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HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

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Honda VTX 1800 Motorcycles EZ-Steer Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Honda VTX 1800 EZ-Steer Instruction Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Honda VTX 1800 Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Recommended Procedures • Disconnect all wiring to headlight and remove headlight, windscreen (if so equipped) and brackets from motorcycle. • Remove handle bars from top clamp. • Remove brake caliper and brackets; disconnect all mounting points on brake lines. Secure calipers to frame being careful not to damage brake lines. • The wheel and fork tube assembly can be removed as one complete unit. • Remove steering lock fromOEM bottom clamp and install on Champion’s bottom clamp. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion’s lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 35 lb. ft.. • Install covers to bottom forks if supplied with OEM motorcycle. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of forks are flush with top surface of clamp. • Torque dome nut to 75 lb. ft.. • Ensure that fork tube extensions are flush with top of upper clamp. Torque lower 8mm bolts to 20 lb.ft. and upper 10 mm clamp bolts to 30 lb. ft.. • Install handle bars to upper clamp using OEM nut and flat washers. • Reinstall brake line holders to the lower triple clamp. • Reinstall all other OEM parts as removed. • Bleed brakes. • OEM windshield # 08R80-MCH-100 can be used on this kit

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HARLEY DAVIDSON TOURING DETACHABLE TOUR-PAK RACK INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE See Figure 3. When installing Tour-Pak to Rack in the following Steps, note that holes on Rack provide two positions for mounting Tour-Pak in desired location. 1. Place Tour-Pak on support tube and open lid. NOTE See Figure 3. In the following step, the longer bolts (6) are used for 2005 and earlier (King only) and Chopped Tour-Paks while the shorter bolts (5) are used for Leather Tour-Pak and 2006 and later King Tour-Paks. 2. See Figure 3. Obtain bolt (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align rear center hole in Tour-Pak with same hole in support tube (8). Slide bolt with flat washer through Tour-Pak, through support tube, then through concave spacer (with concave side facing support tube). At bottom of support tube, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. 3. Obtain bolts (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align top support tube (8) with detachable tour-pak rack holes (four). Slide bolts with flat washer through Tour-Pak, through support tube, through concave spacer (with concave side facing support tube) then through rack. At bottom of detachable tour-pak rack, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. NOTE Always install the mounting bolts from inside the Tour-Pak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak. 4. Repeat Step 3 and install hardware to the remaining three holes in Tour-Pak and mounting rack. 5. In a crosswise pattern, alternately tighten the five bolts to 96-120 in-lbs (10.8-13.5 Nm) . Be sure that concavity on each spacer is inline with the rail and has not rotated out of position. INSTALLATION-TOUR-PAK AND RACK 1. Follow the instructions included in the docking point kit and install docking points. 2. See Figure 1. While standing behind the motorcycle, place the front Tour-Pak rack notches into the front docking points (1). Make sure the notches seat fully into the front docking points. 2 1 is04025 1. Front Docking Point 2. Rear Docking Point Figure 1. Docking Point Bracket 3. See Figure 1 and Figure 2. Position the latches over the rear docking points (2). Check to be sure the latches fit into the neck of the rear docking points as shown in figure 2. This may require some gentle squeezing or spreading of the rack

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HARLEY DAVIDSON TOUR-PAK KIT INTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Remove the rubber mat from the bottom of the Tour-Pak. 2. See Figure 1 and Table 1 to determine the proper hole configuration to attach the Tour-Pak to your luggage rack. Holes will be drilled as explained in Step 3 in the hole location for your luggage rack. Table 1. Luggage Rack and Hole Configurations Hole Configura- tion Luggage Rack C (3 holes) Stock 1997 B (4 holes) Detachable luggage rack 53107-96 A (5 holes) Luggage rack 53118-97A and luggage rack 53118-98 A (5 holes) Stock 1998 and later racks A (5 holes) Detachable Tour-Pak rack 53276-04 B (4 holes) Solo detachable Tour-Pak rack 53655-04 B (4 holes) Detachable Tour-Pak rack 53066-00B B (4 holes) Solo detachable Tour-Pak rack 53559-04A A (5 holes) Solo detachable Tour-Pak rack 53260-02 -J03631 1 of 3 B 1 A C 2 2 2 is00163 1. Front of motorcycle 2. Bottom view of Tour-Pak interior (rubber mat removed) Figure 1. Hole configurations for Tour-Pak attachment NOTE Drilling holes in Tour-Pak without wood underneath each hole site may result in the leather becoming damaged during the drilling process. 3. Place blocks of wood underneath the Tour-Pak where the holes will be drilled to prevent damage to the leather while drilling. Use the pre-drilled holes in the metal base as a guide and carefully drill the holes through the leather in the proper location using a 11/32 inch drill bit. 4. See Figure 2. For detachable luggage racks (53107- 96, 53066-00B and 53276-04): Install black cover tube to the front bar (1) of the luggage rack, as shown. This tube is used to provide a cleaner look. The black cover tube is not for use with other luggage racks. 5. Attach Tour-Pak to rack using the mounting screws provided in the Luggage Rack kit. Put bolt through from inside of Tour-Pak. Tighten screws to specifications found in the Luggage Rack kit. 6. Place the black rubber mat on the bottom of the Tour-Pak. 7. If luggage rack was removed, reattach to motorcycle according to kit instructions or Service Manual instructions

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HARLEY DAVIDSON CONTOURED TOUR-PAK LUGGAGE RACK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION NOTE The location of the Tour-Pak spoiler has a direct relationship to the location of Tour-Pak mounted luggage rack. The spoiler template will locate the Tour-Pak spoiler in the correct position for the luggage rack so that the spoiler may be added in the future. It is recommended that the spoiler be installed first. See Figure 1. 1. Identify if the installation of a Tour-Pak mounted spoiler is desired in the future. Use the template if the spoiler will be installed. Cut the template along the appropriate line. Carefully place template on top of Tour-Pak lid, aligning edges of template with top surface of Tour-Pak. Tape template in desired location. 1 is 00579 1. Check clearance between rack and spoiler Figure 1. Tour-Pak Rack and Spoiler NOTE Position top rack with upright section toward rear of motorcycle. To avoid contact with the passenger backrest pad, do not mount the top rack in too far forward a position. 2. See Figure 2. Place the four mounting pads (1) onto the four mounting supports on top rack (2). Carefully center the rack on the lid and position the rack rear supports 5/8 inch to 3/4 inch (16 mm to 19 mm) in front of the emblem on the Tour-Pak lid, as shown. 1 is 00636 1.5/8 in. – 3/4 in. (16 mm – 19 mm) Figure 2. Locate Holes From Emblem 3. Use a grease pencil to temporarily mark the positions of the four mounting pads on Tour-Pak cover. NOTE Apply masking tape to the Tour-Pak cover painted surface at the four points where the top rack mounting holes will be drilled. The tape can be marked for hole location, and will help prevent the paint from being chipped during the drilling procedure. 4. Carefully remove top rack/mounting pad assembly. Place a strip of masking tape over each grease pencil mark on the Tour-Pak cover. Once again, position top rack/mounting pad assembly on Tour-Pak cover in the desired mounting location. 5. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting pad. Remove top rack/mounting pad assembly. Use a ruler to mark the exact center of each circle drawn on the tape strips. NOTE Remove all contents from within the Tour-Pak to avoid possible contact with the moving drill bit during the following drilling procedure. 6. Drill starter holes using a 1/16 inch drill bit. Drill the finished holes for the mounting screws using a 9/32 inch drill bit. Remove masking tape strips. 7. Apply a small amount of silicone sealant around each mounting hole on interior surface of Tour-Pak cover

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HARLEY DAVIDSON TOUR-PAK RACK LIGHT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION 1. Remove all contents from Tour-Pak®. 2. For easier installation, remove Tour-Pak rack, if installed, by removing cap screw, washers and mounting pads. 3. See Figure 1. Remove rubber plug from bottom rear rail on left side of rack. 4. See Figure 2. Use line wire feeder in kit to thread through left rear rack foot and out through the back opening of rail. 5. Attach light harness wires to line wire feeder loop. 6. Carefully pull line wire feeder and light harness wires through rack mounting foot. 7. See Figure 5 and Table 1. Apply foam pads (5) to top surface of light. 8. Secure light (1) to rack with socket head screws (4) and washers (6). 1 is05242 1. Plug Figure 1. Left Side Rack Plug 1 is05244 1. Line wire feeder Figure 2. Thread Wires Through Rack 9. Position rack/light assembly to Tour-Pak lid and route wires through lid, washer and hollow mounting bolt. 10. Attach rack/light assembly to Tour-Pak using instructions and hardware provided with rack except for use of hollow bolt from Step 9. 11. Remove Tour-Pak liner. 12. Thread wires through black vinyl conduit. 13. Ultra Classic models: Follow Steps 14 through 2114. Locate and disconnect three pin AMP connector for Tour- Pak lights. 15. See Figure 3. Attach the Y-harness (2) to the three pin male connector (1) of Tour-Pak harness. 16. Route light wires from back of Tour-Pak along left side to front. Secure conduit with adhesive clips provided in kit. 17. Trim length of light wires and conduit to reach Y-harness. 18. Refer to the Service Manual electrical appendix to install terminal pins (8) to rack light wires and install terminals to three pin housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead 19. Connect rack light to remaining Y-harness connector. 20. Replace Tour-Pak liner. 21. Check operation of Tour-Pak tail and stop light functions before operating motorcycle. 22. Classic models: See Figure 4. If necessary, drill hole in lower left bottom of Tour-Pak and install grommet. Route rack light wires through grommet. 23. Refer to the Service Manual electrical appendix to install terminal receptacle (8) to rack light wires and install terminals to three pin receptacle housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead NOTE To prevent corrosion, fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. As an additional precaution against moisture seepage into the Tour-Pak, apply silicone sealant (not included in kit) to the entrance of the light harness wire tunnel. See figure 2 for location reference. 24. Connect rack light to male connector of two connector wire harness (12) and connect to accessory connector under seat. 25. Replace Tour-Pak liner. 26. Check operation of Tour-Pak tail and stop light functions before operating motorcycle

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HONDA VTX 1800 AIR HORNS AHVTX INSTALATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-12-2010

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1. Remove the right and left frame side covers and the seat. 2. Unplug and remove the stock horn located behind the left foot peg. Re-route the horn wires up over the front cylinder head and to the rear. Next cut two pieces of wire 36″ long, strip both ends ¼”, crimp two male spade terminals to one end and two females to the other ends. Attach these wires to the stock horn wires and route them over the rear cylinder and behind the frame tube. The end of the wires should come out near the center of the left side cover area (see photo 1 A). Connect these two wires to the relay terminals 85 & 86 (these will be the two that are parallel to each other see wiring diagram for terminal identification). 3. Using a blade screwdriver pry the two hoses with the “Y” connector off of the air horns. Cut a new piece of hose 2 ¾” long, replace the old short hose on the “Y” with this. Re-install the “Y” hose assembly onto the horns with the short hose on the long trumpet, route the hoses behind the horns and connect the long hose to the short horn (see photo 2A). 4. Remove the upper 8mm (12mm wrench size) motor mount bolt (see photo 2B). Install the horn assembly using the 8 x 55mm bolt and spacer tube provided. If the motorcycle is fitted with Honda line tubular radiator or engine guards the above mounting will not work. You will need instead to locate the “J” shaped bracket and small hose clamp provided in the hardware kit (see photo 2 on instructions of multi -application instruction sheet). Thread the hose clamp thru the bracket and attach to the frame or Honda line guards as shown ( see photos 2&3 ) tighten the hose clamp securely using a socket or wrench. Attach the horn set to the “J” bracket using the 5/16 x ¾” bolt, nut and lock washer provided. Position the horns so that they are angled down just slightly then tighten the bolt securely. Attach the remaining air hose to the “Y” connector, route the hose up over the top and to the rear of the engine. Cross the hose over to the right side of the rear cylinder head, then behind the electricals of the right side cover and coming out as shown ( see photo 3 A & B ). 5. Remove the center relay from its mounting bracket by lifting it upward and re-attach it lower and at an angle as shown (see photo 3C) using a small cable tie. Route two long cable ties thru the hole in the relay mounting bracket as shown (see photo 3D). Next cut a 16″ wire, strip both ends, crimp female spades to both ends. Attach this wire to the compressors pos (+) terminal. Cut an 8″ wire, strip both ends, crimp a female spade to one end and a fork terminal to the other. Attach this wire to the compressors neg. (-) terminal. Cable tie the compressor securely in place as shown (see photo 4). Route the hose to the compressor making sure there are no tight bends or kinks cut the hose to the desired length and attach it to the compressor. Route the neg. (-) wire with the fork terminal up and attach it to the 10 mm bolt as shown (see photo 4A) . Route the pos. (+) wire over to the relay on the left side of the motorcycle and attach it to terminal 30 or 87 on the relay (see wiring diagram)

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HARLEY DAVIDSON TOURING DETACHABLE SOLO TOUR-PAK RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Installation NOTE See Service Parts Ilustration. When installing Tour-Pak to Rack in the following Steps, note that holes on Rack provide two positions for mounting Tour-Pak to desired location. 1. Place Tour-Pak on support tube and open lid. NOTE In the following Step, the longer bolts (Item 7), are used for King and Chopped Tour-Paks while the shorter bolts (Item 6) are used for Leather Tour-Pak. 2. See Service Parts Illustration. Obtain bolt (6 or 7), two flat washers (4), concave spacer (5) and hex lock nut (3) from kit. Align rear center hole in Tour-Pak with same hole in support tube (9). Slide bolt with flat washer through Tour- Pak, through support tube, then through concave spacer (with concave side facing surpport tube). At bottom of support tube, install washer and nylock cap nut (3). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. 3. See Service Parts Illustration. Obtain bolt (6 or 7), flat washers (4), concave spacer (5) and hex Nylock nut (3) from kit. Align the remaining four holes in Tour-Pak over holes in solo rack. Slide bolt with flat washer through Tour- Pak, through support tube (9), then through concave spacer (5) (with concave side facing up) and Solo Rack hole. At bottom of Solo rack, install washer and nylock cap nut (3). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. Always install the mounting bolts from inside the Tour- Pak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak. 4. Repeat Step 3 and install hardware to the remaining three holes in Tour-Pak and mounting rack

HARLEY DAVIDSON TOUR-PAK WALL ORGANIZER INSTALLATION INSTRUCTIONS

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

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This kit fits 1997 and later models equipped with King Tour- Paks INSTALLATION NOTE Maximum Wall Organizer weight capacity is 3 pounds (1.4 Kg) evenly distributed. Do not exceed tour-pak weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00401b) Tour-Paks With Molded Liner 1. Remove the two nuts that hold the pouch and liner in the Tour-Pak. Remove pouch and liner and carefully wash the inside of the Tour-Pak with warm, soapy water. Rinse and dry thoroughly. 2. Use the alcohol prep pad in the kit to thoroughly clean the interior surface of the Tour-Pak sides where fastener strips will be attached. Make sure any residue is removed, then allow Tour-Pak to dry completely. Make sure the surface is free of condensed moisture. NOTES The hook and loop fastener strips and organizer must be installed below the edge of Tour-Pak base to avoid interference with top gasket and lock. The ideal temperature range for applying the fastener strip is 70-100° F (21-38° C). Minimum application temperature is 50° F (10° C). If you attempt to apply the tape below these temperatures, the adhesive will become too firm to adhere readily. 3. See Figure 1 and Figure 2. Remove the hook and loop fastener strips from the hinged hook and loop strips. Remove the paper backing and firmly press the fastener strips into the locations (1) shown in Figure 2. The fastener strips should be located approximately 1/8 in. (3 mm) below the edge of the Tour-Pak base. 4. See Figure 1. Bend the hinged hook and loop strips (3) into shape as shown. Attach the hinged strips onto the fastener strips (2) installed in Step 3. NOTE The Tour-pak Wall Organizer installs in place of the pouch removed in Step 1, therefore the pouch will not be re-installed. 5. Reinstall the liner removed in Step 1. The hinged strips (3) will go over the top of the liner (4) as shown in Figure 1. 6. See Figure 1. Attach the organizer (5) to the hinged strips (3). Adjust the organizer’s lock cut out so that it is centered around the lock, and press the hook side of the hook and loop strips on the bottom of the organizer into place on the liner. The hook side will attach to the liner. NOTE 2006 and later Tour-Paks equipped with Passenger Backrest will have two acorn nuts at the front of the base. Remove and discard the 8 in. (200 mm) long hook and loop hinged fastener strip from the center panel. In one of the organizer pockets there will be 4 in. (100 mm) and 1-1/2 in. (38 mm) hook and loop hinged fastener strips. Install the hinged strips on the organizer center panel as shown in Figure 3. 7. Check to make sure the Tour-Pak lid closes over the organizer and the lock works without interference. Adjust as necessary. 8. Allow tape to cure (“wet-out”) for a minimum of 48 hours at 70° F (21° C) (allow extra time if temperature is below 70°). Do not place items in the Wall Organizer while adhesive is curing

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HARLEY DAVIDSON BOOM! AUDIO BASS BOOSTER TOUR-PAK PORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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PREPARATION NOTE For vehicles equipped with security siren: • Verify that the Hands-Free Fob is present. • Turn the ignition key switch to IGNITION. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the owner’s manual and follow the instructions to remove the main fuse. INSTALLATION NOTE The Tour-Pak does not need to be removed from the vehicle to perform this installation. 1. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 2. Models equipped with mat: Remove the mat. Models equipped with liner: Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. 3. Remove four screws from the left-side speaker grille on the Tour-Pak. Remove the speaker grille from the speaker pod. 4. Remove the speaker from the speaker pod. Carefully pull the two socket terminals from the speaker spade contacts. 5. Remove the grommet, and draw the rear speaker/passenger controls connector out of the speaker pod. Separate the connector halves. 6. Repeat Steps 3 through 5 for the right-side speaker. 7. See Figure 1. Get the drill template (3) from the kit. If NOT equipped with power port: a. Remove one speaker pod mounting screw and flat washer. b. Align the drill template on the inside of the Tour-Pak with the speaker pod holes, and hold in place with the mounting screw and washer. c. Repeat for the remaining template mounting holes. If equipped with power port: a. Remove the two screws and flat washers to free the power port from the Tour-Pak. b. Align the drill template on the inside of the Tour-Pak with the power port holes, and hold in place with the mounting screws and washers. c. Repeat with the top speaker pod mounting screw and flat washer. NOTE Tighten the screws enough to hold the speaker pod in place as the pilot hole is drilled. 8. Where indicated on the template, drill a 3/16 inch (5 mm) diameter pilot hole through the Tour-Pak wall and speaker pod. 9. Remove the screws and speaker pod, and set aside. Turn the template over, and repeat Steps 7 and 8 on the left side of the Tour-Pak. NOTE Hole size will affect the fitment of the ports. The hole saw needs to be sharp. 10. Carefully drill a two inch (51 mm) diameter hole with a sharp hole saw, at the pilot location, through each speaker pod and in both locations on the Tour-Pak wall. 11. Temporarily install the Tour-Pak liner (if equipped), and mark the location of the two inch (51 mm) diameter holes on the outside of the liner. Remove the liner, and carefully cut the two holes in the liner front wall

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