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HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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HARLEY DAVIDSON SOFTAIL MUFFLER SLIP-FIT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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1. Disconnect negative battery cable. Perform this installation when the engine is cool. Installing these mufflers when the engine is hot could cause burns which could result in moderate to minor injury. 2. Remove mufflers according to applicable Service Manual instructions. Shotgun exhaust mufflers will come off the vehicle as a pair, attached together. Staggered dual mufflers will come off the vehicle attached to the interconnect tube. 3. For a shotgun exhaust, skip to Step 6. 1 CAUTION 1 WARNING 1 WARNING 1 of 2 4. Remove mufflers from interconnect tube and discard gaskets and mufflers. 5. Install mufflers to interconnect pipe using new gaskets (6) and existing screws. Slip muffler clamps (1) on mufflers and install assembly back on vehicle. Tighten screws to 96-120 in-lbs (10.8-13.6 N-m). Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm). Attach the interconnect tube to the frame using the existing flange lock nuts and washers. Tighten to 30-33 ft-lbs (40.7- 44.7 Nm). 6. On shotgun style assemblies, assemble top and bottom mufflers using interconnect seal. Torque screws to 96-120 in-lbs (61-81.3 Nm). Attach interconnect tube to frame using existing flange locknuts and washers. Torque to 30-33 ft-lbs, (40-7-44.7 Nm). 7. Replace fasteners and tighten as follows: muffler clamps to 45-60 ft-lbs (61-81.3 Nm), flange locknut on carriage bolt to 30-33 ft-lbs (40.7-44.7 Nm) and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 8. Reconnect negative battery cable. 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. Noise Emission Warranty Gabilan Manufacturing, Inc. warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. 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.

HARLEY DAVIDSON DYNA STREET PERFORMANCE SLIP-ON ACCESSORY MUFFLERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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PRODUCT INFORMATION 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. Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. 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 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 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) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HARLEY DAVIDSON SOFTAIL DETACHABLE SADDLEBAG KITS INSTALLATION MANUAL

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

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Detachable Saddlebag Configurations Table 1 provides a short description of the detachable saddlebag configurations. Table 1. Softail Detachable Saddlebag Configurations Accessory Configuration (Long Description) Short Descrip- tion Kit 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Other Detachable Accessories FL Outer 88237-07 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) Without Other Detachable Accessories FL Inner 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Rigid-Mounted Accessories FL Rigid 2006-Later FX Models (Except FXSTD) With Other Detachable Accessories FX Outer 88238-07 2006-Later FX Models (Except FXSTD) Without Other Detachable Accessories FX Inner 2006-Later FX Models (Except FXSTD) With Rigid-Mounted Accessories FX Rigid 2007-Later FXSTC Models With Stock Passenger Upright FXSTC Stock NOTE Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Install Turn Signal Relocation Kit Refer to instructions included with Turn Signal Relocation Kit 69857-07. Install Docking Hardware Kit(s) Without Other Detachable Accessories: Refer to instructions included with Docking Hardware Kit 53932-03. With Other Detachable Accessories: Refer to instructions included with Docking Hardware Kits 53932-03 and 88256-07. Install Rear Docking Adapter NOTE This procedure only applies to models without detachable accessories. 1. See Figure 1. Insert rear docking adapter (1) into holes in saddlebag bracket and hold in place. 2. Install rear docking adapter using screw (2) and nut (3). Tighten snugly.

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2004 – 2005 Camry, Highlander, And Solara, 2005 Matrix & Corolla PASSENGER AIRBAG INDICATOR LAMP

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Filed Under (Toyota Manuals) by admin on 10-10-2011

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passengers weighing approximately less than 100 pounds, depending on their seating position. It is important for the front seat passengers to know that proper operation of the advanced frontal airbag system is highly dependent on the pressure placed on the seat bottom. Situations that add or subtract sensed weight can result in occupant misclassification. To minimize this situation: Check seating posture. Passengers should be seated upright with their back against the seat back and feet on the floor. Check loading conditions. Extra weight from items, such as bags or groceries or toys, hanging on the seat back can add to the sensed weight of the front seat passenger. A rear seat passenger lifting the front seat with their legs, objects placed under the front seat, or the front seatback in contact with the rear seat can subtract from the sensed weight of the front seat passenger. If the passenger airbag indicator lamp continues to switch ON to OFF after checking the above conditions, perform the following repair procedure. NOTE: The safest place for children is in the rear seat. Please note that Toyota recommends that you never install a rear-facing child restraint in the front passenger seat, even if the passenger “Airbag OFF” lamp is illuminated. Please refer to you Owner’s Manual for additional details. 2004 – 2005 model year Camry, Highlander, and Solara vehicles produced BEFORE the Production Change Effective VINs shown on the following page. 2005 model year Matrix and Corolla vehicles produced BEFORE the Production Change Effective VINs shown on the following page

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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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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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

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1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.

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HARLEY DAVIDSON SOFTAIL DELUXE SEATS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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These kits fit 2005 and later FLSTN model motorcycles. Additional Parts Required NOTE A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 3 and Table 1. INSTALLATION 1. Remove existing seat according to Owner’s Manual Instructions. Save all attaching hardware. 2. See Figure 1. Install two flange nuts (1) from kit onto the seat mounting studs. Tighten flange nuts to 5-8 ft-lbs (7- 11 Nm) . 1 is03023 1. Install flange nuts Figure 1. Flange Nut Locations NOTE See Figure 3 for Steps 3-6. 3. Remove two screws (A) and rear mounting bracket (B) from stock seat. Save all hardware. 4. Install the rear mounting bracket (B) removed in Step 3 onto the new seat using the seat bracket screws (A). Tighten screws to 19 in-lbs (2.1 Nm) . 5. Install new seat (1) on the motorcycle by inserting the tab at the front of the seat into the slot at the rear of the fuel tank. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 6. Fasten rear seat bracket (B) to fender nut using stock mounting screw (C). 7. See Figure 2. To install grabstrap, remove front screw and washer from rear fender support. Install grabstrap with thick washers (1), thin washers (3) and screws (4) from kit. Tighten to 21-27 ft-lbs (28-37 Nm)

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2008 Harley Davidson Softail Deluxe Exhaust Installation Supplement to Installation Manua

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Filed Under (Harley Davidson) by admin on 16-02-2011

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1. Install LH and RH passenger foot peg mount using 3/8×2-1/4″ hex head bolts, 3/8″ SAE flat washers, 3/8″ lock was and 1″ spacers between the motorcycl frame and mount. Figure 1 hers e xhaust ter) n’t Cut 6-1/4″ from end Cut 1/2″ from end Figure 2 2. Remove exhaust chrome covers from header pipes. 3. It is not necessary to remove the front cylinder’s front cover. Remove header pipes from cylinder heads. Cut pipes as shown in Figure 2. 4. Replace header pipes Cut cover 5-5/8″ from end – Shown already cut Figure 3 5. Cut top cover as shown in Figure 3. 6. Install supplied extension pipes as shown in Figure 3 using the OE e clamps. (Clamps covered by covers in picture – covers will be installed la Rotate clamps to make sure they don’t interfere with the foot peg mounts. Do tighten clamps yet. 7. Mount exhaust hanger bracket to body frame with (3) supplied vibration mounts. Figure 4. Figure 4 8. Install supplied clamps to ends of mufflers and fit over exhaust extensions. 9. Attach exhaust pipes to hanger bracket with OEM hardware (4 bolts). Apply Red Loctite to OEM bolts. Figure 4. 10. Install all chrome covers 11. Tighten all exhaust clamps. Figure 5 12. Install supplied chrome cover with clamp removed from cut OE chrome cover. Supplied cover slips over OE chrome cover. Push cover forward to prevent the body from hitting the cover. Figure 5. 13. Move OE clamp backwards and install 14. Position luggage rack as shown in figure 5. Install luggage rack with OE bolt in the Figure 6 Bracket OE Bolt Clamp Figure 7 Drill ¼” holes bracket using OE bolt and supplied 3/8″ bolt. Figure 6. 7 and drill two ¼” holes in shock tower mount. 1 rear and the supplied ¼” bolts in the front.

2005-2007 KTM 5018 DCC 5018 SXS 5018 SMR WP SHOCK ABSORBER REPAIR MANUAL

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

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liter fuel consumption is equivalent to approx. 15 operating hours Check the bearing in the shock absorber top / replace if necessary Check the piston rod on scratches / leakage Check the static sag – before riding Check the spring Check the bump rubber Check the O-ring of the spring retainer / replace if necessary Complete maintenance of the shock absorber 10 hours 65 liter 20 hours 130 liter 30 hours 200 liter 40 hours 260 liter 50 hours 325 liter 60 hours 400 liter 70 hours 455 liter 80 hours 520 liter 90 hours 600 liter 100 hours 665 liter Adjusting the position of the compression and rebound damping Rebound damping: -Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: -Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, high speed: -Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Adjusting the spring preload NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. -Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. -Tighten the lock screw on the adjusting nut. Recommended periodic maintenance and inspection of the 5018 SXS/SMR Shock absorber

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