harley softail hard bag conversion

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Harley-Davidson Hard mount installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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1. It is recommended that you create a template from cardboard or heavy paper (not included) of the back of the bag to assist in proper placement on the motorcycle. The template can be used for both bags simply by flipping it over horizontally 180 degree for slant style bags. For all other saddlebags transfer template to other bag making sure that the hole pattern corresponds with the bolts pattern on the opposite fender strut. 2-Assemble the saddlebags support 2. Remove your existing fender strut mounting bolts. 3. (A*) Install replacement 8mm x 70mm or 10mm x 70mm bolts. (Most Harley-Davidson models will utilize the 8mm bolts. Please determine which bolts will fit your specific application prior to assembly. Your make and model of motorcycle may require additional hardware. (See your motorcycle owner’s manual). 4. Install 2 upright and secure tight enough to maintain position and secure with the lock nuts (Metric applications do not require lock nuts). Ensure that bracket angles are away from the bike. 5. Lightly apply a dab of engine oil and lightly coat the exposed bolts(C or D) and barrel bolt Hex- head (E) assemblies (Mark at 4 points for each saddlebag). You can also use a marker or pen to mark. Take the template or bag and place against the brackets. Hold and press firmly to transfer the oil to the bag or template. The oil will leave a mark on the bag or template. If you are not satisfied with the position of the bag wipe the oil off and repeat as many times as necessary. Note: Position according to your specific setup, ensure the bag will not contact hot engine or exhaust components. If planning on carrying a passenger, ensure that there is enough clearance for the passenger’s legs between the bags and the foot pegs. Make sure that the uprights DO NOT contact moving parts, including but not limited to suspension components. 6. Place the Saddlebag on a firm surface and drill 4 holes (make sure you drill holes according to the size of the bolt to be passed) into the back of the bag only, according to your oil drop pattern. Also be careful not to damage the large mesh pocket inside the saddlebag. If a template was utilized cut the corresponding holes into the template and place temple on the back of the bag and drill following above directions. The template can be utilized for both sides of the bag

Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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Filed Under (Harley Davidson) by admin on 16-04-2012

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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HARLEY DAVIDSON MULTI-POCKET WINDSHIELD BAG INSTALLATION MANUAL

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

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Installation 1. Remove the acorn nuts from the inside-center, left and right on the horizontal windshield bracket. 2. Apply protective tape strips to the horizontal windshield bracket to protect chrome finish. 2. Place windshield bag and bracket with eyelets over screws in the horizontal windshield bracket. Mark the location of the vertical supports for correct placement of the rubber bumpers to protect the bottom of the bag bracket. Place two bumpers each at the marked locations of the vertical windshield supports. 3. Align the metal brace with the eyelets, to fit snugly onto the windshield horizontal bracket screws. 4. Fasten the acorn nuts removed in step 1 onto the screws through the eyelets under the windshield bag. Torque the nut to 90-110 in-lbs (10.2-12.4 Nm). NOTE The brace under the bottom of the windshield bag conforms to the contour of the windshield bracket as the acorn nuts are torqued. To keep this surface in the best condition, lightly wipe with a Harley-Davidson Micro Fiber cloth, part number 94663-02, using clear water or a mild Harley-Davidson cleaner such as: • Sunwash (part number 94659-98), • Bug Remover (part number 94657-98) or • Harley Gloss (part number 94627-98).

1987 to Current Harley Davidson Softail (FLST Only) Motorcycle Trike Conversion removal and Installation Guide

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

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Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Seat (to be re-installed without modification). • Left and right saddle bags (if so equipped). • Left and right rear crash bars, saddlebag rails (if so equipped). • Left and right passenger foot rests (to be re-installed without modification) • Complete exhaust system (to be replaced with new system). • Rear wheel NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake caliper is removed • Remove Rear Caliper (disconnect brake line at caliper) NOTE: Cap line to prevent introduction of dust / debris into line. Remove caliper. • Rear Drive Pulley (1987-99 models to be re-installed without modification). • Rear Fender (2000 and newer models, fender mount plates to be reused). • Swing Arm NSTALLING TRIKE CONVERSION KIT 3.1 Sprockets and Drive Belts Specifications See following table for belt installation (1987-99 will use a 4 tooth longer belt) Note : See OEM manual for belt replacement procedure. Year Drive Sprocket OEM Belt New Belt / Sprocket 1987-92 70 T 132 T 136 1993-94 61 T 128 T 132 1995-99 65 T 130 T 136/70TOEM 2000-06 Champion Sprocket, 70 T 135 T Use OEM 2007 Up Champion Sprocket, 66 T Use OEM 3.2 Install Swing Arm É Noting size and location of bolts, remove Cross Assembly from Champion Swing Arm. Do not discard hardware. Figure 1 3.2.1 1987-99 Model Years • Remove bearings from OEM Swing Arm using OEM shop tools and hydraulic press. Note : Although original bearings can be re-used, it is HIGHLY recommended that NEW bearings be installed to Champion Swing Arm a. b. Press bearings into Champion Swing Arm in the same way as the OEM Swing Arm. Using OEM Spacer Tube and supplied washers (four ¾” flat washers), install Champion Swing Arm using OEM bolt, outside washers and nut. Do not torque pivot bolt nut at this time. Figure 2 Note : Insure belt path is over and under Swing Arm pivot. c. d. Replace cross assembly and hardware (previously removed in step 3.2) to Champion Swing Arm. Note that the 2 upper left hand side bolts are countersunk. Torque pivot bolt to OEM specification

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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 Softail Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 02-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the fasteners that secure the seat. Remove seat. 6. Disconnect negative Battery Terminal. 7. Remove the Saddle Bags. And their hardware. If equipped. 8. Loosen Muffler Clamp on both Mufflers and other attaching hardware. Remove and discard both Mufflers. 9. Loosen the 4 exhaust stud nuts and save. Remove and discard head pipes and exhaust gaskets. 10. Disconnect the Rear Lamp Wiring Harness. 11. Remove any fasteners from Electrical Box. 12. Remove and discard Rear Fender, Fender Support and fasteners. NOTE: 2008-Current various models. Remove ECM from Fender and save nuts. 13. Drain all Brake Fluid from the Rear Brake System. 14. Un-clamp Rear Brake Line from the frame and Rear Fork. 15. Remove and discard both Banjo Bolts and Crush Washers from the Rear Brake Caliper and the Rear Brake Master Cylinder. 16. Remove Brake Light Switch from the Brake line, Save for reassembly. 17. Remove the Torx screw from the Brake Line bracket, Save the Torx screw for reassembly. 18. Remove and Discard Brake Line. 19. If Lower Controls option. Remove and Discard right and left floorboards/foot pegs, brake pedal, shifter, and shift linkage. Remove and Discard Passenger Foot pegs or Floorboards and their mounts. Then skip to step 24. 20. If Lower Controls Not purchased. Continue. 21. Remove acorn nut from Shift Linkage. 22. Remove 3 fasteners from Drivers Floorboard and remove. 23. Remove and discard Jiffy Stand. 24. Remove the Primary Cover by first removing the top and rear inspection cover screws. 25. Continue by removing remaining fasteners. 14 total. 26. Remove and discard Primary Cover Gasket. 27. Clean residual gasket material from both surfaces. 28. Loosen the Top Center Nut on the Primary Chain Adjuster. Lower the Primary Chain Adjuster until it rests flat on the Inner Primary Cover. 29. Remove the Clutch Lifter Retaining Ring from the Clutch Basket. Remove Clutch Lifter Assembly. 30. Using the Primary Drive Locking Tool. Loosen the Compensating Sprocket Nut. 31. Using the Primary Drive Locking Tool. Loosen the Clutch Hub Main shaft Nut. WARNING: This nut is LEFT HAND threaded. 32. Remove the Primary Drive Locking Tool, Compensating Sprocket Nut, and Clutch Hub Main shaft Nut. 33. Remove the Sprocket cover and Sliding Cam from the Crank Shaft Extension. 34. Remove the Clutch Assembly, Primary Chain, Compensating Sprocket, and Crank Shaft Extension in one assembly.

Harley Davidson Softail 1987 to Current Trike Conversion Installation Manual

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

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Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported. b. c. d. e. f. Make sure the engine is turned off before you begin work. • Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts: Let the engine and exhaust system cool before working on those areas. • Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries. Use only nonflammable solvent, not gasoline, to clean parts Never drain or store gasoline in an open container. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts. 1.4 Specifications Overall Length: 66″ Body Length: 92″ Wheel Base: 53″ Load Capacity: 620 Lb Tire Size (15″): 205 / 70 / R15 Wheel Size (15″) (4 lug) Offset +35 mm 15x7JJ 4×4.5 – (Current Installations – Alum Rear End) Wheel Size (15″) (5 lug) Offset +35 mm 15x7JJ 5×4.5 – (Later Installations – Black Rear End) Tire Size (16″) 215 / 60 / R16 Wheel Size (16″) (5 lug) Offset +40 mm 16x7JJ 5×4.5 – (First Installations – Black Rear End) Tire Pressure: 20 PSI Suspension: Internal Swing Arm utilizing OEM shocks Rear Differential: Custom-built rear differential utilizing OEM drive belt. Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 3.75 cubic feet. 2 full-face helmets and additional storage

Harley-Davidson Road King Classic Tour Pack INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Close the bag completely. Support the outside of the bag with a covered piece of soft material to prevent marring or scratching. 2. Position the template on the outside of the bag, centered between the buckles. Align the template along the gap between the seams as shown at right. Tape the template in place. 3. Drill all of the small holes on the template using a 1/4″ drill bit for the assembly holes. Drill or punch the 3/4″ hole for the lock. 4. Sandwich the lock. item 4, between items 3 and 5 as shown above in FIG.1. Fasten it to the bag with the black slotted blind screws (items 7). Sandwich the leather between the lock cover plate (item 6) on the outside and the lock assembly. It may be necessary to remove a section of excess overlapped leather. 5. Use the phillips head screws (item 7) provided to attach the spring loaded ratched bar assembly. 6. Lock operation. *a. rotate the locking bar down as the bag is closed * * so that it is started into the lock aseembly. *b. check that the bag straps are outside of the bag. *c. Press the bag lid down as your help to align the * * bag lock assembly with the locking ratched bar. the ratchet bar whill operate smoothly into the * * lock when properly aligned.

HARLEY DAVIDSON T-PAK RACK BAG INSTALLATION INSTRUCTIONS

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

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INSTALLATION See the Accessory and Cargo section in your Owner’s Manual. Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00021a) •Secure the bag straps to the rack to prevent bag shifting during vehicle operation. •See the owner’s manual for recommended tire inflation pressure. 1. See Figure 1. Set the rack bag on top of the luggage rack with carrying handle (1) toward the rear of the vehicle. 2. Install the four corner clips to the connector straps. 3. See Figure 2. Wrap the connector straps around the bars of the luggage rack and install the ends into the strap keepers. Tighten the straps as necessary. Tuck in to tie down any excess strap material. 4. Give the rack bag a final pull to verify the pack is securely attached.

HARLEY DAVIDSON SOFTAIL SPROCKET KIT INSTALLATION NOTES

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

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NORMAL TOOTH WARRANTY This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt. All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed. Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue. Decorative external chrome carries the standard parts and accessories 90 day warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue. All warranty claims must be pursued through your authorized Harley-Davidson Dealer