docking hardware for 2002 ultra classic

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HARLEY DAVIDSON DYNA DOCKING HARDWARE FOR FXDX WITH WIDE TIRE INSTALLATION MANUAL

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

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Installation NOTE Perform the following procedures on one side of the motorcycle until instructed to go to the other side. To keep fender in alignment the front docking point will be mounted first. INSTALLING DOCKING POINTS NOTE Save the acorn nuts and washers removed from the fender support bracket for use when installating docking points. 1. Loosen and remove the acorn nuts, washers, and screws from the fender support (right-hand) bracket. Save the washers and acorn nuts for docking point installation. Discard screws. 2. Obtain 1 plastic bushing, labeled 01, from a bushing set. 3. Place the bushing (4) (beveled side out) into the front support hole as shown in Service Parts illustration. 4. Place the countersunk side of the front docking point (2) so that it engages bushing (4). 5. From underneath (inside) the fender, insert hex-head screw (1) through fender, support bracket and front docking point (2). 6. Install washer (7) split lockwasher (5) and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 7. Obtain another plastic bushing, labeled 01 , from the bushing set. 8. Place bushing (4) (beveled side out) into the the rear support hole as shown in Service Parts illustration. 9. Place the countersunk side of the rear docking point (3) so that it engages bushing (4). 10. From underneath (inside) the fender, insert hex-head screw through fender, support bracket and rear docking point (3). 11. Install washer (7) split lockwasher (5)and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 12. Repeat procedures 1 through 11 for opposite (left-hand) side of the motorcycle. NOTE In time docking points may wear, causing the sideplates to become loose. The fit may be tightened using the following procedure. 1. Loosen docking hardware. 2. Rotate docking points clockwise approximately 45°. 3. Tighten docking hardware to the appropriate torque values. Repeat as often as required, up to 3 times

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HARLEY DAVIDSON FLSTC & FLSTS DOCKING HARDWARE WITH SADDLEBAG SUP- PORTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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The rear docking points in kit part number 90366-03 provide the rear mounting points for the Solo Rack. The rear mounting points from this kit ( 53931-03A ) will need to be installed to provide the clearance for the Solo Rack to be mounted. Table 2. Turn Signal Relocation Kit Requirement Turn Signal Relocation Kit Required Accessory Part Number 2003 and later FLSTC Not required 53815-00 Detachable Sideplates Not required 53066-00A Detachable Tour Pak Rack REMOVAL FLSTS Saddlebag Assembly Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Repeat steps 1 – 2 on the other side of the vehicle. FLSTC Saddlebag and Fixed Mount Sissybar Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts, but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Remove and discard fixed mount sideplates. Retain sissy bar for use with detachable sideplates. 4. Repeat steps 1 – 3 on the other side of the vehicle. 1 is06914 1. Saddlebag support studs Figure 1. Original Equipment Hardware (FLSTS model shown) INSTALLATION Docking Hardware Installation – For Detachable Sideplates or Tour-Pak Rack NOTE See Figure 15. The rear docking point (8) is wider than the front docking point (2). -J02425 1 of 5 1. Place front docking point (2) on front stud (1), with countersunk end of docking point facing fender support. 2. Place spacer (6) for side plates or mid docking point (for detachable sideplate kit) on rear stud (1). 3. Place rear docking point (8) on bolt (7), with countersunk end facing fender support. 4. Insert front stud (1) through front docking point (2), fender support and into bracket underneath fender as shown. 5. Insert rear stud (1) through fender support and into bracket underneath fender as shown. 6. Install bolt (7) through fender support and into bracket underneath fender as shown. 7. Tighten front and rear studs (1) and bolt (7) to 27 ft-lbs (37 Nm) . 8. Repeat steps 1-7 on the other side of the vehicle.

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HARLEY DAVIDSON DYNA DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION Installing the Front Docking Point To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Remove the seat and disconnect the negative (-) battery cable. NOTE To keep the fender aligned, complete ALL the following procedures on one side of the motorcycle before starting the other side. 2. See Figure 1. Remove the stock fender support bracket. Position new rear fender mounting bracket from kit (5) into position. 3. Apply Loctite 243 (Blue) to button head bolt (2) prior to installation. Place the tapered side of front docking point (1) against the strut cover. Insert button head bolt (2) through the docking point, fender support and fender. Tighten to 12-18 ft-lbs (16.3-24.4 Nm) . 4. If used without saddlebags, install rear docking point (3) and recess cover (4) according to instructions in Part Number 53968-06C, Directional Relocation Kit. If used with saddlebags, mount rear docking point according to instructions with saddlebag kit. MAINTENANCE NOTE In time, the docking points may wear causing the mating luggage rack or sideplates to become loose. The fit may be tightened using the following procedure. If any fasteners with Loctite are loosened, then the fasteners must be removed, cleaned of existing Loctite and re-installed with new Loctite. 1. Loosen the docking hardware. 2. Rotate the docking points clockwise approximately 45°. 3. Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures. This procedure can be repeated up to 3 times before replacement of the docking points is recommended.

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HARLEY DAVIDSON FOUR-POINT DETACHABLE DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 3. Remove the screw (A) retaining the rear of the chrome cover to the rear frame extension on each side of the vehicle. 2. Place a washer (7) over the threads of each of the larger TORX® head screws (6) from the kit. Apply 2 or 3 drops of Loctite 262 Threadlocker and Sealant – Red to the threads of each screw. Install the screws through the docking plates (1) and fender covers, and into the threaded holes in the frame extensions on each side of the vehicle, and tighten to 17 ft-lbs (23 Nm) . NOTE See Figure 1. The docking points must be attached to the docking plates (2) with the chamfer (1) facing the plate and the flat side facing out. 1 2 is05506a 1. Docking point chamfer (bevel) 2. Mounting plate Figure 1. Docking Point Installation 3. See Figure 3. Slide a spacer (2) onto the longer pin (B) of each docking plate. Install the four docking points (3), chamfer end first, onto the long and short docking plate pins using the washers (5) and smaller TORX screws (4). Tighten to 10.5 ft-lbs (14.2 Nm) . NOTE Protective tape must be installed to the rear saddlebag mounting bracket to prevent damage to the saddlebag finish when the lid is opened. 4. See Figure 2. Apply protective tape (2) to the rear mounting bracket (1) on the saddlebag in the location shown. Repeat for the other side. 2 1 is05533 1. Rear saddlebag bracket (2) 2. Protective tape %lengthT=0

HARLEY DAVIDSON XL DOCKING HARDWARE/ DIRECTIONAL RELOCATION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION 1. See Figure 2. Following directions supplied with saddlebags to relocate rear turn signals, but also use the following exceptions to install the parts contained in this kit: •Use turn signal studs (4) in place of hex bolts supplied with saddlebags. The longer studs are required to accommodate the rear docking points. •On each side, insert relocation pad plate (3), saddlebag mount spacer (12), rear docking point (2), and docking point spacer (11) between relocation pad (supplied with saddlebags), and fender support cover as shown. •Use 4-inch long cap screw (5) in place of hex bolts supplied with saddlebags. The longer cap screws are required to accommodate the rear docking points. •The turn signal wires should be routed under the fender support cover back to the connectors they were removed from following the directions supplied with saddlebags. 7 1 14 2 12 6 9 3 1 11 4 10 8 16 17 15 18 5 13 is03490a 1. Locknut, 5/16-18 inch (3) 2. Rear docking point 3. Relocation pad plate from saddlebag kit 4. Turn signal stud 5. Cap screw, 5/16-18 x 4 inch 6. Spacer from saddlebag kit 7. Turn signal wire 8. Fender support cover 9. Cap screw, 5/16-18 x 2-1/4 inch 10. Front docking point 11. Docking point spacer 12. Saddlebag spacer 13. Washer, 1/4 inch 14. Locknut 1/4-20 inch 15. Cap screw, 1/2-13 x 3-3/4 inch 16. Spacer 17. Saddlebag support 18. Stock washer Figure 1. Installation shown on 2000 model On 1999 and earlier models: See Figure 2. Before mounting saddlebag supports, remove acorn nut from upper shock mount, and install washer (7), and shock mount spacer (8) as shown. Tighten upper shock mount spacer to 21-35 ft-lbs (28-47 Nm). This will properly space out the saddlebags to accommodate the docking points. On 2000 models: See Figure 1. Before mounting saddlebag supports remove button screw from upper stock mounts, and proceed to Step 2.

HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.

HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

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HARLEY DAVIDSON DETACHABLE TOUR-PAK KIT FOR ELECTRA GLIDE CLASSIC INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION Install Docking Kits and License Plate Holder 1. Install Rear Detachable Docking kit. Refer to the instruction sheet provided with kit. 2. Install Touring Detachable Tour-Pak Rack. Refer to the instruction sheet provided with kit. 1 4 2 3 is03989 1. License Plate Holder 2. Red Reflector 3. Original Equipment Screws 4. Original Equipment Bottom Support Tube Figure 2. Install License Plate Holder 3. See Figure 2. Install the new license plate holder (1) to the bottom support tube (4) using screws (3) saved from prior step. 4. Remove adhesive backing from red reflector (2) and carefully center and align it with the bottom edge of the license plate holder (1) and press firmly into place. -J03930 1 of 4 MOUNTING ANTENNA RELOCATION BRACKET 1. See Figure 6. Assemble joint assembly (9) to antenna mounting bracket (6) using lock washer (5) and 2 hex nuts (4). Tighten hardware securely. 2 1 5 4 3 is03992 1. Rear Docking Point 2. Docking Point Support Bracket 3. Antenna Mounting Bracket 4. Antenna/Cable Adapter 5. Rear Docking Point Screw and Locknut Figure 3. Relocated Antenna Bracket and Cable 2. See Figure 3. Install assembled antenna bracket (3) by removing screw and locknut (5) securing left rear docking point (1) to docking support (2). Install bracket as shown and reinstall rear docking point screw and locknut. Tighten screw and locknut to 15-19 ft-lbs (20.3-25.7 Nm) . 3. Thread antenna/cable adapter (4) onto joint assembly. ROUTING ANTENNA CABLES 1. See Figure 4. Gently remove left side cover (1) by pulling from frame tubes (no tools required). 2. Connect original antenna cable (not shown) to bottom of joint assembly. 3. Route antenna cable/wiring between left frame rail and fender. 4. See Figure 5. Attach cable to docking point support bracket in location (1) using short cable strap. 5. See Figure 4. Coil excess antenna cable/wiring (2) and use long cable strap (3) to fasten cable to frame under left side cover (1) with vehicle wiring harness. 6. See Figure 6. Cap unused wiring connector with connector housing (10).

2002 URAL Classic Motorcycles BC-75 (Bavarian Classic) LC-75 (Luxury Cruiser) Tourist, Adirondac & Patro Owner's Manual

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Filed Under (Ural) by admin on 02-11-2010

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Front brake control lever (Fig.1, #5). When the lever is squeezed, the front wheel brake is actuated. The front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal lamps are switched on. Kick lever (Fig.1, #11) is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Note: this is a backup to the electric starter. Gear shift foot pedal (Fig.1, #12) is a two-arm type. When the front arm is pressed, shifting from high to lower gears takes place. When the rear arm is pressed, shifting from low to higher gears takes place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift up if you rotate the heel of your left foot in towards the rear arm before stepping on it with your heel. The neutral position is fixed between the I and II gears. Speedometer is on the dash board, with trip (Note..BC-75 has no trip odometer) and total odometer. The trip odometer is reset to zero by rotating push-button (Fig.1, # 3) counterclockwise. Note that the odometer reads in kilometers not miles. Ignition Switch (Fig.1, # 19) has three fixed positions of the key. The position and switching diagram of the ignition locks are shown above.
18 The indicator lamps are mounted on the instrument board: (Fig. 1, # 2) — turn indicator pilot lamp, (orange) (Fig. 1, # 4) — gearbox neutral and reverse gear engagement, (green) (Fig. 1, # 18) — head lamp high beam indicator, (dark blue) (Fig. 1, # 20) — alternator fault indicator lamp, (red) Note: If the red alternator fault light stays on continuously during normal operation above approximately 1500 RPM, there is a problem with the charging system or battery. Throttle Control (Fig.1, # 6) is on the right handlebar. Turning the twist grip counterclockwise increases engine speed. Ignition Cutoff Switch (Fig.1, # 7) has two positions, ignition off (up), and ignition on (down). Low and High Beam Light Switch (Fig.1, # 15), turn indicator switch (Fig.1, #13) and horn push-button (Fig.1, # 14) are combined in one unit on the left-hand handle bar control housing. Master Battery Switch (Fig.1, # 21) is under the seat. Electric Start Button (Fig. 1, # 8) is located on the right-hand twist grip, below the kill switch. The Steering Damper absorbs lateral kicks on the front wheel. Turning tightening bolt (Fig.1, # 17) clockwise increases friction. This can be used while riding over bad roads

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

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