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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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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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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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Harley Davidson Dakota Digital HLY-6000 Road Star Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The Road Star wiring is split into 2 different bundles with black connectors on the ends that were used to plug into the stock gauge cluster. Cut off both connectors. They are no longer needed The speed sensor wires on the HLY-6000 have a connector on the end that allows you to plug it directly into Harley Davidson speed sensors by using an appropriate adapter (sold separately). Luckily for us, the Road Star’s stock speed sensor will work just fine without an adapter so go ahead and cut off that connector, you don’t need it.
Ideally, the best location for the “brain box” unit of the HLY-6000 would be under the left side cover. Unfortunately, mine is full of other stuff so I had to improvise the location and decided to mount it to the back portion of the under-seat area. I would recommend that you mount yours under the left side cover though. The wires are the perfect length for that location. The brain box and wires could fit under the right side cover, but I don’t believe that the main gauge connector would reach. Using the wiring scheme on the last page of this guide, match up the wires on the Road Star with the corresponding wires on the HLY-6000 wiring harness and solder them together. Important Wiring Information: Both BLACK wires on the brain box need to be connected directly to the (-) terminal on the battery. Don’t connect them to anything else. The following wires from the Road Star are not used and can be taped off: • BLACK • RED / GREEN • BROWN The following wires from the HLY-6000 are not used and can be taped off: • GRAY • WHITE/ BLUE • WHITE (on main harness) • BROWN (*optional) The HLY-6000 has a “dimmer” function which is controlled by the BROWN wire. If you want the gauge to be bright all the time, then leave this wire disconnected. If you want the gauge to dim for night driving, then connect this wire to the GREEN Low Beam (+12v) wire

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HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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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 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. 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) 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. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to 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

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2000 Harley-Davidson FLHRCI Road King Classic

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

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the Road King® Classic is a motorcycle with enough traditional styling to drop jaws throughout the continent. The Road King® Classic boasts laced wheels, fat white-walls and gorgeous leather saddlebags with hard inserts so they keep their shape across the long miles. Slightly narrower new handlebars provide improved ergonomics. Fender tips, tank and seat valance all boast a metal emblem. The model is available with a fuel-injected, chrome-and-black Harley- Davidson® Twin Cam 88 engine. Specifications: Engine Type: 1449 cc, 4-Stroke, Air Cooled, V-Twin Engine Bore and Stroke: 95.3 mm x 101.6 mm Valves 2 valves/cylinder Claimed Horsepower: 67 hp (50 kW) @ 5200 rpm Maximum Torque: 110 Nm (81.1 ft. lbs) @ 3100 rpm Transmission type: 5 speed Final Drive: Belt Tire – Front: 130/90-16 Tire – Rear: 130/90-16 Brakes – Front: dual 292 mm discs with 4-piston calipers Brakes – Rear: single 292 mm disc with 4-piston calipers

Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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Filed Under (Harley Davidson) by admin on 16-04-2012

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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