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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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HARLEY DAVIDSON ADJUSTABLE AIR DEFLECTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 1. Models with NO air deflectors installed: Remove and discard the eight hole plugs (1) from the right and left edges of the inner fairing assembly. Models WITH air deflectors currently installed: Remove and discard the eight screws that retain the right and left air deflectors. Remove and discard the deflectors. 2. See Figure 2. Select a right-side (1) or left-side (2) air deflector, and four screws (3) from the kit. Determine the correct side by holding the mounting-hole side of the deflector against the fairing. 3. Place the deflector against the inner fairing, lining up the holes. Insert the screws through the deflector holes and into the fairing air deflector holes. Tighten the screws to 25-30 in-lbs (2.8-3.4 Nm) . 1 1 is04653a Figure 1. Remove Hole Plugs SERVICE PARTS 3 2 1 is04654 Figure 2. Service Parts: Adjustable Air Deflector Kit Table 1. Service Parts Table Part Number Description (Quantity) Item 58128-08A Air deflector, adjustable (right side) – Dark Smoke 1 57655-08A Air deflector, adjustable (right side) – Light Smoke 58129-08A Air deflector, adjustable (left side) – Dark Smoke 2 57657-08A Air deflector, adjustable (left side) – Light Smoke 2563 Screw (8

HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle 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 owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Connect positive (+) 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. (00068a) 4. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

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Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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Filed Under (Victory) by admin on 31-10-2010

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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HARLEY DAVIDSON DETACHABLE QUARTER FAIRING AND DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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Installation 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 If your motorcycle has directional lights mounted on the upper fork bracket they must be relocated to the bottom fork bracket. Some models have front directional lights equipped with three wires, the third black wire is a ground wire. Check to determine how many wires are connected to the front directional lights and follow the following procedure that applies. Ifdirectional lights are not mounted on the upper fork bracket proceed to “ASSEMBLING FAIRING”. Relocating Two Wire Directional Lights 1. Support motorcycle on a center stand such that front wheel is raised slightly off the ground. 2. Remove fork tube pinch screw from right side of lower bracket. 3. Cut wires connected to right directional light about 2 in. away from directional light body. 4. Remove fork tube pinch screw from right side of upper fork bracket. (This is the screw that secures the right directional light.) 5. Install right directional light on right side of lower fork bracket using pinch screw removed in step 4. Install pinch screw removed in step 2 into right side of upper bracket. Tighten both pinch screws to 30-35 ft-lbs. 6. Repeat steps 1 through 5 to relocate left directional light. NOTE Fork tubes may slide downward within fork brackets. If this occurs, front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures. 7. Connect the right directional light as follows: Strip approx. 5/16 in. of insulation from the wires cut in step 3. 8. Crimp solderless connectors from kit on two wires coming from motorcycle. 9. Split one end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 10. Slide a piece of shrink tubing from kit over each of the wire ends stripped in step 9 and crimp the wires into the terminals installed in step 8. Make sure you connect the silver and copper colored wires to like colored wires. NOTE Polarized wire is used in this application to ensure correct wiring. One wire is silver, one is copper colored. Wire colors of spliced wire must match wire color of original directional wire leads. 11. Cut polarized wires to the length required for connection to the wires at the relocated directional light. Make certain you leave enough slack in wires to allow routing the harness along the fork tube. 12. Split remaining end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 13. Slide heat shrink tubes over the two wire end. 14. Strip 5/16 in. of insulation from wires connected to directional light and connect like colored wires at directional light with connectors from kit. 15. Slide heat shrink tubing over connectors installed in steps 10 and 14. Activate shrink tubing with heat gun or hair dryer.

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 HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. 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 A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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