exchange lifters on 1986 harley davidson sportster 1100

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HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (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 (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. 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. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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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 DYNA AND SPORTSTER Chrome Front Wheel Spacers INSTALLATION ISNTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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HARLEY DAVIDSON CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT INSTALLATION MANUAL

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

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CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT GENERAL Kit Number 56032-08 Models For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only). This kit does not fit models equipped with a hydraulic clutch, handlebar mounted gauges or the Road Tech® Radio. Additional Parts or Accessories Required Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on this model motorcycle. Please see the P&A retail catalog or the Parts and Accessories section of for a list of required parts or accessories for this model. For Australia, Brazil, England, Europe and Japan, two special screws (Part Number 2935A) will also be required. Tools and Supplies Required Loctite® 271 Threadlocker and Sealant – Red (H-D Part Number 99671-97) is required for the proper installation of this kit. Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed. Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) For models that retain the original brake line, the two brake- line gaskets found at each banjo fitting must be replaced . Refer to the appropriate parts catalog or see a Harley-Davidson dealer for the correct part numbers. Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the parts catalog for replacement stock hand grips. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available. 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 this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 6 and Table 1. INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills)

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HARLEY DAVIDSON SECURITY SYSTEM KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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FL Touring models equipped with a TLE/ TLE Ultra Sidecar will require the additional installation of a Bank Angle Switch Kit (88115-03) and is available for separate purchase. See a Harley-Davidson dealer.INSTALLATION 1. Remove the original equipment (OE) Turn Signal Module (TSM) or Body Control Module (BCM) following the instructions in the service manual. 2. Install the Bank Angle Sensor (BAS) on sidecar vehicles. 3. Install the new turn signal/security module (TSSM) (7), Hands Free Security Module (HFSM) (1) or BCM (9, 11) from this kit, following the instructions in the service manual. Configure the Trike or sidecar TSSM, HFSM or BCM to “Side Car Enabled” using Digital Technician. 4. Install the Hands Free Security Module (HFSM) Antenna and antenna mount (6) if necessary, using the service manual instructions. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) ACTUATION 1. See a Harley-Davidson dealer to activate the key fob to the TSSM, HFSM or BCM. NOTE You can activate the TSSM fob by referring to the procedure in the electrical diagnostic manual. TRIKE AND SIDECAR CONFIGURATION (FL TOURING MODELS ONLY) Only Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a) NOTES FL Touring Models equipped with TLE/TLE-Ultra Sidecar require the installation of a Bank Angle Sensor (88115-03). Failure to install and configure a Bank Angle Sensor may result in death or serious injury. Sidecar and Trike configuration of the security system requires the use of a Digital Technician. Consult your Harley-Davidson dealer or the sidecar or Trike service manual for complete details. On vehicles equipped with a sidecar, the security system must be reconfigured from the default solo vehicle setting to the sidecar setting

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HARLEY DAVIDSON SPORTSTER LOW REAR SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION NOTE Internal shock absorber components are not repairable beyond the Service Parts listed on this instruction sheet. Consult your Harley-Davidson dealer if further service is required. The installation procedures for this kit are the same as the original equipment (OE) installation procedures in the Service Manual. Refer to the appropriate Service Manual for the rear suspension system removal and installation procedures. The OE hardware will be re-used in the kit installation. 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) SHOCK PRELOAD (SPRING) ADJUSTMENT Refer to the appropriate Service Manual for spring adjustment. Spanner wrench (94700-52L) is required for spring adjustment. SERVICE PARTS 1 is04854 Figure 1. Service Parts: Sportster Low Rear Suspension Kit Table 1. Service Parts: Sportster Low Rear Suspension Kit Part Number Description (Quantity) Item 54734-04 Rear shock (2)

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Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. A Service Manual is needed to install this kit. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation of this kit could result in death or serious injury. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

HARLEY DAVIDSON 80-SPOKE REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Additional Parts Required This kit includes the custom wheel only. Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley-Davidson dealer: •Wheel Bearing Remover and Installer (HD-44060) •Wheel Installation Kit (See Service Parts Tables for part number) The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning: •Harley® Bright™ Chrome Cleaner (94683-99) •Harley® Glaze™ Polish and Sealant (99701-84) •Harley®Wheel and Spoke Brush (43078-99) •Harley-Davidson®Wheel and Tire Cleaner (94658-98) 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 the Service Parts section for kit contents. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. NOTE Remove the rear brake caliper before removing the wheel. 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. Install the tube and tire on wheel. Refer to REAR WHEEL in the Service manual. 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) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. 4. Install rear wheel (1), stock axle and stock axle nut. Refer to REAR WHEEL in Service Manual

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REKLUSE MOTOR SPORTS Pro Start Clutch Harley-Davidson OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 24-11-2010

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REAK-IN PERIOD The ProStart clutch requires a short break-in period. During the break-in period, the ProStart should not be operated at steady engine speeds above 3000 RPMs for more than 10 minutes. Breaking-in the ProStart clutch equires start and stop cycles. Riding the ProStart clutch in stop-and-go city traffic for one hour will provide sufficient break-in. If you would like to accelerate the break-in period, find an empty parking lot with ample room and no other traffic. From a stop, bring the motorcycle to 20 miles per hour and then back to a stop. Repeat this process at least 20 times. MAINTENANCE Proper maintenance is important to ensure the longevity of the Rekluse ProStart clutch and the rest of the stock clutch components in your Harley- Davidson Motorcycle. Refer to your owner’s manual for proper primary chaincase oil levels and oil type. Rekluse recommends the use of Harley- Davidson Primary Chaincase lubricant with the Rekluse ProStart clutch. Do not use oils designed for use as automotive engine oil in your Primary Chaincase. If Harley-Davidson Primary Chaincase lubricant is not readily available, a premium-quality Diesel engine oil, such as Shell Rotella T, that does not contain friction modifiers may be substituted. Inspection and adjustment of the Rekluse ProStart clutch should only be performed by a service center trained in Harley-Davidson and Rekluse ProStart repair and maintenance. The Rekluse ProStart clutch should be inspected for adjustment after 1,000 miles of operation. Thereafter, inspection for adjustment should be performed at 5,000 mile intervals

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