harley davidson 1999 wide glide spark plug gap

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SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings 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. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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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 1984 – 1999 Evo/ 5-Speed & 1999 – 2004 Twin Cam Transmissions Installation Instructions

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

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Illustrated Parts List Main Shaft Gear (Small Gear) (1) Special Tools (1 set): • 3/4″ Socket Adapter • Ring-Seat Tool • Spring Tapered Split Ring (2) Counter Shaft Gear (Large Gear) (1) Trap Door Gasket (1) Trap Door (1) .010 Shim /Spacer (20) Delrin Crush Washer (2) Wavy Washer (2) Bearing Lock Nut (2) Nylon Set Screws (4+1 spare) Trap Door Cover Gasket (1) * Not illustrated : Champion Super-lock compound : 0-ring for clutch cable (if needed) : .010″ feeler gauge (3/16″ wide) : Scotch Brite Pad

Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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HARLEY-DAVIDSON 5 Speed Transmissions 1984 – 1999 EVO / 5 Speed & 1999 – 2006 Twin Cam Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-11-2010

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Remove Original Parts From Vehicle. 2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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HARLEY DAVIDSON SOFTAIL SADDLEBAG KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTES Maximum saddlebag weight capacity is 7 lbs (3.18 kg) for each bag. Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. 2000-2002 Models with Wide Tire Kit 1. See Figure 1. Remove and discard stock screws (1) and washers (2) from fender support. Button head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b) 2. See Table 3. Determine appropriate screw from wide tire kit. 3. See Figure 2. Install saddlebag using screw (from wide tire kit) (1), washer (2) and nut (3). The screws are installed from inside to outside of fender. NOTE If you do not have the appropriate screw from the wide tire kit, it can be purchased from a Harley-Davidson dealer. Table 3. Wide Tire Kit Screws (3/8-16) Wide Tire Kit 44490-00, Hardware Kit 43763-00 Wide Tire Kit 44490-00, Hardware Kit 43761-00 Part Number and Length X X 4030 – 2-1/2 inch X X 4225 – 3-1/2 inch X X 4224 – 1-1/2 inch X X 4044 – 1-1/4 inch X 4215 – 2 inch X 3912 – 2-3/4 inch X X 4228 – 2-1/4 inch X X 4229 – 3-1/4 inch Failure to tighten saddlebag mounting bolts to specified torque could result in damage to saddlebags. (00406c) 4. Tighten all saddlebag hardware to 22 ft-lbs (30 Nm). NOTE Check that front screws have at least one thread exposed beyond the nut after proper torque has been applied. 5. Install reflectors on saddlebag. Refer to Install Reflectors subtopic.

Harley-Davidson Electronic Fuel Injection Tuner INSTALLATION Manual

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Filed Under (Harley Davidson) by admin on 14-04-2012

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Harley-Davidson Electronic Sequential Port Fuel Injection System, (ESPFI) This completely new engine management system was released starting with select 2001 model year Softail motorcycles. This system is a speed/density, open loop, sequential port fuel injection design that also controls spark timing and spark intensity. Speed/Density System – When the ECM monitors manifold air pressure, air temperature, throttle position and engine rpm to manage fuel delivery. Open Loop Control – When the ECM monitors sensors positioned on the intake side of the engine and does not monitor the end result of internal combustion at the exhaust. Sequential Port Fuel Injection – When the injector nozzle is positioned in the manifold near the intake valve and is precisely timed to deliver fuel to each cylinder. This ESPFI system is the exclusive design used on 2001 and Later EFI-equipped Softail models, 2002 and Later EFI-equipped Touring models, 2004 and Later Dyna models, and 2004 and later V-Rod models. Current ESPFI Components The following is a list of the major components of Harley-Davidson’s current ESPFI system. It is important to have an understanding of what these components do before learning how the ESPFI system functions. Refer to the appropriate Harley-Davidson Service Manual for the vehicle you are working on for additional information on component design and function and for the physical location and testing procedures for each individual component. ECM – Electronic Control Module – this is the brain of the system that collects input signals from multiple sensors, makes decisions and sends output signals to deliver fuel and spark to the engine. CKP – Crank Position Sensor – this sensor provides input signals to the ECM that indicate engine rpm, (how fast the engine is running in R evolutions P er M inute). The ECM also uses these inputs to determine what stroke the engine is in so it can deliver the fuel and spark at the desired time.

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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