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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)

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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

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

Harley Davidson Softails Shocks Installation download

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

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Progressive Suspension shocks for your Softail are designed as a direct bolt on replacement for your stockers. Although they are very similar in appearance, they have vastly improved damping and spring rates. Our shocks do not use the remote reservoir system used on earlier model Softail models. 1. Place motorcycle securely on stand or blocks so the rear wheel is slightly off the ground. 2. Per instructions in a authorized shop manual, remove your old shocks. Note location of the mounting hardware. 3. Install the Progressive Suspension shocks using the stock mounting bolts and washers. 4. Tighten all shock mounting bolts to the proper torque specifications (see shop manual for specs) 5. Progressive Suspension shocks have adjustable pre-load to compensate for varying weights. The included wrench or a Harley Davidson pre-load adjustment wrench is necessary to adjust the pre-load setting. Replacement Progressive Suspension, Inc. wrenches are available as Part # SW-784 from most Dealers and Accessory Stores and the Harley Davidson wrench is available as part #94455-89 from any Harley Davidson Dealer. Spring preload is set by us to the lightest setting. To increase preload for heavier riders/loads/passengers, loosen locknut with the inside portion of the supplied wrench or a 1 1/ 16 ” wrench and back it off several turns. Use the supplied wrench or a Harley adjustment wrench to turn the adjustment nut counterclockwise to the desired preload setting. Then tighten the 11/ 16 ” lock nut. Both shocks must be adjusted to the same, equal setting

HARLEY DAVIDSON ADVANCED AUDIO HANDS FREE PHONE INTERFACE KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 12-04-2011

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The Hands Free interface module in this kit requires proximity to a BluetoothTM-enabled cellular phone in order to function. The phone must be a model that is compatible with the interface module (go to to view the compatibility chart), and must be paired to the interface module according to the instructions included with the cell phone. NOTE The cell phone MUST be available to the installer in the final steps of the installation (prior to re-installation of the outer fairing) in order to program and test the hands free functions. To avoid unnecessary delays, please take this into consideration when scheduling the installation. FLHT models will require prior installation of an Advanced Audio AM/ FM/ CD Radio Kit (Part Number 76412-06) and a Tour-Pak Mount AM/ FM Antenna Kit (Part Number 76317-06). FLHT, FLHX and FLTR models will require the prior installation of a Tour Pak®. See a Harley-Davidson dealer for avail- ability of color-matched King or Chopped Tour-Paks to match your vehicle, and additional items that may be required when mounting the Tour-Pak to your model. Unless one has already been fitted as part of another Advanced Audio kit installation: FLHTCU models will require the additional purchase of an Ultra Overlay Harness (Part Number 70164-06). FLHT, FLHTC and FLHX models will require the separate purchase of a Communication Switch Kit (Part Number 77173- 06). FLHX models will require the separate purchase of: •a fuel tank console (Part Number 61270-98A), •a console extension (Part Number 52447-96), •a rubber molding (71294-89), •a 1/4-20 clip nut (Part Number 7964), •a button-head screw (Part Number 3652), •a plastic wire clip (Part Number 10120), and •an adhesive-backed metal wire clip (Part Number 10103). FLTR models will require the separate purchase of: •a Console Pod Assembly (Part Number 77136-03), and •three pan-head screws (Part Number 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 (Part Number 70169-06), and EITHER : •a Premium Stereo Helmet Headset (Part Number 77147- 98) OR a Hand-Held CB Microphone Kit (Part Number 76312-98

Harley-Davidson FLH Series 2008 and Down, Independent Suspension Trike Conversion Installation Manual

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Filed Under (Harley Davidson) by admin on 07-03-2012

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Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported. b. Make sure the engine is turned off and battery disconnected before you begin work.  Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine.  Burns from hot parts: Let the engine and exhaust system cool before working on those areas.  Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts. c. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries. d. Use only nonflammable solvent, not gasoline, to clean parts e. Never drain or store gasoline in an open container. f. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts. 1.5 Specifications Overall Length: 103″ Overall Width: 57.25″ Wheel Base: 53″ Load Capacity: 600 Lb Tire Size (15″): 205 / 70 / R15 Wheel Size (15″) (4 lug) Offset +35 mm 15x7JJ 4 on 4.5 Tire Pressure: 24-26 PSI Suspension: Double A-arm Independent Rear Differential: Custom-built rear differential utilizing OEM drive belt. Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 5.75 cubic feet. Two full-face helmets and additional storage.
Harley-Davidson® FLH 2008 & Down Independent Suspension CHAMPION TRIKES Installation Guide Page 6 of 20 Revision 4 2 Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted.  Seat – to be re-installed; without modification.  Left and right side covers – to be re-installed after modification.  Tour Box – to be re-installed (if so equipped).  Left and right saddle bags (if so equipped).  Left and right rear crash bars, saddlebag rails (if so equipped).  Tour Box mounting frame (if so equipped).  Left and right passenger foot rests – to be re-installed without modification.  Left and right mufflers  Rear wheel NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake Caliper is removed.  Remove Rear Caliper (disconnect brake line at Caliper). NOTE: Cap line to prevent introduction of dust / debris into line. Remove Caliper

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