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HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

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HARLEY DAVIDSON CHROME FOOTPEG BOLT KIT INSTALLATION MANUAL

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

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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 The bolts supplied in this kit are designed for a one-time installation only. If this kit is removed after initial installation, you must re-apply Loctite 243 (Blue) to the threads of the bolts. Kit Contents 3 1 3 is05122a Figure 1. Service Parts: Chrome Footpeg Bolt Kit Table 1. Service Parts Part Number Description (Quantity) Item 94128-01 Washer, chrome (2) 1 8023 Nut, chrome (2) 2 4233 Screw, TORX®, button head, chrome (2) 3 INSTALLATION 1. Remove existing nut and bolt securing footpeg to mount. Discard nut and bolt. 2. See Figure 2. Install chrome washer to bolt, then install bolt through mount and footpeg as shown. 3. Install nut to bolt. Tighten hardware to 10-16 ft-lbs (13.6- 21.7 Nm) . 4. Repeat Steps 1 through 3 for the opposite side

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HARLEY DAVIDSON BATTERY CHARGING HARNESS (THREE-PIN) INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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1. Follow the instructions in your Owner’s Manual to remove the seat and any other components (side covers, etc.) necessary to provide access to the battery. 2. Refer to the applicable view in Figure 1 for your model. Break the battery negative (-) connection by removing the hardware assembly from the negative battery terminal. 3. Break the positive (+) battery connection by removing the hardware assembly from the positive battery terminal. 4. Clean the battery terminals and cable connectors using a wire brush or sandpaper to remove any oxidation. 5. Apply a light coating of Harley-Davidson electrical contact lubricant (Part Number 99861-02) to the battery terminals, cable connectors, battery charging harness ring terminals and connector located under the weather- shield cap. Connect positive (+) 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. (00068a) 6. Refer to the view in Figure 1 used for disassembly. Install the positive (RED) lead of the harness to the positive (+) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the positive (+) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the positive (+) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). 7. Attach the negative (BLACK) lead of the harness to the negative (-) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the negative (-) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the negative (-) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). Harness Routing Do not route the harness near any moving parts. Contact with moving parts may result in damage to harness. Refer to the following sections to determine the correct harness routing for your model. Be sure to avoid any components that may pinch or cut the harness, and avoid components that radiate heat. Take up any slack in the cable and store out of sight. Secure the harness with cable straps (H-D Part Number 10006), which can be purchased separately from any Harley Davidson Dealer. VRSC Model Harness Routing 1. See Figure 2. Route the battery harness/ connector (3) toward the front of the bike following the upper left frame tube. Cleanly tuck the in-line fuse (2) into the space in front of the battery. 2. Continue to route the harness/ gray connector to the front of the bike and behind the vent cover. Secure the harness with a cable strap and let the connector protrude past the cover for easy access. Trim any excess from the cable strap

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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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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 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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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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2000 & later Harley Davidson Softails Drag Specialties Shocks Installation Manual

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Filed Under (Harley Davidson) by admin on 31-03-2012

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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 hard- ware. 3. Before reinstalling a Drag Specialties adjustable ride height shock, spin the non-flanged nut all the way onto the stud mount, followed by a bushing-cup, bushing, and sleeve. Then install shocks as you would a stock unit, following an authorized shop manual. With the non-flanged nut spun all the way onto the stud, the stock ride height is achieved. Once you have installed the other bushing, bushing-cup, and flanged nut you can now install the safety E-clip. This E-clip is snapped into the groove near the end of the stud mount where the threads stop. This is to serve as a reference point ONLY – when the flanged-nut reaches it you have lowered your ride height the maximum 2 inches. DO NOT torque the flange-nut against the E- clip (see figure 1). 4. Tighten all shock mounting bolts to the proper torque specifications (see shop manual for specs). 5. Drag Specialties shocks have adjustable pre-load to compensate for varying weights. A Harley Davidson pre-load adjustment wrench is necessary to adjust the pre-load setting. 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

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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

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Harley Davidson 2004-Up Sportster EZ-Steer Installation Manual

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

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Installation Notes • Remove front fender, wheel, brake caliper, and fork tubes. • Remove all components attached to stock triple clamps, then the triple clamps themselves. • Remove upper and lower bearings including race. • Install new steering stem bearing races into neck. • Install new upper steering stem bearing with seal into neck. • Install Top and Bottom triple clamps into neck and snug steering stem bolt with washer. • Remove fork tube cap from both forks. • Install fork extensions with o-ring into fork tubes and tighten until fully seated. • Install fork tube caps with o-rings and tighten (see torque table). • Slide fork tubes into triple clamps until the top of each tube cap extends 0.42-0.50 in. above top surface of upper triple clamp. • Tighten 3/8-16 x 1.5″ bolts on upper triple clamp (see torque table). • Tighten steering stem bolt (see torque table). • Tighten pinch bolts on lower triple clamp (see torque table). • Install front wheel assembly and front brake caliper. • Install front fender. Item # Part Description Torque Spec (Lb. Ft.) – Fork Tube Cap 22-58 8 Bolt, Steering Stem, SP 30-35 11 3/8 – 16 X 1.5″ Socket Head Cap Screw 30-35 EZ-Steer Maintenance The bearings in your EZ-Steer rake kit are normal wear items, not subject to replacement under Champion’s one year Limited Warranty for the product. Failure to follow your motorcycle manufacturer’s recommendations for periodic OEM triple-tree maintenance will accelerate the wear on these bearings. Checking/adjustment of the steering stem nut torque with the front end lifted, in accordance with your motorcycle manufacturer’s recommendations, is important to reliable bearing service. Windshield Notes Please note that this EZ-Steer kit accommodates all known windshield types with the exception of a minor modification to Quick Release Compact Windshield, example part no. 58063-04. You will need to oblong the lower bolt holes as shown in figure

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