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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT MANUAL

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

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SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT KIT SIREN BOX REMOVAL Read the following instructions and make sure you fully understand them prior to replacing the battery. If the procedure is not within your capabilities, or you do not have the correct tool, have a Harley-Davidson dealer replace the battery. Improper installation could result in damage to this product. (00419b) 1. Refer to the Owner’s Manual and follow the instructions given to disarm the security system. 2. Remove the siren box from the vehicle. Reference the siren installation procedures found in the Siren Kit Instruction Sheet or contact a Harley-Davidson dealer for specific information on locating and removing the siren box from your model. Battery replacement, Smart Siren 1. See Figure 1. Remove the battery cover (2) from the siren box as follows: a. Place the siren on a sturdy, flat surface with the potting (1) and battery cover facing up. b. Using a blunt, stiff blade such as a table knife, insert the blade between the case and cover at a 45 degree angle to the side of the case. Insert the blade until it touches the snaps on the inside face of the cover. Figure 2 shows the four barbed snaps (2). c. Twist the blade slowly so the inserted edge presses against the inside face of the cover. The cover will pop off and can be replaced later using silicone adhesive if necessary

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HARLEY DAVIDSON FLST REPLACEMENT WINDSHIELD KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. See Figure 1. Remove stock windshield. 2. Remove all hardware that secures mounting brackets to windshield. The nine screws must be removed with a T- 27 TORX® screwdriver. Save all hardware and brackets for installing new windshield. 3. Remove all old tape from brackets and apply new tape (1, 2) from kit onto brackets. Align holes in tape with holes in brackets. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets. Tighten all screws and acorn nuts to 48-60 in-lbs (5.4 to 6.8 Nm) . 5. Install windshield (3) on motorcycle CARE AND CLEANING Polycarbonate windscreens/windshields require proper attention and care to maintain. Failure to maintain polycarbonate properly can result in damage to the windscreen/windshield. (00483d) •Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windscreen/windshield. Doing so will damage the surface. •Do not clean Lexan® polycarbonate in hot sun or high temperature. •Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. •Never scrape the windshield with a razor blade or other sharp instruments, as permanent damage will result. •Sunlight reflections off of the inside curvature of a windscreen/windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windscreen/windshield to avoid reflections. •Do not use benzene, paint thinner, gasoline or any other cleaning agents on the rubber bushings. Doing so will damage the bushing surfaces. Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant (00231a) NOTES Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier. Harley-Davidson Windshield Water Repellent Treatment Part Number 99841-01 is approved for use on Harley-Davidson Lexan windshields

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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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 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.

1984-1999 Harley-Davidson Evolution Engines Replacement Cylinder Heads Installation Instructions

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Filed Under (Harley Davidson) by admin on 28-10-2010

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Installation of an S&S Super Stock cylinder head kit is easy and can be performed by any Harley-Davidson®repair shop equipped to do engine overhauls. No special tools other than those used in normal overhaul repair work are required. Read instructions thoroughly before starting work. When they are completely understood proceed with installation. 1. Remove Components and Inspect Parts Follow procedures outlined in appropriate Harley-Davidson® service manual to prepare motorcycle for top end service. NOTE: Disconnect batteryand drain all gasoline from gas tanks beforedoing any work. Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. A. Remove gas tanks and all other parts required to perform top end service. B. Remove carburetor, rocker covers, pushrods and pushrod tube assemblies, cylinder heads and cylinders. Also remove piston rings from piston. Do not remove pistons. NOTE: Be careful not to introduce any dirt or other foreign material into crankcase during disassembly of engine. Metal filings, dirtand any other foreign contamination in engine may cause premature wear and/or irreversible damage to bearings and other internal engine components. C. Thoroughly clean and inspect all parts that are to be reused. Any parts that show signs of wear or damage should be replaced. WARNING CAUTION 2. Check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result isthat the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as blue printing, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore.

HONDA CB650/ 750F/ 900F/ 1100F/ GL1100 Spark Unit Set Installation Manual

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Filed Under (Honda) by admin on 05-04-2011

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INSTALLATION INSTRUCTIONS: 1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back to back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows: GREEN Ö GROUND (0 VOLTS) BLACK/WHITE Ö IGNITION SUPPLY (+12 VOLTS) VIA ENGINE STOP SWITCH YELLOW Ö IGNITION COIL OUTPUT (TO COIL —) WHITE Ö PULSE GENERATOR (WHITE RING) BLUE Ö PULSE GENERATOR (UNMARKED) There are two pulse generators, one for cylinders 1&4 and one for cylinders 2&3. The left hand one is normally for cylinders 1&4 (see fig.1). There are two wires of the same colour coming from each pulse generator, one of these wires is normally marked with a white band. The pulse generator wire with the white band connects to the white wire from the corresponding spark unit, the other pulse generator wire connects to the blue wire on the corresponding spark unit. If the white band is missing, this is normally the upper wire coming from the pulse generator. 9. Refit the seat and tank (if removed earlier). 10. Fitting is now complete, although for best results you may wish to verify the ignition timing, see the following guide

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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 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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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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