extended forks for softail

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HARLEY DAVIDSON SOFTAIL EXTENDED REACH CONTROLS KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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PREPARE THE MOTORCYCLE 1. For models equipped with saddlebags: Remove the saddlebags following the instructions in the appropriate Service Manual. 2. Remove the seat following the directions in the Owner’s Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect the negative battery cable. 4. Secure motorcycle in upright position. NOTE This kit is not compatible with engine guards. 5. If the engine guard is present, remove and discard it. LEFT SIDE Component Removal 1 3 4 2 7 5 6 8 2 is05048 1. Pretzel clip 2. Bushing (2) 3. Screw (6) 4. Jiffy stand bracket 5. Bumper 6. Jiffy stand leg 7. Clevis pin 8. Spring Figure 1. Jiffy Stand 1 2 3 5 4 is05053 1. Jam nut 2. Shifter rod end 3. Acorn nut 4. Shifter rod 5. Shifter arm Figure 2. Shifter Linkage 1. For HDI Vehicles: Remove the left side foot control support, and jiffy stand sensor, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. For all other models: Remove the left side foot control support, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. NOTE Two bearing sleeves will remain inside the footrest bracket. The extended controls bracket from the kit will include two sleeves pressed into the bore of the shift lever arm support. 2. Remove rod ends and jam nuts from the shifter rod. Save the rod ends and jam nuts for installation. Component Installation 1. See Figure 9. Select shifter mounting assembly (6), O- rings (5), nylon washer (4) and the shift rod (1) from the kit. 2. Install the shift arm and new O-rings in the bracket. 3. Apply LOCTITE 243 Threadlocker and Sealant to the three mounting screws and mount the shifter bracket with shift arm to the frame. Tighten the mounting screws to 25-30 ft-lbs (33.9-40.7 Nm)

SUSPENSION SERVICE TOOLS/ FORK DAMPER ROD BLEED TOOL

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Filed Under (Tips and Review) by admin on 30-11-2010

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33 SHOP EQUIPMENT & TOOLS SUSPENSION SERVICE TOOLS K&L FORK TUBE U-BLOCKS Precision machined from billet aluminum, these quality three piece sets are a handy, accurate and safe way to straighten and check fork tubes. 35-9411 36mm (for 33 thru 36mm tubes) 35-9412 40mm (for 37 thru 40mm tubes) 35-9413 43mm (for 41 thru 43mm tubes) 35-9414 46mm (for 44 thru 46mm tubes) 35-1964 35-8579 35-7995 DAMPER ROD HOLDERS Holds damper rod when disassembling forks. 35-8578 Yamaha front forks, 43mm Kayaba YZ125/250 (1988) YZ490 (88-90) 35-8579 Yamaha YZ125/250 with UD(upside down) forks FORK DAMPER ROD TOOLS Sold each. 35-7995 Combination Fork Damper Tool Designed to hold the damper rod during assembly & disassembly of Honda XR400′s or Suzuki DR-Z400S. One end features spanner type prongs for the XR400 and the other a 27mm hex for Suzuki. 35-1964 Combination Damper Rod Fork Tool Designed for assembly and disassembly of most inverted Kayaba and Showa 41mm, 43mm, 46, and 47mm forks. Use one end for Kayaba forks and the other for Showa forks. (not required for 91-92 Honda CR models) ROD HOLDER Double sided damper rod holder. Works on Kayaba U.D (upside down) 41mm forks. 35-8580 Yamaha YZ125/250Amodels (89-90) FRONT FORK CAP SOCKET Designed to remove and install Yamaha front fork caps with female hex head. Sold each. 35-8571 14mm female socket 35-8573 19mm female socket FORK DAMPER ROD HOLDERS Holds damper rod when disassembling and assembling front forks. 35-8576 Use for Yamaha 43mm Kayaba forks, 30mm hex YZ125 (84-87), YZ250 (81-87) IT250 (1983) YZ490 (82-87) 35-8577 Use for Yamaha 38mm Kayaba forks, 24mm hex YZ125 (81-83), IT175 (82-83), IT250 (81-82) YZ250 (77-80), YZ400 (77-79), IT465 (81-82) FORK CAP WRENCH Designed to remove the front fork caps on late model Honda CR’s and Suzuki RM’s. Can also be used for adjusting compression. One end of wrench is 49mm, the other is 50mm. Sold each. 35-7803 Fork Cap Wrench 35-8576 35-8577 35-8571 35-8573 6 Point Hex 35-8578

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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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HARLEY DAVIDSON FL SOFTAIL PROFILE LOW FRONT SUSPENSION KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-11-2010

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Fork Spring Removal 1. Elevate and support the vehicle so the front tire is off the floor and the forks are fully extended. 4 9 3 1 10 11 2 5 6 7 8 is04004 1. Slider tube cap 2. Spacer washer 3. Oil seal 4. Clamp bolt and washer 5. Fork tube plug 6. O-ring 7. Fork spring 8. Tight-wound end of spring 9. Fork slider tube 10. Fork slider 11. Drain screw and washer Figure 1. Front Fork NOTE Remove the brake caliper from the fork slider. DO NOT remove the brake line from the caliper. 2. Remove the front wheel. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. 3. Remove the front fender. See FRONT FENDER in the Service Manual. 4. See Figure 1. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side. Save the cap and spacer. The oil seal can be discarded. 5. Loosen the clamp bolt (4) and pull the fork from the brackets. 6. Repeat Steps 4 and 5 for the other fork side. -J00280 1 of 4 Wear saf ety glasses or gog gles when ser vicing f ork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) NOTE Be careful not to damage the O-ring. 7. See Figure 1. Remove the fork tube plug (5) and O-ring (6). Pull the spring (7) out of the slider tube (9). Remove the drain screw and washer (11), and drain the fork. Reinstall the drain screw and washer, and tighten to 52-78 in-lbs (5.9-8.9 Nm). 8. Repeat Step 7 for the other fork side. NOTE The Profile® Low Front Suspension Kit requires a different amount of H-D TYPE E FORK OIL than is listed in the Service Manual. NOTE Measure the oil level from the top of the fork tube with the fork spring removed and the fork fully compressed. 9. See FRONT FORK OIL in the Service Manual, but substitute the measures below. Fill the forks with Harley- Davidson TYPE E FORK OIL: • 1986 through 1999 models: •11.7 oz (345 cc) of oil, or •5.2 inch (132 mm) from top of oil level to top of tube. • 2000 and later models: •13.4 oz (396 cc) of oil, or •4.1 inch (104 mm) from top of oil level to top of tube. Fork Spring Installation 1. Insert a new Profile Low spring (7) from the kit into each slider tube (9), with the tight-wound portion (8) toward the bottom of the fork slider. NOTE Be careful not to damage the O-ring. 2. Install the fork tube plug (5) and O-ring (6) assembly into the slider tube and tighten securely. Be sure that one flat on each fork tube plug faces toward the inside of the fork. 3. Insert both fork side assemblies up through the slider covers, the fork stem and bracket, and the upper bracket. 4. Obtain two new oil seals (3), H-D Part Number 45733-48, and the spacer washers (2) and slider tube caps (1) saved earlier. Place an oil seal, followed by a spacer washer, onto each fork tube plug. 5. Insert the threads of a slider tube cap through each washer and seal, and into the fork tube plugs. Tighten to 40-60 ft- lbs (54.2-81.3 Nm). 6. Tighten the fork stem bracket clamp bolts (4) to 30-35 ft- lbs (40.7-47.5 Nm). 7. Install the front fender. See FRONT FENDER in the Service Manual. Install the front wheel and brake caliper. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. Jiffy Stand Removal/Installation 1. Move the jiffy stand to the retracted (up) position. Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c) 2. See Figure 3. Unfasten the jiffy stand leg spring (A) from the vehicle. Remove the hex bolt (B), lock washer (C), flat washer (D) and leg stop (E) from the threaded end of the jiffy stand leg. Discard the jiffy stand leg, but retain all other components. 3. Clean and inspect the jiffy stand attaching parts and mounting bracket for wear or damage. If parts replacement is necessary, refer to the Jiffy Stand section of your Service Manual for replacement procedures

HARLEY DAVIDSON CHROME FORK SLIDERS REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVAL 1. Support the motorcycle so the front end is off the floor and the forks are fully extended. 2. Remove the front fender, front brake caliper(s) and front wheel according to instructions found in the Chassis section of the appropriate service manual. NOTE On some models other parts will also need to be removed to access the front forks. See the service manual. 3. For All Models EXCEPT Touring: Drain and remove the front forks. See the service manual. 4. For Touring models equipped with air-adjustable suspension: Bleed the air-adjustable suspension according to the instructions in the appropriate service manual. Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) 5. For 2000 and Later Models EXCEPT Touring: See Figure 1. Using a piece of dental floss (or similar material) in a back and forth motion, loosen reflector from fork slider at both ends. Rotate reflector from side-to-side until it can be removed. Save reflector for future use. See Figure 2. Repeat procedure on the opposite side fork slider. Peel off any excess adhesive from both reflectors . Surface must be clean for installation. 6. Disassemble the front fork tubes according to instructions in the service manual. INSTALLATION NOTES The chrome fork sliders included in this kit install in the same manner as the original equipment parts. Refer to the service manual for proper installation procedures. Prior to installation of this kit, check the bores of the new chrome sliders to be certain they are free of dirt and debris or damage to the new sliders may occur. 1. Assemble the front fork tubes, replacing worn seals, bushings or other items as needed. NOTE Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws. 2. Tighten the drain screws: •Early Models with 39 mm forks (see Figure 2): Tighten to 13-17 in-lbs (1.5-1.9 Nm) •Early Models with 41 mm forks (see Figure 2): Tighten to 52-78 in-lbs (5.8-8.8 Nm) •Later Models (see Figure 3): Tighten to 52-78 in-lbs (5.8- 8.8 Nm) 3. Fill with TYPE E FORK OIL (99884-80) according to the instructions in the service manual. 4. Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel and caliper(s) according to instructions in the service manual. 5. For Touring models equipped with air-adjustable suspension: Refill the air-adjustable suspension system after assembly according to the service manual instruc- tions

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HARLEY-DAVIDSON SPRINGER FORKS MOUNTING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-04-2012

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1. The shock mounts with the body up —shaft pointing down. The nitrogen fill valve can be positioned toward the rear of the motorcycle. 2. Make sure that both halves of the upper and lower bushings are in place. NOTE: Do not try to install the shock with only half of the bushings, as this will lead to poor performance and premature seal leakage. The amount of “float” in the bushing set is necessary to ensure smooth operation of the damper assembly. 3. It is easiest to install the shock when the forks are fully extended, however the shock can be installed with the bike on the kick stand. 4. Insert the body eye into the mounting channel on the fork crown. Rotate the shock down into the lower channel. NOTE: A thread locking compound such as Red Loctite 262 or other similar product should be used on the shock fasteners. 5. Install the upper mounting stud and nuts, finger tight. 6. Push the shaft up far enough to insert the lower mounting stud and nuts. This will take a little effort because of the gas pressure in the shock. 7. Torque the upper and lower shock mount nuts to 22 ft. lb.

DUCATI TITANIUM EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Ducati) by admin on 26-10-2010

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BILLET BRAKE RADIAL MOUNTS Moto Corse brake radial mounts are crafted by precision machine tools as shown, the caliper mount is “box” type precision tooled from single ERGAL 7075 solid piece. The result: performance, reduced weight, quality and beauty unmatched by none used extensively in moto gp as standard technology Moto Corse delivers moto gp technology for the ultimate performance. The kit is available for caliper with bolt distance 108mm or 100mm and includes all the parts to assemble it on the bike. 102143002 102143003 102143005 102143006 102143008 102143009 102143011 raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM Ducati 999s/999r/749r Ducati 748r/996sps/996r/998r/998 eF Ducati 748r/996sps/996r/998r/998 eF Ducati 999s/999r/749/r Ducati 749/749s/999 748/998 – MOnster 1000/s4/s2r Ducati MultistraDa 1000D

DETACHABLE KING SIZE WINDSHIELD FOR SOFTAIL MODELS WITH CHROME HEADLAMP NACELLE OR STREET STALKER HEADLAMP NACELLE (WITHOUT PASSING LAMPS)

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

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Installation 1. Remove upper screws that attach the chrome headlamp nacelle to the front forks. 2. See Service Parts illustration. Attach the upper docking bushings (22) using washer (21) and mushroom head screws (20) Use Loctite 242 (blue) on screw threads. Torque screws to 19 ft-lbs (25.8 Nm). 3. Remove lower screws that attach the chrome headlamp nacelle to the front forks. 4a. For vehicles equipped with the Chrome Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (23). 4b. For vehicles equipped with the Street Stalker Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (24). Installing/Removing Windshield 1. Carefully lock bottom windshield assembly jaws into grooves of the lower rubber docking bushings. 2. Hook the top windshield assembly jaws into grooves of the upper rubber docking bushings. 3. Firmly press the windshield into place until seated on docking bushings. 4. To remove windshield, grab windshield edges on each side of center brace and firmly pull windshield loose from docking bushings. 1 WARNING Carefully inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. Restricted movement could affect handling, resulting in personal injury. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. 1 CAUTION Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of either or both. 1 CAUTION Do not clean Lexan®polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result. Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan®. Lexan®is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. • Do not use liquid windshield “protectors” on your windshield. Although they may work well on automobile safety glass, Harley-Davidson cannot ensure the results when used on Lexan®Harley- Davidson windshields. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant®. • Do not use benzine, paint thinner, gasoline, or other types of harsh cleaning agents on windshield. They will damage the windshield surface. • Do not use benzine, paint thinner, gasoline, lubricants (including Armorall), or other cleaning agents on the rubber bushings. They will damage the bushing surfaces

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HARLEY DAVIDSON FX SOFTAIL FRONT LOWERING SUSPENSION KIT INSTALLATION MANUAL

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

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REMOVAL 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to the appropriate Service Manual and remove the front forks. 3. Move forks to bench area. Place suitable drain pan on floor beneath a vise. INSTALLATION Fork Disassembly 1. See Figure 6. Remove nuts (T), lockwashers (S), flat washers (R) and axle cap from studs at end of fork slider. 2. See Figure 1. Obtain FORK TUBE HOLDER (HD-41177) and proceed as follows: a. Clamp end of tool in vise (1) in a horizontal position with plastic knobs facing toward you. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 6 for Steps 3-17. 3. Remove fork cap bolt (A) and spacer (O) from fork tube plug (B). Remove quad ring seal (D). Save bolt and spacer but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug (B) from fork tube (G). Be aware that fork tube plug is under spring -J03923 1 of 4 pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring (1) from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove screw and washer (Q) from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring (1). 11. Remove dust cover (E). 12. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 13. Remove fork tube (G) from fork slider. Slide fork tube gently in a slide hammer motion against the slider to remove the seals and bushing from slider. 14. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). NOTE The lower stop (L) may come out with the damper tube or remain in the slider tube. Ensure that the lower stop is removed from the slider tube. 15. Remove the lower stop (L). 16. Remove damper tube (2) from fork tube. 17. Remove rebound spring (F) from damper tube. 18. Repeat Steps 1-17 for the opposite side fork assembly. Fork Assembly

Harley Davidson Softail Motorcycles EZ-Steer Installation Manual

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

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Softail EZ-Steer Instruction Supplement Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Harley Davidson Softail Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Installation Notes • Note the torque specifications for the items listed below. Item # Description (Qty) Torque Spec. (Lb.Ft.) N/A OEM Steering Stem Bolt (1) 35 7 7/16-20 x 1.5 Socket Head Cap Screw (2) 45 • The supplied fork tube extensions (Item #2) must be used with the Champion EZ-Steer system. • Do not torque the steering stem bolt until fork tubes have been installed to the assembly. • Remove O-rings from OEM fork tube ends and install to Champion fork tube extensions (Item #2) prior to installation onto fork tubes. • The supplied fork tube covers (Item #9) must be installed to lower triple clamp prior to installation of fork tubes. WARNING: If the Champion EZ-Steer system is installed on a motorcycle / sidecar combination and the sidecar is removed, the motorcycle is not safe to ride, and OEM triple clamps should be replaced.