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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 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 EFI SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

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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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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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HARLEY DAVIDSON SCREAMIN' EAGLE ELECTRONIC FUEL INJECTION (EFI) STAGE 1 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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Installation NOTE The installation procedure is divided into three parts: 1) Replacing ECM (1996 and earlier models ONLY) 2) Calibrating the ECM 3) Replacing stock air cleaner with air cleaner from kit. 1) REPLACING ECM (1996 and earlier models ONLY) 1. Refer to the REMOVAL/REPLACEMENT section 9C in the 1995-1996 FLT Service Manual, Part No. 99483- 96A. 2. Install ECM in accordance with the installation procedure given in the Service Manual. 2) CALIBRATING THE ECM Have dealer recalibrate the ECM prior to starting vehicle. NOTE The product information (EO) label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the information label on the right side of the frame directly beneath the VIN sticker. Do not place the label over other product information labels. Do not place the label on motorcycles other than those specified in the instruction sheet. 3) REPLACING STOCK AIR CLEANER Removing Stock Air Cleaner NOTE Refer to the applicable Service Manual and check the warm- slow idle speed adjustment before removing stock backplate. 1. Remove stock backplate following the instructions given in the appropriate Service Manual. 2. See Service Parts Illustration. Retain stock air cleaner cover and buttonhead screw and washer. Installing High Performance Air Cleaner 1. See Service Parts Illustration. Locate banjo bolts (10) included with kit. Place one washer (11) over each banjo bolt. Insert bolts through holes in mounting bracket (15). Place a second washer over each bolt. Place manifold breather (16) over bolts with hose fitting toward rear of motorcycle. Install remaining washers over the ends of bolts

Harley Davidson engine modification

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Filed Under (Harley Davidson) by admin on 02-11-2010

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Looking for high performance engine specifications for your Harley- Davidson motorcycle? Need to know what high performance equipment provides the best performance at the lowest costs for your H-D. Here you can look at performance modifications with the dyno runs of many different engine combinations, so you can pick your own equipment, horsepower rating and dollars to spend. An incremental approach to engine development has provided some good results on many engines. Find out what combination of carburetor, camshaft, exhaust systems, ignition systems, head work, pistons and the other high performance components work well. There are tests of some equipment that did not work well. Know what works and what does not. Compare the results of your current bike to those seen here. Are you getting the performance you paid for? If you have had success in your engine development program, send a picture of the bike and your performance results (dyno sheets or time slips) to the V -Twin Café for publication. The V -Twin Café is always looking for good articles on motorcycle performance work. If you write performance oriented articles, contact us. Twin Cam 88 and 95 cubic inches Twin Cam Engines from Harley-Davidson have a good design and some nice upgrades available from the local Dealer including a 95 cubic inch big bore kit. What can you expect from this engine? Here are some engine configurations that have been tested. 45 to 50 HP Stock Evolution Engines are the starting point for all the modifications. The only way to validate what the performance gain was for any change is to have dyno runs before and after. These are the before runs of several bikes. 55 to 65 HP Up to $750 Stage One Evolution Harley-Davidson engines involve no internal changes made to the engine. All modifications are made by changing or modifications to external components on the engine. These components include air cleaners, carburetors, exhaust systems and ignition systems. No special tools or training is required to perform stage one modifications.

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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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HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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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. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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