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1999-2003 Harley Davidson TC88 Micro Tach TM Tachometer Installation Manual

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Filed Under (Harley Davidson) by admin on 10-03-2012

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Installation of the Speedway Instruments microTach+TM tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. The microTach+ TM tachometer designed for 1999-2003 TC88 Harley Davidson motorcycles is designed to operate when connected to a dedicated Tachometer signal from the Electronic Ignition Controller. It is not intended to run off signals going to the ignition coil unless utilizing a Speedway Instruments Tach Adapter. WARNING: Damage may occur to the microTach+ TM tachometer or your motorcycle if micro Tach+ TM tachometer is connected directly to coil signals, you must use a Speedway Instruments tach Adapter (sold seperately) ! ! 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservoir

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2004 Harley Davidson Micro Tach Tachometer Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-03-2012

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Tachometer Installation Instructions for 2004+ Harley Davidson Sportster Custom Look for other model instructions online at www.speedwayinstruments.com Introduction: Installation of the Speedway Instruments microTach+ TM tachometer Tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. These instructions utilize a 2004 Harley Davidson XL1200C motorcycle as basis for the all descriptions and pictures. Variations in location, color and procedure may be required for different year and make. Please refer to the Service manual to confirm the proper color and location of wires. Please make sure you have the proper service manual and tools before starting the installation. 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservior b. Top handle bar clamp

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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1980-2003 HARLEY DAVIDSON BARON TACHOMETER installation manual

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Filed Under (Harley Davidson) by admin on 12-03-2012

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1. Mount new Baron Tach on handlebar in your preferred position. Ideal location is between handlebar risers. If mounted off-center, you can rotate tach face back to vertical (or any position you desire) by first loosening tach unit’s set screw (found either in handlebar area of housing or underside of housing, depending on tach style), then unscrewing tach housing’s bezel, rotating the tach internals, re-installing the bezel and retightening the set screw. 2. Secure handlebar clamp by first tightening the rear, flat side of clamp all the way down, and then tighten the tapered front side of clamp until tach does not rotate. There should be a small gap on the pointed side and no gap on the flat side when the clamp is correctly tightened. 3. Route tach’s wire harness lead under dash for simplest and cleanest installation. 4. Make your wire connections as follows: a. Locate the pink wire under the speedo (sometimes has a plastic bullet end on it). Cut the plastic off and splice the pink wire with the green wire from the tachometer. b. Find the orange wire and attach the tach power wires to it (usually blue & red from tach (incandescent) or red & yellow for single color LED tachs. On 7-color LED models it is red from tach and red from LED controller box) . c. Locate a suitable ground (usually a bare frame bolt) and attach the black wires from the tachometer and the LED controller box (if equipped).

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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.

HARLEY DAVIDSON COMBINATION SPEEDOMETER/ TACHOMETER GAUGE KIT INSTALLATION MANUAL

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

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REMOVING THE OLD SPEEDOMETER NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Make sure you locate and follow the procedures that apply to the motorcycle receiving the new gauge. 1. Apply power to motorcycle and record the odometer reading. 2. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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) 3. Disconnect battery cables, negative cable first. NOTE Cover the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 4. Remove the instrument console acorn nut (and mounting screw with a flat washer on some models). Lay clean shop towels on the fuel tank. Lift the console from the fuel tank, turn it upside down and lay it on the towels. NOTE If necessary, bend back the flexible metal clip to free the harness conduit from the underside of the console. 5. Unplug the 12-terminal connector [39B] from the back of the speedometer. Depress the external latches and use a rocking motion to separate the pin and socket halves. 6. Remove the back clamp. All models except FXSTD: Gently pry the three latches upward to release the back clamp from the back of the speedometer. FXSTD: Depress the three external legs of the lock ring, then gently pry the three latches upward to release the back clamp from the back of the speedometer. 7. Unscrew the trip-meter reset button, and pull the harness from the clamp (remove the screw if necessary). 8. Lift the console and remove the old speedometer from the console. Discard the old speedometer, but retain the rubber gasket and back clamp for use with the new gauge. NOTE Set the console securely on the towel-covered fuel tank, and take care that it does not fall off during the following operations. 9. Set the console securely on the fuel tank

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 COMBINATION SPEEDOMETER/TACHOMETER GAUGE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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Removing the Old Speedometer NOTE This Instruction Sheet covers several different Harley- Davidson models and years. Make sure you locate and follow the procedures that apply to the motorcycle receiving the new gauge. 1. Apply power to motorcycle and record the odometer reading. 2. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) 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) 2. Disconnect battery cables, negative cable first. NOTE Cover the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 3. Remove the instrument console acorn nut (and mounting screw with a flat washer on some models). Lay clean shop towels on the fuel tank. Lift the console from the fuel tank, turn it upside down and lay it on the towels. NOTE If necessary, bend back the flexible metal clip to free the harness conduit from the underside of the console. 4. Unplug the 12-terminal connector (39B) from the back of the speedometer. Depress the external latches and use a rocking motion to separate the pin and socket halves. 5. Remove the back clamp: All models except FXSTD: Gently pry the three latches upward to release the back clamp from the back of the speedometer. FXSTD: Depress the three external legs of the lock ring, then gently pry the three latches upward to release the back clamp from the back of the speedometer. 6. Unscrew the trip-meter reset button, and pull the harness from the clamp (remove the screw if necessary). 7. Lift the console and remove the old speedometer from the console. Discard the old speedometer, but retain the rubber gasket and back clamp for use with the new gauge. NOTE Set the console securely on the towel-covered fuel tank, and take care that it doesn’t fall off during the following opera- tions. 8. Set the console securelyon the fuel tank. Installation and Final Check NOTE Apply window cleaning fluid or mild soapy water to the speedometer gasket as needed to aid installation. 1. Turn the console over, facing upward. 2. Place the speedometer gasket into position around the console speedometer bore. 3. Fit the new gauge into the bore so that it fits snugly against the rubber gasket. Rotate the gauge into approximate visual alignment. The back clamp will complete the alignment. 4. Turn the console over, face down. 5. Install the back clamp

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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