diagram for harley davidson sportster evolution rear wheel spacers

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HARLEY DAVIDSON TIMKEN BEARING CONVERSION TOOL INSTALLATION MANUAL

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

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2-ton press (must be square to within .010″, ram to table) Inch-lb torque wrench Foot-lb torque wrench T15 TORX® drive socket (for inch-lb torque wrench) 5/32 inch hex drive socket (for inch-lb torque wrench) 5/16 inch hex drive socket (for foot-lb torque wrench) 5/64 inch hex key wrench 1/16 inch hex key wrench 3/8 inch drive hand drill small tap handle (suitable for #8-32 tap) Tapping Fluid Press Fit Lube (non-drip) Loctite® 620 threadlocker and sealant 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 21 and Table 3. If replacement parts are needed contact JIMS® at 805-482- 6913 or INSTALLATION 1. Remove and disassemble the engine as necessary to remove the left side engine case. Bearings and seals must be removed from the left case. Refer to the service manual for the disassembly procedures. 2. Use an appropriate solvent to clean the left engine case. Also clean the bearing sleeve (1) supplied in the kit. 3. Apply Loctite 620 to the smaller inside diameter portion of the left case bearing bore. 4. See Figure 1. Apply Loctite 620 using a cotton swab to the smaller portion of the outside diameter (2) surface of the bearing sleeve (1). 5. Apply a spare amount of non-drip press fit lube (3) to the larger outside diameter of the bearing sleeve. 6. See Figure 2. Fit the bottom locater plate (1) to the to the outside of the case over the bearing bore. The word “BOTTOM” will be at the bottom of the case when installed at the 6 o’clock position

HARLEY DAVIDSON FLSTC SOFTAIL SADDLEBAG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Additional Fitment Information Detachables NOTE If motorcycle has not been altered from fixed saddlebag hardware to accessory mounting detachable docking points. the separate purchase of Turn Signal Mounting Bar (Part Number 68611-98) is required for sufficient lock clearance. This kit is available at your Harley-Davidson Dealer. Installing these saddlebags on models equipped with a detachable sissy bar or detachable luggage rack requires the additional purchase of mounting hardware kit as follows: Hardware Kit Fitment 53075-03 2003 and later FLSTC models with detachables 53009-03 1987 through 2002 FLSTC models with detachables See Service Parts Page for kit contents. Additional weight can affect motorcycle stability, handling characteristics, and safe operating speed. Do not exceed 7 lbs. (3.18Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury. Wide Tire If a wide tire kit has been installed, utilize the hardware and installation instructions found in that kit to reorient the fasteners to come from the inside to the outside of the finder. Button head screws from wide tire kit must be installed from the inside out, with the button heads on the inside of the fender. Failure to do so could result in bolt contacting tire, which could result in death or serious injury. Installation NOTE A Service Manual for your vehicle is available at your Harley-Davidson Dealer. 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect the negative (-) battery cable first. If positive (+) cable should contact ground with the negative (-) cable connected, the resulting sparks may cause a battery explosion which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Following instructions in applicable Service Manual, remove original saddlebags from supports. Install Turn Signal Mounting Bar If motorcycle is not equipped with accessory mounting detachable docking points, install Turn Signal Mounting Bar (Part No. 68611-98) following instructions provided with the kit. See Figure 1

HARLEY DAVIDSON SCREAMIN’ EAGLE STREET PERFORMANCE TOURING END CAP MUFFLER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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PRODUCT INFORMATION Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for proposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION NOTE Install end caps on mufflers before installing mufflers on vehicle. Install Direct Bolt-On End Caps 1. See Figure 1. Install end cap (2) to muffler (3) with four socket head cap screws (1). Tighten to 82-86 in-lbs (9.3- 9.7 Nm) . 2. Repeat for opposite side muffler. 3 2 1 is05426 1. Socket head screw (4) 2. End cap 3. Muffler Figure 1. Install End Cap on Muffler Install Attachment Ring End Caps 1. See Figure 2. Slide the three U-nuts (2) onto the bosses of the end cap attachment ring cup on the muffler. 2. Install attachment ring (1) to muffler with four socket head cap screws (3). Locate the attachment ring with a U-nut in the 12 o’clock position. Tighten to 82-86 in-lbs (9.3-9.7 Nm) . 3. Slide end cap (5) onto muffler body being careful to align holes in end cap with U-nuts. 4. Install the three countersunk screws (4) and tighten screws securely. 5. Repeat for opposite side muffler

HARLEY DAVIDSON ADVANCED AUDIO HANDS FREE PHONE INTERFACE KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 12-04-2011

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The Hands Free interface module in this kit requires proximity to a BluetoothTM-enabled cellular phone in order to function. The phone must be a model that is compatible with the interface module (go to to view the compatibility chart), and must be paired to the interface module according to the instructions included with the cell phone. NOTE The cell phone MUST be available to the installer in the final steps of the installation (prior to re-installation of the outer fairing) in order to program and test the hands free functions. To avoid unnecessary delays, please take this into consideration when scheduling the installation. FLHT models will require prior installation of an Advanced Audio AM/ FM/ CD Radio Kit (Part Number 76412-06) and a Tour-Pak Mount AM/ FM Antenna Kit (Part Number 76317-06). FLHT, FLHX and FLTR models will require the prior installation of a Tour Pak®. See a Harley-Davidson dealer for avail- ability of color-matched King or Chopped Tour-Paks to match your vehicle, and additional items that may be required when mounting the Tour-Pak to your model. Unless one has already been fitted as part of another Advanced Audio kit installation: FLHTCU models will require the additional purchase of an Ultra Overlay Harness (Part Number 70164-06). FLHT, FLHTC and FLHX models will require the separate purchase of a Communication Switch Kit (Part Number 77173- 06). FLHX models will require the separate purchase of: •a fuel tank console (Part Number 61270-98A), •a console extension (Part Number 52447-96), •a rubber molding (71294-89), •a 1/4-20 clip nut (Part Number 7964), •a button-head screw (Part Number 3652), •a plastic wire clip (Part Number 10120), and •an adhesive-backed metal wire clip (Part Number 10103). FLTR models will require the separate purchase of: •a Console Pod Assembly (Part Number 77136-03), and •three pan-head screws (Part Number 2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (Part Number 70169-06), and EITHER : •a Premium Stereo Helmet Headset (Part Number 77147- 98) OR a Hand-Held CB Microphone Kit (Part Number 76312-98

HARLEY DAVIDSON FAT HANDLEBAR RISER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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INSTALLATION NOTES The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. See Figure 1 for the following procedure. 1. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the internal tooth lock washer (H) are located on the right side only. Do not tighten the riser mounting screws (I) 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 re-install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers using four socket head screws (3) as shown. 4. Ensure that the risers stay properly aligned with the handlebar and tighten the riser mounting screws (I) to 50-60 ft-lbs (68-81 Nm) . 5. Adjust handlebar to the desired position, ensure that it is centered on the risers, then, starting with the front screws, tighten the four socket head screws (3) to 12-15 ft-lbs (16- 20 Nm) . 6. Turn the handlebars full right and left. Check that: •The handlebars and triple tree clamps do not contact the fuel tank. •The steering stops function properly. •The wiring and brake line are not pinched or kinked in the steering assembly. •Throttle returns from full open to close at both fork stops. Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) •If you are installing different handlebars, measure the change in distance that will be required from the end of the stock brake line to the brake master cylinder. •Compare this revised length to the brake line provided in your kit. •If the line is more than 2.0 in. (50.8 mm) longer or more than 1.0 in. (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct brake line length

Related Item : Harley Riser Extensions (1)