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HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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Victory V92SC Sport Cruiser COMFORT SPORT HANDLEBAR REMOVAL AND INSTALLATION

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Filed Under (Victory) by admin on 13-11-2010

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1. Remove wiring harness dart clips. 2. Disconnect clutch switch connector. 3. Remove 2screwsforclutch lever bracket clamp, remove clutch lever bracket from handlebar. 4. Remove screws for left handlebar switch assembly. Disconnect fast idle cable from lever. Remove switch assembly. 5. Grasp left grip end firmly. While twisting grip end back&forth, pull grip end off and discard. 6. Remove left grip by insertingathin screwdriver between the grip and handlebar end. Spray as mall amount of water/soap solution into the area between the grip and handlebar end. Aggressively twist the grip back-and-forth while simultaneously pulling the grip off. 1. Locate accessory handlebar. 2. Clean inside of throttle grip assembly and throttle cable flange grooves. Ill. 1. 3. Clean throttle grip area. Ill. 1. 4. Slide throttle assembly onto right handlebar end (cableshavenot been removed and should still be attached to the throttle tube). 5. Position the handlebar over the top of the triple clamp and reinstall using bolts removed instep 10. of handlebar removal. Torque to 30 ft. lbs. 6. Install right handlebar switch housing onto handlebar. NOTE: Make sure that locating pin of switch assembly aligns with hole in handlebars. 7. Install right handlebar switch housing screws, make sure locating pin properly aligns with hole in handlebar. Tighten screws to specified torque. 8. Install master cylinder and clamp, install screws. 9. Torque screws to specification. 10. Connect front brake switch wiring harness. 11. Install fast idle cable onto fast idle lever. 12. Clean inside of left grip and handlebar grip surfaces

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HARLEY DAVIDSON CHROME HANDLEBAR CLAMP BOLT KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION Improperly aligned handlebars can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372a) NOTES Check that the handlebar is centered on the risers. To make sure that the handlebar is centered, verify that the knurled areas on the outboard side of each riser are equal. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact with the fuel tank occurs or the handlebars are not properly centered, see Figure 1. Slightly loosen the four upper clamp screws, and center the handlebar or raise the handlebar angle as necessary until proper clearance is obtained, then temporarily snug the screws, but do not fully tighten. 4 1 2 3 4 is00868 1. Upper clamp 2. Screw (4) 3. Handlebar 4. Handlebar risers (2) Figure 1. Handlebar Clamp Hardware 1. Remove and discard screws (2) that fasten upper clamps (1) to handlebar risers (4). Save washers under screw head for later use. 2. For Kit 94453-04: Select new chrome screws from the kit that match the length of the screws removed. For all other Kits: Select new chrome screws from the kit. 3. Slide washers previously removed onto screws, and thread screws through the upper clamps into risers. -J03586 1 of 2 4. If handlebar adjustments were made, snug screws but do not fully tighten. a. The bottom surfaces of upper clamps are offset, creating a gap between the clamp and riser on one side. b. Tighten clamps so the gaps appear to the rear of the handlebar, then tighten screw to 12-15 ft-lbs (16.3- 20.3 Nm). 5. If handlebar adjustments were not made, tighten screws to 12-15 ft-lbs (16.3-20.3 Nm). SERVICE PARTS

HARLEY DAVIDSON SLOTTED HANDLEBAR RISER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Cover the fuel tank with a clean shop towel to prevent scratching. Damage to the finish could result. 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for re-assembly. Retain all additional hardware components that become dislodged from the riser when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers, and carefully allow the handlebar to rest on the fuel tank. 3. Obtain the new slotted risers (1) and hex head cap screws (2) from the kit, and the split lockwashers and hardware components removed in Step 1. NOTE The upper cup washer (A) must be oriented with the flat side up , and the lower cup washer (D) with the flat side down . The ground wire (G) and internal tooth lockwasher (H) are mounted to the right-side riser. 4. Refer to Figure 1 for the correct orientation and reassembly sequence. Install the new risers onto the upper fork bracket using the saved hardware and new screws. Snug the riser screws, but do not fully tighten at this time. 5. Center the handlebar on the risers. To make sure that the handlebar is centered, verify that the knurled areas on the outboard side of each riser are equal. 6. Position the new handlebar upper clamps (3) from the kit, and install with new hex socket head screws (4). Snug the upper screws, but do not fully tighten. Improperly aligned handlebars can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372a) 7. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is attained. 8. Tighten the upper handlebar-clamp screws as follows: a. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . b. Tighten the rear screws to 12-15 ft-lbs (16-20 Nm) . c. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . NOTE The gap between the upper clamps and the risers should be equal at the front and rear of the handlebar after tightening. 9. One at a time, remove the riser bolts installed in Step 4. Apply two drops of Loctite® 271 (Red) to the bolt threads and re-install. Tighten the riser bolts to 50-60 ft-lbs (68-81 Nm)

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HARLEY DAVIDSON HANDLEBAR GRIPS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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INSTALLATION Remove and Install the Left Grip 1. See Figure 1. Remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Loosen, but do not remove, the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lb (6.8-9 Nm) . 9. Tighten first the lower, then the upper switch housing screws to 35-45 in-lb (4-5.4 Nm)

HARLEY DAVIDSON "LIVE TO RIDE" HANDLEBAR GRIPS INSTALLATION MANUAL

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

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installation Do not lubricate the left grip of handlebar in any way before installation. This could allow grip to come off while riding which could result in loss of control of vehicle and death or serious injury. 1. Remove existing left handlebar grip by carefully cutting it away from the handlebar using a sharp blade or knife. Remove right grip/throttle sleeve assembly following instructions in appropriate Service Manual. After removal, make sure that left and right handlebar ends are clean and smooth. 2. Check that end caps are securely fastened to grips. Tighten screw inside grip to secure end caps. 3. Assemble new throttle sleeve to handlebar. Refer to appropriate Service Manual for detailed procedure. NOTE Surfaces to be glued must be clean, dry, and free from oil. If surfaces are not clean, dry, and free from oil, then the new application may not adhere as desired. Please observe the following WARNINGS when using the adhesive contained in this kit. FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWALLOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS METHYL ETHYL KETONE. Use only in well ventilated areas. Avoid contact with eyes, mucous membranes, and prolonged skin contact. KEEP OUT OF REACH OF CHILDREN. If swallowed, do not induce vomiting. Call a physician immediately. This product contains a chemical(s) known to the State of California to cause cancer, birth defects or other reproductive harm. 4. Liberally apply a coating of Harley-Davidson Adhesive (Part No. 99839-95) to the inside of left handlebar grip using the cotton swab. Make sure adhesive fully covers all inside surface area of the grip. Also, apply a coat of adhesive to the handlebar end. 5. Check how the rectangular pattern is oriented on the throttle (right) grip. Align pattern on left grip to match right grip and immediately push the new grip completely onto handlebar end. 6. Rotate the end caps so the “Live to Ride”text is positioned at the top of both grips. NOTE Do not hesitate when installing left grip or adhesive will dry before installation is complete. Allow 6-8 hours at 70°F to achieve full cure of the adhesive. Prior to starting engine, verify that the throttle control will snap back to the idle position when released. A throttle control that prevents the engine from automatically returning to idle can lead to a loss of control of vehicle which could result in death or serious injury. Cleaning

HARLEY DAVIDSON SPORTSTER HAND GRIPS INSTALLATION MANUAL

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

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Remove and Install the Left Grip 1. See Figure 1. Using a T27 TORX®drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX®drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX®drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9.0 Nm). 9. Using a T25 TORX®drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm). Remove and Install the Right Grip 1. Refer to the RIGHTHANDLEBARSWITCH section of the service manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLECONTROL section of the service manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the service manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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WORKS PERFORMANCE STREET TRACKER SHOCKS FOR BIG DOG MOTORCYCLES

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Filed Under (Tips and Review) by admin on 17-12-2010

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SHOCK REMOVAL AND INSTALLATION– The shocks are fitted with special length spacers to maintain correct alignment between the frame and the swingarm. If the shocks are removed for service or repair, they must be installed in the correct position. Refer to the diagram on the next page for spacer positioning and layout. NOTE: Misalignment between the mounts on the frame and the mounts on the swingarm can cause binding between the shock shaft and shaft bushing. Misalignment of more than 1/4 inch can cause the shocks to bind up and not function properly. If this binding occurs, the shocks will feel overly stiff and harsh. Follow the procedures below to check for misalignment when installing the shocks. NOTE: The shock bushings are designed to have a certain side-to-side “float” to keep them from binding. As a result, do not grind or file the inner or outer edges of the bushings to make them narrower. The amount of “float” in the bushing set is necessary to ensure smooth operation of the damper assembly. If the shock eyes are tightened metal-to-metal (the outer faces of the eyes to the flanges or washers), this will lead to a harsh, stiff or choppy ride and premature seal leakage or damage to the shafts. MULTI-RATE SPRINGS Depending on each application, single or dual-rate springs are available. Dual-rate springs are just that– a spring set with two separate rates. This is done with a short spring stacked on a longer spring. As both springs compress they produce a soft, or initial, rate. The spring set will maintain this initial rate until the short spring stops compressing. At that point, the spring rate “crosses over” to the stiffer, or final, rate. This multi-rate system allows a soft initial rate for comfort on small bumps, but has the capability of soaking up the big pot-holes and other road hazards. PRELOAD ADJUSTMENT— On Works shocks, threaded preload is standard. (See Fig. 2.) This allows the adjustment of the ride height of the motorcycle. The preload is changed by turning a threaded nut down towards the spring (higher ride height) or up away from the spring (lower ride height). The nut is a right-hand thread. It is used primarily to set the ride height for solo riding, but can also be used when

HARLEY DAVIDSON PULLBACK RISER KIT FOR 1.25-INCH HANDLEBARS REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTES Cover the fuel tank with clean shop towels to prevent scratching. If replacing the handlebar, refer to the service manual to remove controls, hand levers, handlebar and risers. If only the risers are being replaced, proceed as follows: 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for assembly. Retain all additional components from the riser assembly when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers and carefully set the handlebar on the fuel tank. INSTALLATION NOTES See Figure 3. The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. 1. See Figure 3. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the lock washer (F) are located on the right side only. Do not tighten the riser mounting screws (4) at this time. 2. If an appropriate Harley-Davidson 1-1/4 inch handlebar has not been installed, install one according to the Instruction Sheet included with the kit, or install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers with the Bar & Shield toward the front of the motorcycle (Figure 1, Item 1). Install four socket head screws (3) with four washers (6). 1 is05253 1. Bar & Shield (install toward front of motorcycle) Figure 1. Bar & Shield on Riser and Cap 4. Check that the risers stay properly aligned with the handlebar and tighten the riser mounting screws following the instructions in the service manual. 5. Adjust handlebar to the desired position, verify that it is centered on the risers, then tighten the front socket head screws (3) to 12-15 ft-lb (16-20 Nm) . There should be no gap at the front of the risers.

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HARLEY DAVIDSON HANDLEBAR POLYURETHANE RISER BUSHING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION NOTES • Cover fuel tank with blanket or towels to keep paint from being scratched. • See the Touring Service Manual for the Fairing Removal procedure in order to gain access to the handlebar assembly. 1. For Touring Models: See Figure 1. Remove and save the the existing capscrews (C). Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard cup washers (D), rubber bushings (E) and spacers (F). Install the new bushings. For All Models Except Touring: Remove and save the two capscrews (C) from underneath the upper fork bracket that hold the existing lower clamps (risers) (B) in place. Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard the existing cup washers (D), rubber bushings (E) and spacers (F). NOTE The upper bushing and lower bushing must be oriented with flat side opposite from each other as shown. 2. Install the new polyurethane riser bushings (1) in place of the removed cup washers, bushings, and spacers. 3. Align components as shown in Figure 1. 4. Secure components with two hex head capscrews removed in Step 1. Insert the capscrews, from the bottom, thru the upper fork bracket, thru the bushings (1) and into the clamps (risers). See the service manual for the torque specification. 5. See the service manual and install the handlebars

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