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Harley Davidson 6- SPEED CONVERSION KIT FOR BIG TWIN 5- SPEED TRANSMISSIONS INSTALLATION

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

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5/16 Bolt hole boss clearance This can easily be checked with the trap door gasket. Put the gasket on the dowel pins. AII material of the boss around the hole that “sticks outside” the gasket (60 degrees forward to 60 degree backwards) must be removed (see figure A). Primary fork clearance Place the gasket on the housing and remove material as indicated for clearing the shifter fork (see figure B). WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® INSTALLATION INSTRUCTIONS FOR 6 SPEED CONVERSION KIT AND 6 SPEED BUILDER KIT speed transmission. Also make sure you have a 1990 or later Factory Service Manual available. Tools The conversion kit should only be used in new or low milage transmissions. If gears or bearings of a used Gear set Removal Refer to the Factory Service Manual Section for Mainshaft and Countershaft removal. When you get to the point of actually sliding the gear set out make sure you properly mark the 5th gear set as described in the Factory Service Manual (for used transmissions only). Further follow the factory removal procedure. Clearance Checks The 6 Speed conversion and builder kit will fit in most OEM or aftermarket transmission housings without may be needed. The following clearances must be checked before assembling the 6 speed transmission. 28-05-2008 We recommend the kits are installed by a qualified mechanic with knowledge of the Harley-Davidson 5 needed are the same as used for a 5 Speed transmission. 5 speed transmission are worn, new ones must be installed, or better, the builder kit should be used. any modification of the housing. However due to casting differences, in some instances some modification
WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® Pillow block clearance (right side) Make sure there is clearance between the pillow block and the housing. Any clearance is O.K. (see figure C). Fork shaft support clearance Again use the gasket as the template and remove the material as indicated (see figure D). Shift drum end play The end play of the shift drum must be checked prior to final installation. Install the shift drum. Measure the end play with feeler gauges at the right pillow block (see figure E). End play should be between .004″ and .010″, some 1/2″ X 7/8″ 0.008″ thick shims are included to adjust the end play

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HARLEY-DAVIDSON TURN SIGNAL MIRRORS WITH CONVEX GLASS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 03-04-2012

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STEP 1 Remove the stock mirrors. LEFT SIDE: STEP 2 Choose the longest Allen bolt from the hardware kit that passes through the hand control, a split lock washer, an internal tooth star washer, the turn signal mount (if applicable), and still provides maximum thread engagement in the mirror stem without bottoming out. Mount the mirror with the hardware listed above. (Place the star washer between the mirror stem and the hand control). RIGHT SIDE: STEP 3 If the turn signals are not mounted under the mirror, proceed in the same manner as the left side. STEP 4 If the turn signal is mounted under the mirror proceed as follows: Apply Red loctite to the short threaded end of the special mounting stud. Screw this end securely into the mirror stem. -cont.- 1432-22HD-0105 TURN SIGNAL MIRRORS WITH CONVEX GLASS 1432 INSTALLATION Illiana CUSTOMER SERVICE 877.370.3604 (toll free) INSTALLATION QUESTIONS techsupport@kuryakyn.com or call 715.247.2983 WARRANTY Küryakyn™warrants that any Küryakyn product sold hereunder, if properly installed, maintained and operated under normal conditions, shall be free from any defects in materials and workmanship for a period of one (1) year from the date the Küryakyn products are sold to the customer. CONSEQUENTIAL DAMAGES: Küryakyn shall not be liable for any consequential or incidental damages. ABOUTOURCA TA LOG You’ll find all our innovations for H-D, GL and Metric Cruisers in our annual catalogs. Order online today-select the “CATALOGS” icon. Each Küryakyn™ product comes with a Proof-of-Purchase good for a complimentary catalog. Details in packaging. Be sure to ask your local dealer about other Küryakynproducts, the motorcycle parts and accessories designed for riders by riders. ©2004 Küryakyn USA™All Rights reserved.
STEP 5 Remove the turn signal assembly from the stock mirror. Pay close attention to how the stock turn signal ball joint assembly comes apart as this will aid in re-assembly. STEP 6 Place a star washer over the mounting stud and insert the mirror and stud assembly into the hand control. Re-assemble the turn signal ball joint being sure the turn signal light is aimed to your liking. You may wish to consult your H-D shop manual when re-assembling this ball joint. WIRING: STEP 7 Determine where you wish to splice into the H-D turn signal wiring harness. Cut the harness or strip back an appropriate amount to vinyl wire covering and prepare the wires for splicing. Make the wire connections as follows: Wires from Turn Signal Mirror H-D Turn Signal Wire Colors Black – (Ground) Black (Ground) Red – (Running Light) Blue (Running Light) White (Turn Signal) Violet (Turn Signal) If a more pronounced flash is desired, one may eliminate the running light function and wire as follows: Black Black Red and White together Violet If these turn signal mirrors are to be used in conjunction with stock front turn signals, no load equalizer will be required. If the turn signal mirrors are REPLACING stock front turn signals, in most cases, a load equalizer is required. For easiest access we suggest installing the load equalizer under the seat; tapping into the main wiring harness that leads to the tail lights and rear turn signals.

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HARLEY DAVIDSON SECURITY SYSTEM KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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FL Touring models equipped with a TLE/ TLE Ultra Sidecar will require the additional installation of a Bank Angle Switch Kit (88115-03) and is available for separate purchase. See a Harley-Davidson dealer.INSTALLATION 1. Remove the original equipment (OE) Turn Signal Module (TSM) or Body Control Module (BCM) following the instructions in the service manual. 2. Install the Bank Angle Sensor (BAS) on sidecar vehicles. 3. Install the new turn signal/security module (TSSM) (7), Hands Free Security Module (HFSM) (1) or BCM (9, 11) from this kit, following the instructions in the service manual. Configure the Trike or sidecar TSSM, HFSM or BCM to “Side Car Enabled” using Digital Technician. 4. Install the Hands Free Security Module (HFSM) Antenna and antenna mount (6) if necessary, using the service manual instructions. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) ACTUATION 1. See a Harley-Davidson dealer to activate the key fob to the TSSM, HFSM or BCM. NOTE You can activate the TSSM fob by referring to the procedure in the electrical diagnostic manual. TRIKE AND SIDECAR CONFIGURATION (FL TOURING MODELS ONLY) Only Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a) NOTES FL Touring Models equipped with TLE/TLE-Ultra Sidecar require the installation of a Bank Angle Sensor (88115-03). Failure to install and configure a Bank Angle Sensor may result in death or serious injury. Sidecar and Trike configuration of the security system requires the use of a Digital Technician. Consult your Harley-Davidson dealer or the sidecar or Trike service manual for complete details. On vehicles equipped with a sidecar, the security system must be reconfigured from the default solo vehicle setting to the sidecar setting

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Ignition Upgrade Module for 2004-up Carbureted Harley Davidson Motorcycles Owner's Manual

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. Disconnect the negative battery cable. 2. Grasp the sides of the electrical caddy (located next the ignition coil) and pull outward to remove. 3. Remove the relay and fuse panels from the electrical caddy. a. Insert a small screwdriver into the slot under each fuse and relay panel. b. Using a screwdriver, disengage the panel from the electrical caddy. 4. Disconnect the main fuse connector from the electrical caddy a. Remove the main fuse from the connector b. Insert small screwdrivers into the slots on each side of the main fuse c. Depress the tabs of the main fuse connector to disengage it from the electrical caddy
Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com 2 EI5075.doc 5. Depress the tab located on the electrical caddy securing the TSM/TSSM. Pull it from the electrical caddy. Disconnect the TSM/TSSM connector. 6. Slide the data link connector towards the front of the motorcycle to disengage it from the electrical caddy. 7. Disconnect the ignition control module connector. 8. Disconnect the ignition coil connector and spark plug cables from the coil. 9. Remove the electrical caddy fasteners (3 total). 10. Remove the wiring from the electrical caddy. 11. Remove the fasteners securing the factory ignition control module from the electrical caddy. 12. Installation of the Digital Ignition Module is the reverse of removal. 2.2 Touring Models 1. Disconnect the negative battery cable. 2. Remove the right saddlebag. 3. Gently pull the side cover from the frame downtubes (no tools required). 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. Remove the two socket screws to detach the ignition control module from the electrical bracket. 6. To install the Digital Ignition Module, install and tighten the socket screws to 50-60 in-lbs . The remainder of installation is the reverse of removal. 2.3 Softail Models 1. Remove the seat. 2. Disconnect the negative battery cable. 3. Remove the two screws to free the ignition control module from the mounting bracket. 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. To install the Digital Ignition Module, install and tighten the socket screws to 15-21 in-lbs . The remainder of installation is the reverse of removal

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HARLEY DAVIDSON TURN SIGNAL TRIM RINGS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION 1. Remove turn signal lens 2. Place O-ring (4) in groove between lens and turn signal housing. 3. Reinstall signal lens. 4. Install the trim ring (3) onto the turn signal. Notches on turn signal lens must be aligned with notches on trim ring. 5. Secure trim ring with the provided screw (1) and nut (2). Tighten securely. 6. Repeat Steps 1-5 for the other turn signal. SERVICE PARTS See Figure 1 and Table 1. 1 B A 2 4 3 is00628 Figure 1. Service Parts: Turn Signal Trim Rings Table 1. Service Parts: Turn Signal Trim Rings Part Number Description (Quantity) Item 3824 Screw 1 8006 Nut 2 Not Sold Separately Trim Ring 3 11371 O-ring 4 Items mentioned in text but not included in kit: Original lens and screw A Turn signal housing

HARLEY DAVIDSON CLEAR/ SMOKED DOMED OR FLAT TURN SIGNAL LENS KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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CLEAR/SMOKED DOMED OR FLAT TURN SIGNAL LENS KITS Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson Dealer. 1. See Figure 1. Remove existing turn signal lenses and discard. Retain lens mounting screws for installation. 2. Remove bulbs from turn signal assemblies. 3. Obtain new amber bulbs from kit. Install bulbs marked 1157A (Dual Filament) to the front turn signal assem- blies. Install bulbs marked 1156 (Single Filament) to the rear turn signal assemblies. 4. Refer to Figure 1. Using screws saved during removal, install the new turn signal lenses to front and rear turn signal assemblies. 5. Check turn signals for proper operation

HARLEY DAVIDSON SOFTAIL TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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REMOVAL 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 owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 2. Raise the motorcycle on a floor jack to lower the rear wheel for fender hardware access. 3. See Figure 1. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 1. Remove Tail Lamp Lens 4. See Figure 2. Using a Terminal Pick Tool (1), press locking tabs and disconnect turn signal connectors (2-place, Items 2 and 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. NOTE FXST/S/B tail lamp and connectors are positioned 180° from orientation shown in Figure 2. 6. Reach under fender to locate clips fastening turn signal wires in place. Carefully pull wires out of clips, and pull turn signal connectors and wires out from under fender. a. Remove two-inch (51 mm) section of conduit 4 inches (102 mm) from turn signal connectors. b. Cut black turn signal wire about 5-1/2 inches (140 mm) from its connector. c. Cut violet/brown turn signal wire about 4-1/2 inches (114 mm) from its connector. d. Save cut wires with respective turn signal connectors. 7. Remove the sissy bar and/or sideplate assembly, if equipped

HARLEY DAVIDSON CLEAR/SMOKED BULLET STYLE OR VRSC TURN SIGNAL LENS KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson Dealer. 1. See Figure 1. Locate the removal notch on the turn signal lens and carefully pry from housing. Discard lens. Repeat for remaining lenses. 2. Remove bulbs from turn signal assemblies. 3. Obtain new amber bulbs from kit. Install the bulbs marked 1157A (Dual Filament) to the front turn signal assemblies. Install the bulbs marked 1156 (Single Filament) to the rear turn signal assemblies. NOTE See Figure 1. VRSC (V-Rod) Models have unique rear turn signal lenses. The rear lens is identified with a dimple mark in the center of lens. The front has no dimple. 4. Obtain new lens from kit and install by snapping into place. Check turn signals for proper operation. ® Figure 1. “Bullet” and VRSC Turn Signal Lenses Kit Numbers 69303-02, 69304-02, 69309-02 and 69315-02 Service Parts Clear/Smoked “Bullet” and VRSC Lens Kits Date 5/02 Part No. 69303-02 and Others Item Description Part Number Kit Number 69303-02 1 Clear lens, bullet, front and rear (4) 69324-02 Kit Number 69304-02 2 Smoked lens, bullet, front and rear (4) 69325-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear) 69330-02 Item Description Part Number Kit Number 69309-02 1 Clear lens, VRSC, front (2) 69324-02 5 Clear lens, VRSC, rear (2) 69322-02 Kit Number 69315-02 2 Smoked lens, VRSC, front (2) 69325-02 6 Smoked lens, VRSC, rear (2) 69323-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear

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 AUXILIARY BRAKE/ RUN/ TURN SIGNAL CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) -J03990 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. 2. See Figure 1. Locate the rear wiring harness coming out of the rear fender in the area underneath the seat. Disconnect the rear fender lighting wiring connector (1) from the main harness connector (2). 3. Obtain the turn signal module from the kit, and mate the module connectors to the male and female rear fender wiring harness connections. Snap into place. NOTE Due to variations between models, there is no single best location to secure the module. When deciding on a location for securing the module, make sure that the connectors and module will not be bound, and that the wiring will not be pinched when the seat is re-installed. Also, be certain to maintain clearance between the wiring harness and the rear wheel underneath the fender. 4. Using cable straps from the kit, secure the module, connector and wiring in the area underneath seat. 1997-1999 FLHR and FLHRCI models: Go to Step 5. All other models: Proceed to Step 6.

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