swing arm over the brake hose clip mounting hole. Starting at the rear of the swing arm slide the cover carefully into place and align the small hole in the top of the cover with the washer and the threaded hole. Place the screw thru the hose clip then the cover and finally the washer, next thread the screw into the hole finger tight only. 4. Press the front area of the cover with the adhesive tape firmly into place. Tighten the 6mm brake hose clip screw securely.

TRIUMPH ROCKET III SWING ARM COVER INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-12-2010

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1. Locate and remove the 6mm screw which secures the rear brake hose clip to the top of the swing arm (just in front of the lower right shock absorbers mounting point. 2. Notice the double faced adhesive tape on the inside of the cover and where it will contact the swing arm when installed, clean this area with rubbing alcohol and remove the backing from the adhesive tape on the inside of the cover. 3. Place the ¼” washer provided on the top of the swing arm over the brake hose clip mounting hole. Starting at the rear of the swing arm slide the cover carefully into place and align the small hole in the top of the cover with the washer and the threaded hole. Place the screw thru the hose clip then the cover and finally the washer, next thread the screw into the hole finger tight only. 4. Press the front area of the cover with the adhesive tape firmly into place. Tighten the 6mm brake hose clip screw securely.

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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INSTRUCTIONS ON HOW TO R & R YOUR Swingarm

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Filed Under (Tips and Review) by admin on 12-12-2010

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• Upgrade Your Pre- 2002 FL Or FXR Rear Fork & Get Rid Of The Crappy & Dangerous (Cleve Blocks) & Replace Them With A Stable System. • R & R your Swing Arm, Belt Drive, Swing Arm Pivot Shaft, and Rear Wheel. The paragraphs below are a photo journey into the replacement of a FL or FXR swing arm. To upgrade the pre 2002 FL, here is a How-To on cheaply replacing the poor parts Harley stuck you with. Now – Let’s Get Er’ Done • Pre- 2002 had weak swing arms and are known to fail. The cleve blocks are the cause of “Rear Steer” or “Rear Fork Deflection”. Harley came up with a patch in 2002, using bearings. Because the pre 2002 transmissions have a 5/8″ mounting hole for the 5/8″ swing arm pivot shaft, a conversion unit has been made. No transmission removal for boring is necessary. Under no circumstances, do I recommend drilling out the transmission case with a hand drill. The drill will “wander” (drift)! • Solution: Go to either a trike shop/manufacturer, e-Bay, or shop and buy a new style swingarm. Harley made an additional upgrade in 2007, try and buy this type 2007 & above). If upgrading to a 2008, Harley use 25mm (smaller than 1″) axles & wheel bearings, you will have to use 25mm bearings. With that said, let’s get on with it. • In the case of a 2007 swingarm; buy and do not pay over $40 for the swing arm and axle. You must use the corresponding axle as a ¾” axle set-up is different (along with wheel bearings & spacers). You positively can not use a pre -2002 HD stock wheel because the wheel bearing spacer will fit into the wheel. Buy 2002 & above style wheels as they (9 spoke) are cheep. • You are going to have to either bore out your stock rear caliper bracket or better still, upgrade your whole rear brake to the new model & sell yours on e-Bay. • I recommend doing the following before hand and have it ready for installation; Remove bearings et al. from the 2002 & later swing arm via press. Bike Work: • Jack up your bike using a center jack. Secure the bike so it will not fall over. You can also use a motorcycle jack. I use a motorcycle dolly

HARLEY DAVIDSON FLHT (Electra Glide Standard) FAIRING COMPARTMENT POUCH INSTALLATION MANUAL

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

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General This kit is designed for 1996 and later FLHT, Electra Glide Standard, model motorcycles Kit contents: QTY DESCRIPTION 1 Pouch 4 Velcro™strip Installation 1. Wash inside of fairing compartment with a clean, soft, nonabrasive cloth, water and mild soap. 1 CAUTION DO NOT use benzine, paint thinner, gasoline, powdered abrasives, alkaline cleansers, or any other harsh cleansers to clean the fairing compartment. They will damage the surface. Never scrape fairing surfaces with a razor blade or other sharp instrument because permanent damage will result. 2. Arrange pouch in compartment. 3. Align and attach velcro strips from kit to top, bottom and sides of compartment so they match the placement of velcro strips on pouch. 4. To secure pouch to fairing compartment, press pouch velcro strips against compartment velcro strips. Care of Pouch 1. When necessary, remove and wash pouch with mild soap and warm water

HONDA VTX 1800 AND VTX1300 SWING ARM COVER INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-12-2010

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1. Remove the two (2) 6mm bolts holding the brake hose clips in place. 2. Slide the cover in from the rear over the swing arm and align the holes. (NOTE: on Retro models and some aftermarket exhausts it is necessary to remove the two (2) muffler mounting bolts and loosen the two (2) exhaust nuts on the rear cylinder head then pull the exhaust outward to gain clearance to slide the cover into position). 3. Replace the original front bolt or bolts into the cover and hose clip. NOTE: the hose clip should go behind the chrome cover and it may be necessary to straighten out the bend in the clip slightly to gain alignment of the holes. Replace the rear bolt with the one supplied and tighten both securely. 4. Replace and tighten the exhaust bolts if removed earlier

Yamaha Road Star Trike Conversion Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. c. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for re-installation after modification are noted. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model Installation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster

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