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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)

HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. A Service Manual is needed to install this kit. 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 your Harley-Davidson Dealer perform the installation. Improper installation of this kit could result in death or serious injury. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

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 FLH Accent Panel Installation Manual

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

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1 Install Accent Panels Note: See hardware list on Page 4 for usage and descriptions. 1.1 Elevate the rear of the vehicle and support with jack stands under the rear differential tubes. 1.2 Remove the rear wheels 1.3 Remove the passenger foot rests. 1.4 Remove front fairing (for wiring later in installation) . 1.5 Install cross brace and frame clamps to frame in the approximate position shown in Figure 1. 1.6 Note orientation of cross brace (Figure 2). Flat side of the brace against bottom of frame tubes. Outboard tabs up and to the rear of the vehicle. 1.7 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.8 Install front brackets to vehicle between the frame and crash bars as shown, using the supplied hardware (the left side bracket is longer than the right. Figure 3 1.9 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.10 Position the accent panel to vehicle. Figure 4 1.11 Install supplied hardware to front and cross brackets. Figure 5 &Figure 6 1.12 Leave the bolts loose to allow the accent panel’s position to be adjusted later in installation. 1.13 If not already preinstalled to your accent panel, install rubber bead edge molding between trike body (fender) and accent panel. Bead edge molding 1.14 Clamp the accent panel to the body (fender). Check position of accent panel and ensure proper positioning of bead edge molding. 1.15 Four holes will be drilled though body (fender) and accent panel in the approximate positions shown (both left and right accent panels). Figure 8 Note: Hole location dimension in Figure 8 are approximations. Your drill location may and can vary. Note: Hole position should be as high an possible on the accent panel, allowing space to install hardware 1.16 With accent panel and bead edge molding properly positioned and clamped to body (fender), Drill the two outboard holes in the approximate position shown from inside the fender well through mounting surface of accent panel. Note: Drill outboard hole first and install hardware to reduce risk of accidental movement. Figure 9 1.17 Drill remaining two inboard holes from the accent panel mounting surface through the body (fender). Figure 10 1.18 With both left and right accent panels installed, tighten all hardware at the left and right front mounting positions. 1.19 Trim off excess bead edge molding. 1.20 With left and right front mounting secure, check position and alignment of cross bar and accent panel mid mounts and tighten all hardware. 1.21 With fairing removed, crimp supplied xxx to the black, purple and blues wires of the vehicle’s turn signal wire loom. 1.22 Crimp one of the supplied male spade connectors to the end each wire from the accent panel. 1.23 Connect wiring as indicated in Table 1 below. Accent Panel Wire Color Vehicle Turn Signal Loom Wire Color Yellow Purple (Signal) Orange Blue (Running) Black Black (Ground) Table 1

HARLEY DAVIDSON DYNA DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION Installing the Front Docking Point To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Remove the seat and disconnect the negative (-) battery cable. NOTE To keep the fender aligned, complete ALL the following procedures on one side of the motorcycle before starting the other side. 2. See Figure 1. Remove the stock fender support bracket. Position new rear fender mounting bracket from kit (5) into position. 3. Apply Loctite 243 (Blue) to button head bolt (2) prior to installation. Place the tapered side of front docking point (1) against the strut cover. Insert button head bolt (2) through the docking point, fender support and fender. Tighten to 12-18 ft-lbs (16.3-24.4 Nm) . 4. If used without saddlebags, install rear docking point (3) and recess cover (4) according to instructions in Part Number 53968-06C, Directional Relocation Kit. If used with saddlebags, mount rear docking point according to instructions with saddlebag kit. MAINTENANCE NOTE In time, the docking points may wear causing the mating luggage rack or sideplates to become loose. The fit may be tightened using the following procedure. If any fasteners with Loctite are loosened, then the fasteners must be removed, cleaned of existing Loctite and re-installed with new Loctite. 1. Loosen the docking hardware. 2. Rotate the docking points clockwise approximately 45°. 3. Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures. This procedure can be repeated up to 3 times before replacement of the docking points is recommended.

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HARLEY DAVIDSON CHROME REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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Kits 41017-00, 41026-00 and 41262-03 are designed for installation on 2000 and later XL, FXD and 2000-2002 Softail Model Motorcycles (except FXSTD and FLSTS). Kits 41260-03, 41261-03 and 41265-03 are designed for installation on 2003 and later Softail Model Motorcycles (except FXSTD and FLSTS). Kit Numbers 41017-00 and 41261-03 contain a16 inch chrome slotted rear wheel. Kit Numbers 41026-00 and 41260-03 contain a 16 inch chrome fatboy rear wheel. Kit Numbers 41262-03 and 41265-03 contain a 16 inch mirror chrome disc rear wheel. See Service Parts Illustration for kit contents. nstallation Do not re-use brake disc screws. New screws are provided for disc installation. Re-using original disc screws can result in torque loss and damage to rotor and/ or brake assembly. (00319a) Refer to the appropriate Service Manual for wheel removal and installation procedures. See Service Parts Illustration. This kit contains the necessary parts for wheel installation, however you will need to save the Axle, Axle Nut, Brake Disc, and the Drive Pulley with related hardware for reinstallation. NOTE The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Apply two drops of LOCTITE THREADLOCKER 262 (red) to each of the five sprocket mounting screws. Follow the bolt torque procedure in your service manual or, if installing an accessory hardware kit, in the I-sheet included with the hardware kit. Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel & Tire Cleaner Part Number 94658-98 applied with Harley Wheel & Spoke Brush Part Number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner Part Number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, Part Number 99701-84

HARLEY DAVIDSON DETACHABLE QUARTER FAIRING AND DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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Installation 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 If your motorcycle has directional lights mounted on the upper fork bracket they must be relocated to the bottom fork bracket. Some models have front directional lights equipped with three wires, the third black wire is a ground wire. Check to determine how many wires are connected to the front directional lights and follow the following procedure that applies. Ifdirectional lights are not mounted on the upper fork bracket proceed to “ASSEMBLING FAIRING”. Relocating Two Wire Directional Lights 1. Support motorcycle on a center stand such that front wheel is raised slightly off the ground. 2. Remove fork tube pinch screw from right side of lower bracket. 3. Cut wires connected to right directional light about 2 in. away from directional light body. 4. Remove fork tube pinch screw from right side of upper fork bracket. (This is the screw that secures the right directional light.) 5. Install right directional light on right side of lower fork bracket using pinch screw removed in step 4. Install pinch screw removed in step 2 into right side of upper bracket. Tighten both pinch screws to 30-35 ft-lbs. 6. Repeat steps 1 through 5 to relocate left directional light. NOTE Fork tubes may slide downward within fork brackets. If this occurs, front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures. 7. Connect the right directional light as follows: Strip approx. 5/16 in. of insulation from the wires cut in step 3. 8. Crimp solderless connectors from kit on two wires coming from motorcycle. 9. Split one end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 10. Slide a piece of shrink tubing from kit over each of the wire ends stripped in step 9 and crimp the wires into the terminals installed in step 8. Make sure you connect the silver and copper colored wires to like colored wires. NOTE Polarized wire is used in this application to ensure correct wiring. One wire is silver, one is copper colored. Wire colors of spliced wire must match wire color of original directional wire leads. 11. Cut polarized wires to the length required for connection to the wires at the relocated directional light. Make certain you leave enough slack in wires to allow routing the harness along the fork tube. 12. Split remaining end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 13. Slide heat shrink tubes over the two wire end. 14. Strip 5/16 in. of insulation from wires connected to directional light and connect like colored wires at directional light with connectors from kit. 15. Slide heat shrink tubing over connectors installed in steps 10 and 14. Activate shrink tubing with heat gun or hair dryer.

HARLEY DAVIDSON DETACHABLE DYNA SIDEPLATE KIT INSTALLATION INSTRUCTIONS

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

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Additional Parts Required The appropriate docking hardware and possibly a directional relocation kit must be installed prior to installation of this side- plate kit. These kits must be purchased separately from a Harley-Davidson Dealer. Table 1. Docking Hardware Kits Model Year Docking Hardware Kit FXDWG 53964-06 only Table 2. Directional Relocation Kits Model Year Docking Hardware and Directional Relocation Kit All except FXDWG 53961-06 and 53968-06 If mounting this kit with Saddlebags, part number 53968-06 is not required. Loctite® 262 (red), Part Number 94759-99, is available from your Harley-Davidson Dealer. Kit Contents Table 3. Kit Contents Part Number Description (Quantity) 52869-06 Side Plate, detachable, right 52870-06 Side Plate, detachable, left 94592-98 Button head screws (4) SISSYBAR INSTALLATION 2 3 1 4 1 is 01079 1. Sideplate 2. Sissybar 3. Buttonhead screw 4. Rotary latch Figure 1. Detachable Sissybar Sideplate Assembly See Figure 1. Install new or existing sissybar (2) to detachable sideplates (1) using four buttonhead screws (3). Apply Loctite® 262 (red) to screws before installation. Tighten screws to 96- 120 in-lbs (11-14 N-m)

HARLEY DAVIDSON FLSTC SOFTAIL SADDLEBAG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Additional Fitment Information Detachables NOTE If motorcycle has not been altered from fixed saddlebag hardware to accessory mounting detachable docking points. the separate purchase of Turn Signal Mounting Bar (Part Number 68611-98) is required for sufficient lock clearance. This kit is available at your Harley-Davidson Dealer. Installing these saddlebags on models equipped with a detachable sissy bar or detachable luggage rack requires the additional purchase of mounting hardware kit as follows: Hardware Kit Fitment 53075-03 2003 and later FLSTC models with detachables 53009-03 1987 through 2002 FLSTC models with detachables See Service Parts Page for kit contents. Additional weight can affect motorcycle stability, handling characteristics, and safe operating speed. Do not exceed 7 lbs. (3.18Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury. Wide Tire If a wide tire kit has been installed, utilize the hardware and installation instructions found in that kit to reorient the fasteners to come from the inside to the outside of the finder. Button head screws from wide tire kit must be installed from the inside out, with the button heads on the inside of the fender. Failure to do so could result in bolt contacting tire, which could result in death or serious injury. Installation NOTE A Service Manual for your vehicle is available at your Harley-Davidson Dealer. 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect the negative (-) battery cable first. If positive (+) cable should contact ground with the negative (-) cable connected, the resulting sparks may cause a battery explosion which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Following instructions in applicable Service Manual, remove original saddlebags from supports. Install Turn Signal Mounting Bar If motorcycle is not equipped with accessory mounting detachable docking points, install Turn Signal Mounting Bar (Part No. 68611-98) following instructions provided with the kit. See Figure 1

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HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.