harley automatic compression release problems

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HARLEY DAVIDSON AUTOMATIC COMPRESSION RELEASE TOOLS INSTALLATION MANUAL

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

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INSTALLATION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) 4 3 6 5 6 1 2 7 is05443 1. Drill, 1.250 inch 2. Drill stop collar, 1.250 inch 3. Drill stop gauge 4. Socket head screw, 5/16 inch 5. Socket head screw, 1/4 inch 6. Dowel pin 7. Top plate Figure 1. Top Plate and Drill Bit Stop Collar Installation 1. Remove valves from cylinder heads. NOTE Do not allow the threaded studs to damage the gasket sealing surface of the cylinder head. 2. See Figure 7 and Table 1. Mount a cylinder head to the tooling plate (1). 3. Place a head bolt spacer (7) over each stock head bolt and lubricate threads and thrust faces, dowels and studs. Tighten head bolts in a crisscross pattern to 10 ft-lbs (13.5 Nm) . 4. See Figure 1. Align the top plate (7) bolt and dowel holes with the head hole pattern, Screamin’ Eagle logo towards the spark plug. This plate will only fit one way for the cylinder head it is being installed on. If the plate does not align with the head, turn it over keeping the logo towards the spark plug and install the cylinder head. 5. Lubricate the two dowel pins (6) and insert in the top plate and into the cylinder head. 6. Apply lubricant to the two socket head screws (4 and 5). Insert into their respective holes in the plate to the cylinder head and tighten to 5 ft-lbs (6.8 Nm)

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HARLEY DAVIDSON SCREAMIN' EAGLE MECHANICAL COMPRESSION RELEASE FIX- TURE

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Filed Under (Harley Davidson) by admin on 04-02-2011

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DRILLING AND TAPPING PROCEDURE Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) NOTE Perform the following procedure on both the front and rear cylinder heads. Tool Setup NOTE Due to slight manufacturing differences, it may be necessary to tap the fixture into place with a rubber mallet. Do NOT use excessive force. 1. Align the fixture’s locating pins with the 3/8 inch tooling holes in the head and install the fixture on the head. 2. See Figure 1 and Figure 6. Secure the fixture (1) to the head with two 5/16-18 socket head cap screws (2) and washers (9) included in the kit. Install the screws in the holes marked “F” when modifying the front head or in the holes marked “R” when modifying the rear head. Tighten screws to 80 in-lbs (9 Nm) . 3. See Figure 3 and Figure 6. Install the drill bushing (3) in the bore marked “FRONT” when modifying the front head or in the bore marked “REAR” when modifying the rear head. 4. Tighten drill bushing set screw to 50 in-lbs (5.6 Nm) . 5. See Figure 2 and Figure 6. Install collar stop (4) onto the 1/2 inch diameter shank of the step drill bit (5). Secure the collar stop with the set screw 3.900 inches (9.90 cm) from the beginning of the 3/4 inch diameter step of the drill bi

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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.

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HARLEY DAVIDSON QUICK RELEASE DETACHABLE WINDSHIELD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation 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 a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) NOTE Cover the front fender, headlamp and the front of the fuel tank with clean shop towels to prevent scratching. Make sure the windshield assembly does not contact chrome or painted parts. Damage to the finish could result. Turn Signal Relocation Relocate the turn signals according to instructions included in the Turn Signal Relocation Kit, item 20. Assemble the Clamps to the Windshield 1. See Figure 1. Remove the windshield sub-assembly from the packaging and place face down on a clean, soft surface with the mount brackets facing upward. 2. See the Service Parts illustration. Remove both the clamp and hardware kits from the packaging, and separate similar parts in preparation for assembly. Note that upper and lower clamps are exactly alike. 3. See Figure 2. Assemble the clamp assemblies and hardware stacks. The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce the windshield’s ability to break away in a collision, which could result in death or serious injury. 4. See Figure 2. One clamp at a time, with the clamp facing upward and inboard of the windshield bracket (2), tighten the shoulder bolts (1) enough to hold the clamp orientation to the windshield during mounting of the windshield to the bike. The bolts will be fully tightened later. Install the Windshield NOTE Keep front wheel straight to prevent brackets from scratching fuel tank. 1. Make sure all four clamps are in the “open” position, then bring the windshield (with the clamp side away from you) to the front of the bike. 1 WARNING 1 WARNING ® Kit Numbers 58779-05, 57160-05 1 of 3 Figure 1. Windshield Mounting Brackets i07503 Figure 2. Windshield MountingClamp i07504 1 Shoulder bolt 2 Right windshield bracket 3 Cup washer 4 Belleville washers (cupped sides face each other with windshield bracket between)

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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 AUTOMATIC PRIMARY CHAIN TENSIONER INSTALLATION INSTRUCTIONS

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

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1. Refer to the appropriate Service Manual and remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect negative (-) battery cable. 3. Refer to the appropriate Service Manual and remove primary cover. 3 1 2 5 4 is00561 1. Screw (2) 2. Anchor plate 3. Nut and washer 4. Manual tensioner 5. Screw (2) Figure 1. Manual Tensioner: 1985-2000 Models 4. For 1985-2000 model motorcycles, remove manual tensioner and replace the carriage bolt as follows: a. See Figure 1. Remove two screws (5) and nut and washer (3), and remove chain tensioner (4). b. Remove two screws (1) and anchor plate (2). c. Replace the carriage bolt in the anchor plate with the carriage bolt from the kit. d. Apply 2-3 drops of Loctite 262 (red) to the threads of the anchor plate mounting screws (1), then install anchor plate and two screws. Tighten screws to 12- 14 ft-lbs (16-19 Nm) . For 2001 and later model motorcycles, remove manual tensioner as follows: a. See Figure 2. Remove nut and washer (1) and remove chain tensioner (2) Removing the Autotensioner for Service 1. Use a tie wrap and secure the shoe to the base of the autotensioner, without securing it to the autotensioner bracket. This will retain the autotensioner adjustment for reinstallation during service. 2. Remove two autotensioner hex screws, and autotensioner. Resetting the Autotensioner 1. See Figure 5. Compress autotensioner wedge (1) and spring back to the base. 2. Hold wedge in position by inserting a hex wrench or pick tool through the hole in the base of the autotensioner. 3. See Figure 6. Move plastic autotensioner shoe (1) into place as shown. 4. If available, install shipping plate (2) to secure the shoe to the base. If it is not available, secure the shoe to the base with a tie wrap

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Harley Davidson Steering Wheel Radio Control Interface Installation instructions

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Filed Under (Harley Davidson) by admin on 03-05-2012

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1) Turn on the ignition to supply power to the SWI-3. 2) Use a pen to depress the “program mode” button. Remove pen when left LED light comes on. 3) Within 10 seconds press and hold one of the steering wheel function buttons. Continue to hold steering wheel button until the left LED turns off. Release the steering wheel button and the right LED turns on. 4) Place the stereo’s IR remote within 3″ of the “IR Input” port on the side of the SWI-3 next to the program button. Press and hold the remote’s button that corresponds to the steering wheel button that was pressed. Continue to hold the remote’s button until the right LED turns off. Release the button and the left LED will turn on. 5) Repeat steps 3 and 4 until all radio steering wheel functions are programmed. 6) When programming is complete, wait 10 seconds and both LED’s will flash 3 times. This indicates an automatic program exit. Do not stop more than 10 seconds while programming or there will be an automatic program exit and you will have to start over at step number 2 above. Turning off ignition before the automatic exit will require starting over at step 2 above. The SWI-3 can be reprogrammed unlimited times. Testing • Test the SWI-3 by holding it’s infrared LED (LED on the end of 4′ lead) close to the stereo and verify that it works properly. Experiment with various locations for the LED. You should be able to find a hidden and convenient mounting location. Try along the top front and /or bottom of the stereo as well as it’s sides. The LED can be replaced with most any IR LED, like Radio Shack’s # 276-143. The longest lead of the LED connects to the red wire of the 4′ cable and the short lead of the LED connects to the black wire of the 4′ cable

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HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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HARLEY-DAVIDSON MOTORCYCLE WASH KIT MANUAL

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

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THE WASHING PROCESS Allow the motorcycle to cool to the touch. Cool water can damage a hot motorcycle. 1. Pre-Wash: a. Verify the motorcycle is cool to the touch. b. Rinse the motorcycle from the bottom up. c. Verify you have the proper cleaning supplies. d. Spray on Bug Remover and let the product activate while proceeding to the next step. 2. Wheels and Tires: a. Rinse wheel and tire surfaces. b. Apply Wheel and Tire Cleaner. c. Wait one minute after spraying product. d. Clean wheel with a Soft Detailing Pad or Wheel and Spoke Brush. e. Rinse well. 3. The Wash: a. Have two buckets; one for the cleaner and one for rinsing. b. Pour Sunwash into the Harley-Davidson Cleaning Bucket and fill with water. c. Fill the rinsing bucket with clean, plain water. d. Soak the Wash Mitt in the Sunwash solution. e. Wash all surfaces from the top working down. f. Rinse from the bottom up first. g. End with top down rinse. 4. Drying the Motorcycle: a. Use the Soft Drying Towel to dry surfaces of the motorcycle. b. Dampen the towel in clean water. c. Wring out the towel as often as needed and continue until the surface is completely dry. 5. The Polish and Seal : (not applicable for denim paint finishes) Polishing and sealing isn’t just about good looks . A well cared-for motorcycle repels dust, dirt, bugs and dirty water. a. Use Harley Glaze polish and sealant and follow the instructions on the bottle. b. Use Softcloth disposable towels for application. c. A Softcloth or Microfiber detailing cloth is an absolute must for finish buffing. d. In between Harley Glaze applications, use Harley Spray Cleaner and Polish and Harley Gloss to maintain shine and protection of painted and chrome fin- ishes.

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