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Harley-Davidson Style Rocker Cover Assemblies installation Instructions

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Filed Under (Harley Davidson) by admin on 27-10-2010

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Installation 1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of OEM rocker housings. Refer to authorized Harley-Davidson Service Manual as necessary. WARNING – Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. WARNING – Gasoline is toxic when fumes inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head.
3 Picture 3 Picture 4 Right Left Rocker shaft reliefs must align with these holes. NOTE – Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. CAUTION – Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

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Harley-Davidson Evolution Engines S&S Billet Rocker Cover Assemblies Installation Instructions

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Filed Under (Harley Davidson) by admin on 30-10-2010

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1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of rocker housings. Refer to authorized Harley-Davidson®Service Manual as necessary. Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. Gasoline is toxic if fumes are inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson®Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head. NOTE: Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 3 CAUTION WARNING WARNING CAUTION 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

Harley-Davidson Twin Cam 88 S&S Billet Rocker Covers Installation Instructions

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Filed Under (Harley Davidson) by admin on 30-10-2010

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Failure to confirm pushrod/lifter placement before proceeding with installation can result in damage to rocker arm support plates and other parts. With pushrods at lowest point, front piston will be at TDC on Compression stroke. 4. Remove breather cover and baffle assembly. See Picture 2. 5. Remove rocker arm/rocker support plate. See Picture 3. NOTE – Gradually loosen rocker arm support bolts in following sequence (See Figure 1): 1. Left (driveside) rear 2. Right (camside) front 3. Right (camside) rear 4. Left (driveside) front Loosen bolts in sequence and in 1⁄ 4 -turnincrements for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 6. Remove lower rocker housing bolts. NOTE – Gradually loosen lower rocker housing bolts in following sequence (See Figure 2): 1. Right (camside) front 2. Left (driveside) rear 3. Left (driveside) front 4. Right (camside) rear 5. Center front 6. Center rear Loosen bolts in sequence and in 1⁄ 4 -turn increments for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 7. Remove lower rocker housing and gasket from head. Remove oil and any remaining gasket material from cylinder head gasket surface and clean gasket surface with lacquer thinner

Indian Rocker Arm End Play Rear Cylinder/ Front Cylinder Installation

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Filed Under (Indian) by admin on 12-11-2010

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Rear Cylinder 1Rotate the engine so that the rear piston is at Top Dead Center (TDC), compression stroke, so no load is on the valves. 2Using a 3/16″ allen wrench, remove the four screws securing the rear cylinder rocker cover. 3Remove the cover and inspect both O-ring seals. Discard if damaged or worn. 4Push both rocker arms towards the valve end support bracket (A) and using a feeler gauge check the gap between the rocker arms and the pushrod end support bracket (B). NOTE: The Rocker arm end play specification should be between 0.003″ to 0.012″. 5 Compare the measurement to the specification an determine whether adjustment is necessary. If the end play is within specification, adjustment will not be required. Refit the rocker cover (instructions 14 to 15) and carry out the same inspection on the front cylinder . If the measurement is outside the specification, adjustment will be required and shimming will be necessary (follow the remainder of these instructions). Adjustment 6Using a 1/4″ allen wrench remove the 4 screws securing the rocker shaft assembly.Refit the LH support bracket and reposition the complete assembly on the rocker base. Make sure that the three dowels are in place and the slots in the rocker shafts are properly aligned with the mounting screw holes in the RH support bracket. 11Clean the threads of the 4 support bracket screws and apply Blue Loctite to the first 4 threads. 12Fit the 1-3/4″ screws into the LH support bracket (A) and the 2″ screws to the RH bracket (B). Torque all screws in cross pattern to 16-20 foot-pounds. CAUTION: The rear piston must be at TDC, compression stroke, when tightening the support bracket screws. 13Re-check the rocker end play to ensure it is within specifica- tion. 13Lubricate the two O-rings with clean engine oil and refit them in the grooves in the rocker base. 14Refit the rocker cover.

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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 Twin Cam Engines Performer RPM Gear Drive Camshaft Kit INSTALLATION PROCEDURE

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

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1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 INSTALLATION PROCEDURE 1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 . 7. On pre-2000 models with a cam position sensor, you may want to remove the inspection cover, unplug the wires, and remove the sensor at this time to ease installation later on. 8. Remove the cam housing cover keeping the bolts in a separate cup. ( Note: Oil will run out of the cam housing.) 9. Using the Chain Tensioner Unloader Tool, unload pressure on the outside chain tensioner, and pin it in place with the retaining pin (See Figure 2) .

2008 HARLEY-DAVIDSON FXCW Softail Rocker Specifications

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Three-phase, 38-amp system ………………………………………. (439W @ 13V, 2000 rpm, 489W max power @ 13V) Starting……………….. 1.2 kW electric with solenoid shift starter motor engagement Lights (as per country regulation): Headlamp ……………….. Quartz Halogen, 55-watt low beam, 60-watt high beam Tail/Stop ghts……………………………………………………………….. Integrated LED Turn Signal Lights ……………………………………………………… 21W self-canceling Instruments …………………. Tank-mounted electronic speedometer with odometer; ………………………………………………… Time-of-day clock; Dual resettable tripmeter Indicator Lamps …………………… High beam, neutral, low oil pressure, turn signals, ………………………………………………………….. engine diagnostics, security system6, ……………………………………………………………………….. 6-speed, low fuel warnings Colour Options7 Vivid Black; Pacific Blue Pearl; Crimson Red Sunglo Model Features Silver powder-coated engine; Custom finned cast aluminium “horseshoe” oil tank with chrome external oil lines; Painted, stretch low profile tank console; Fire-truck inspired bullet headlamp; Bullet style LED turn signals; Adjustable, V-bar riser; Forward-mounted rider footpegs; Stainless steel, pull-back, internally-wired handlebars; Lowest seat height of all Harley-Davidson® motorcycles Warranty Warranty8 ……………………………………………………… 24 months (unlimited mileage) Service Interval9 ………………………………………………. First 1,000 miles (1,600 km), ………………………………………………………. every 5,000 miles (8,000 km) thereafter Dimensions

HARLEY DAVIDSON SCREAMIN' EAGLE STREET PERFORMANCE TOURING END CAP MUFFLER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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PRODUCT INFORMATION Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for proposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION NOTE Install end caps on mufflers before installing mufflers on vehicle. Install Direct Bolt-On End Caps 1. See Figure 1. Install end cap (2) to muffler (3) with four socket head cap screws (1). Tighten to 82-86 in-lbs (9.3- 9.7 Nm) . 2. Repeat for opposite side muffler. 3 2 1 is05426 1. Socket head screw (4) 2. End cap 3. Muffler Figure 1. Install End Cap on Muffler Install Attachment Ring End Caps 1. See Figure 2. Slide the three U-nuts (2) onto the bosses of the end cap attachment ring cup on the muffler. 2. Install attachment ring (1) to muffler with four socket head cap screws (3). Locate the attachment ring with a U-nut in the 12 o’clock position. Tighten to 82-86 in-lbs (9.3-9.7 Nm) . 3. Slide end cap (5) onto muffler body being careful to align holes in end cap with U-nuts. 4. Install the three countersunk screws (4) and tighten screws securely. 5. Repeat for opposite side muffler

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HARLEY DAVIDSON DYNA STREET PERFORMANCE SLIP-ON ACCESSORY MUFFLERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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PRODUCT INFORMATION Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

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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