chrome shock studs for 20160 wide glide upper and lower

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HARLEY DAVIDSON LOW REAR SHOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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See Figure 3 and Table 1. INSTALLATION Shock Absorbers 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) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) NOTES This procedure requires that both shocks be removed prior to installing the new shock absorbers. You need to place the motorcycle on a center stand with the rear wheel raised off of the ground. The jiffy stand should be able to move through its full range of travel. The exhaust system may interfere when removing and installing the lower right shock mounting hardware. If necessary, see Service Manual and remove the rear exhaust pipe. 2 4 5 7 1 6 3 is05206 1. Lower screw 2. Upper screw 3. Lower washer 4. Upper washer 5. Cover 6. Nut 7. Shock absorber Figure 1. Remove / Install Shock Absorber 1. Block the motorcycle under the frame so that the motorcycle is securely resting upright, the jiffystand may be moved through its full range of travel, and rear wheel is just off the ground. 2. Remove the lower shock mounting screw (1), washer (3) and nut (6) from the shock absorber (7). Save the hardware for reuse. 3. Remove the upper bolt (2), washer (4) and cover (5) and remove the shock absorber. Save the hardware for reuse. 4. Repeat Steps 1 and 2 for opposite side and save the hardware. 5. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the lower mounting bolt, then install bolt, lower washer and nut to the shock. 6. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the upper mounting bolt, then install the shock cover, upper mounting bolt and washer to the shock. Verify the cutout in shock cover locates properly

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HARLEY DAVIDSON CHROME UPPER BELT GUARD KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE When performing the following step, it is not necessary to completely remove the shock mount bolt, back the bolt out only until it is flush with the swingarm. 1. See Figure 1. Loosen the left rear shock mount bolt (1) and back it out until the threaded portion of the bolt is flush with the swingarm. 1 2 is03762 1. Shock mounting bolt (left side) 2. Belt guard Figure 1. Loosen Shock Mounting Bolt 2. Pull the belt guard (2) straight back toward the rear of the bike to remove the guard from upper and lower grommets. See Figure 2. It may be necessary to work the guard up and down slightly to dislodge it from the upper (1) and lower (2) grommets. Remove the belt guard and discard. 2 1 3 is03763 1. Upper grommet mount 2. Lower grommet mount 3. Front belt cover Figure 2. Rubber Grommet Mount Locations 3. Obtain the chrome belt guard from kit. While making sure belt guard is over the belt, slide the guard straight in between the shock and sprocket and align cover just below front belt cover (3). The cutouts in the bracket should be lined up to engage with upper and lower grommets. NOTE When performing the following step, gently pull the guard in and out at the center; it should feel fairly tight even though the rear mounting bracket has not been secured. 4. See Figure 3. Firmly push the guard toward the front of the bike until the cutouts are secured by the grommets and the belt guard mounting bracket (1) hole lines up with the shock bolt

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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ATK 50MX INSTALLATION AND ADJUSTMENT TIPS

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Filed Under (Atk) by admin on 01-11-2010

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PRELOAD ADJUSTMENT— On some Works shocks a threaded preload is standard. 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. CHECKING RIDE HEIGHT— 1. With the bike unloaded on the side stand and the shock fully extended, have an assistant measure from a point at the axle (center point) to a point on the frame, fender or bodywork directly above it. Record this measurement. 2. With the bike off the stand and the rider in the seat, bounce on the suspension and let the bike settle. Have the assistant measure from the same two points. Subtract the second measurement from the first. HM CRX50 / BAJA & ATK 50MX INSTALLATION AND ADJUSTMENT TIPS Continued on next page. #HM50 – 5/27/99 #HM50 – 5/27/99 To Front Valve Mounting channel Spacer Flange Shock eye Top View of Shock Mount Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike 3. The amount of settle, or “sag” is a function of the wheel travel. It should only be between 1/4 and 1/3 of the total travel. 4. If the difference is less than the minimum, reduce the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. 5. If the difference is more than the maximum, increase the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. Note: If the ride height is too low, the shock will bottom unnecessarily, resulting in a harsh ride. If the ride height is too high, the shock will “top out” too easily when rebounding from a bump or under hard deceleration. NITROGEN PRESSURES IN EMULSION SHOCKS CAUTION: The pressure in these shocks cannot successfully be checked. Concerns with the gauge volume and the gas volume in the shock body create a situation where you cannot accurately determine what pressure was in the shock. In addition when the pressure is lowered (i.e. checking the pressure) the gas and some of the shock oil escapes into the gauge. It is possible to lose a large percentage of the shock oil by depressing the core of a charged shock to the atmosphere. Please note that in order to check the pressure, some of the gas must escape and fill the gauge assembly. The volume of the gas pocket is about half the size of your thumb, so a very small volume change results in a large pressure drop. Because the gauges’ volumes vary, it is not possible to deduce the actual pressure in the shock prior to attaching the gauge. Therefore it is imperative that any attempt to check pressure be accompanied by the capability of refilling the shock. In other words: If you don’t have a nitrogen source handy, don’t check the pressure! PRESSURIZING EMULSION SHOCKS The pressure setting for Works gas shocks is 250 p.s.i. of dry nitrogen. To pressurize a shock with some residual pressure in it, bring the gauge manifold up to 250 p.s.i. and depress the core with the T-handle. This will either equalize the pressure or refill the shock without transferring oil from the shock into the gauge assembly. The best gauges for this purpose screw on to the valve and incorporate a T-handled core depressor to isolate the shock from the gauge. This allows a leak-free separation once the desired pressure is reached. For simplified operation, an extra valve is provided for the filling apparatus, allowing pressure adjustment with the gauge in place. Works offers a suitable gauge and filling manifold. Most motorcycle shops that deal with dirt bikes can pressurize the shock

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HARLEY DAVIDSON FXSTD DETACHABLE WINDSHIELD AND DOCKING HARDWARE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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INSTALLATION NOTE Use the Docking Hardware Kit to assemble two upper and two lower clamps. See the Service Parts illustration. The upper clamps use a mounting pin (4) and the lower clamps use a button head screw (5) to fasten the windshield mounting bushing. 1. Assemble the windshield docking hardware as follows: a. Install a larger chrome washer (6) and bushing (7) onto a button head screw (5). Thread the screw into the boss on one of the clamps (1), and tighten finger tight. Repeat for a second lower clamp. b. Install a larger chrome washer (6) and bushing (7) onto a mounting pin (4). Thread the pin into the boss on one of the clamps (1), and tighten finger tight. Repeat for a second lower clamp. 2 1 3 4 4 5 is 02187 1. Upper clamp 2. Lower clamp 3. Fork tubes 4.1/8 inch (3 mm) approximately 5.3.0 inch (76 mm) Figure 1. Installing Clamps NOTE Place shop rags on the headlamp, front fender and front of the fuel tank to prevent scratches to these components. Be sure the windshield assembly does not contact chrome or painted parts. Contact will cause scratches to chrome or painted parts. 2. See Figure 1. Install a lower clamp onto a fork tube using a smaller chrome washer and lock nut from the kit. Adjust so the clamp is approximately 1/8 inch (3 mm) from the top of the lower triple clamp, then finger tighten the lock nut. Repeat with the second lower clamp and fork tube. NOTE Keep front wheel straight to prevent brackets from scratching fuel tanks. See Figure 1. Install the clamps on the fork tubes so the bushing center lines are 3 inches (76 mm) apart. 3. Install an upper clamp onto a fork tube using a smaller chrome washer and lock nut from the kit. Adjust so the clamp is approximately 1/8 inch (3 mm) from the bottom of the upper triple clamp. Ensure that the center lines of the upper and lower bushings are 3 inches (76 mm) apart, then finger tighten the lock nut. Repeat with the second upper clamp and fork tube

KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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Filed Under (KTM) by admin on 12-11-2010

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

HARLEY-DAVIDSON SOFTAIL MODELS STEALTH AIR SHOCK MOUNTING

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Filed Under (Harley Davidson) by admin on 16-12-2010

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INSTALLATION 1. Remove the seat, inner fender, and ignition coil cover. Removing the rear wheel assembly is recommended for ease of installation, but not absolutely necessary. Remove the nut cup and outer grommet on each of the Works shocks. If you intend to leave the ride height at stock height for road riding, position the inner nut cup SHOC KS SHOC KS WORKS PERFORMANCE PRODUCTS, INC. 21045 Osborne St., Canoga Park, CA 91304 818.701.1010 fax 818.701.9043 STEALTH AIR SHOCK MOUNTING FOR HARLEY-DAVIDSON SOFTAIL MODELS 2000-ON #HDAIR-00 – 02/15/2006 WARNING! THESE SHOCKS MUST ONLY BE USED WITH STOCK SWINGARMS AND ON STOCK FRAMES WITH THE STOCK BOTTOMING BUMPERS ON THE CHASSIS TO LIMIT THE TRAVEL OF THE SHOCKS. AFTERMARKET SWINGARMS, OR MODIFIED SWINGARMS THAT DO NOT HAVE THE UPPER BRACE THAT ACTS AGAINST THE BOTTOMING BUMPERS CANNOT BE USED WITH THESE SHOCKS. INCREASING THE TRAVEL BY ELIMINATING THE BUMP STOPS OR A NON-STANDARD SWINGARM DESIGN WILL ALLOW THE TIRE TO MAKE CONTACT WITH THE FENDER OR OTHER CHASSIS COMPONENTS, AND CAN DAMAGE THE SHOCKS. 19. Lock Washers 20. Long Bolts (2) 21. Short Bolts (2) 13. Din Plug Screw 14. Din Plug Gasket 15. Cap 16. Eye Spacers (4) 17. Cotter Pins (2) 18. Switch Bracket 7. Compressor Bracket 8. Harness 9. Fuse Block 10. Din Connector 11. Solenoid 12. Hose 1. Damper Shock 2. Air Spring Shock 3. Nut Cup 4. Grommet 5. Hose 6. Compressor 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 14 18 19 20 21 Fig. 1–Nomenclature on the damper shock up against the ring nut. The shocks are now ready to install. 2. Place the motorcycle on a suitable frame stand allowing unrestricted access to the shocks. 3. Place a small screw jack under the swing arm to support the weight as well as allow you to position the swing arm correctly to line up the shock mounting bolts. Remove stock shocks. 4. Install the left side (damping) shock with the stock mounting bolt. Make sure that the bolt threads and threaded portions of the frame are free of oil and grease. Grease the shoulders of the bolts and use thread lock compounds on the threads. Discard the stock shock washers on both shocks. Do not use any washers- -including the stock washers on these bolts. Use only the spacers included. The 3/16-inch wide spacers are used on each side of the shock eye. Do not “double-up” the spacers together on either side of the shock eye, as this will cause misalignment of the shocks which can lead to premature wear or damage to the shocks. 5. Put the supplied spacers on each side of the eye. The shoulder of the bolt must protrude a small amount through the shock eyes in order to allow the shock to pivot freely. This is extremely important. With the shocks fully tightened, the spacers should be free to rotate with finger pressure. If the washer is used or a non-stock bolt is used, the bolts will work loose or break because the shocks are in a bind.

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Honda ST 1300 Series Single Shock Supplement

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Filed Under (Honda) by admin on 13-02-2011

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Check the orientation of the adjuster on the shock body – looking at the top of the shock, the hydraulic line port should be165 degrees (clockwise) from the nitrogen pressure valve (see figure 2) . If it is not properly oriented, you will need to reposition it. To do this, hold the upper shock eye securely in a vice and carefully rotate the Remote Adjustable Pre-Load adjuster the desired direction. This may be somewhat difficult due to spring tension, and may require slight loosening of the locking ring. Also, the spring, shaft, and lower mount may rotate while repositioning the adjuster. This is OK, just be sure to realign it with the upper mount (also be sure the rebound adjuster on the lower mount is properly oriented as noted below). Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the same path as the stock line was routed to the same location. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing up and towards the rear (figure 3) . n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket adapter using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80- 90 in/lbs (9-10 N-m). Then mount the bracket and adjuster to the bike in the same location as the stock preload adjuster using the supplied M6-1.0X20mm SHCS fasteners & nuts, and torque them to 80-90 in/lbs (9-10 N-m) (figure 4 & 5) . n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources.

HARLEY DAVIDSON VRSC REAR AXLE COVERS INSTALLATION MANUAL

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

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This kit fits 2002 and later VRSC model motorcycles. Kit Contents There are no Service Parts available with this kit. INSTALLATION 1. Using a suitable lift, support the vehicle beneath the frame until the rear tire is just slightly off the ground. 2. See Figure 1. Remove the right side upper shock mounting bolt (2) and spacer (4). Retain the shock mounting nut (not shown) which passes through the fender support and side rail assembly. 3. Pivot the shock towards the vertical position. 4. Remove the left side lower shock mounting bolt (1) and washer (5). 5. Pivot the shock towards the horizontal position. 6. Insure that the shocks are clear of all components and carefully lower the vehicle to provide access to the right side lower shock bolt. 7. Support the right shock and remove the lower shock mounting bolt (1), washer (5) and nut (6). 8. Position the right side cover provided in the kit over the swingarm 9. Reposition the right side shock and re-install the lower shock mounting bolt (1) and washer (5) by inserting through the shock, cover and swingarm. Thread into nut (6) and tighten to 41-68 Nm (30-50 ft-lbs)

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