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2007 Ural Models Gear Up Patrol Tourist Installation Manual

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Filed Under (Ural) by admin on 02-11-2010

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Font Brake Control Lever Clutch control lever: When the clutch lever is squeezed, the engine is disengaged from the gearbox. When the lever is released, the engine and gearbox are engaged. WARNING: MAKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED . WARNING: B EFORE STARTING ENGINE , ALWAYS SHIFT TRANSMISSION TO NEUTRAL TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY . Caution: Always engage the clutch release lever when shifting. Serious internal damage may result to the transmission if the clutch release lever is not engaged. Front brake control lever: When the lever is squeezed, the front wheel brake is actuated. The front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal lights are switched on. 19 Kickstart lever : Designed to start the engine. Upon kicking the lever the crankshaft is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Gear shift lever: This is a heal shift type of lever. To shift up from a low gear to a high gear the rear arm(heal shift) is pressed. To shift down from a high gear to a low gear the from arm is depressed. Since the heel-toe shift lever is short-coupled, it is much easier to shift up using the heal shift, and to shift down using the toe shift with the ball of your foot. The neutral gear is between the 1st and 2nd gears. It is important to shift smoothly with a constant force, and not to kick the gear shift pedal. Serious damage may result to the shifting mechanism if the gear shift pedal is kicked, rather than pressed. NOTE: The neutral lamp will illuminate when the transmission is in neutral. (see “Starting the Engine”). Gear Shift Foot Pedal Kick Lever 20 Parking Brake Sidecar Drive Lever Rear Brake Pedal Parking Brake: Used to hold the bike when parked. To engage, press the rear brake pedal, push down and twist the parking brake lever counter clockwise. Sidecar drive engagement lever: Used to engage the drive axle to the sidecar wheel on the Patrol and Gear Up model motorcycles. WARNING: Never engage sidecar drive on concrete or hard surface. Severe damage to drivetrain will result if the sidecar drive is engaged on pavement. Rear brake lever: Actuates the rear brakes on both the motorcycle and sidecar. WARNING: DO NOT APPLY EITHER BRAKE STRONGLY ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE . ALWAYS USE BOTH BRAKES . NEVER STOP WITH FRONT OR REAR BRAKE ONLY . WARNING: AN IMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR BRAKE OPERATION RESULTING IN POOR BRAKE ACTION

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HARLEY DAVIDSON CUSTOM HAND LEVER KIT BRAKE LEVER INSTALLATION

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

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1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (B) from the groove in the pivot pin (C). Inspect the retaining ring (part number 11143) and replace if needed. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. 4. Insert the pivot lever bushing (2) from the kit into the new brake lever (1). NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04165 1 of 3
5. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 6. Install the pivot pin and retaining ring removed in Steps 1 and 2. 7. Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is per- missible. A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) 8. To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. 9. Reinstall the master cylinder cover. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Check that the stop light goes on when the brake lever is actuated. CLUTCH LEVER INSTALLATION See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures.

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HARLEY DAVIDSON HAND LEVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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BRAKE LEVER INSTALLATION Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 1. 5/32 in. (4 mm) Cardboard Insert 1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (4) from the groove in the pivot pin (B) and discard retaining ring. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. NOTE New brake levers come with the pivot lever bushing installed. NOTE Follow the instructions in Steps 3 and 4 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04342 1 of 3 4. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 5. Install the pivot pin removed in Step 2 and new retaining ring (4) from kit. 6. Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is per- missible. A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) 7. To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. 8. Reinstall the master cylinder cover. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 9. Check that the stop light goes on when the brake lever is actuated. CLUTCH LEVER INSTALLATION See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures. SERVICE PARTS

HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required 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. Kit Contents See Figure 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

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harley- davidson DYNA BLACK FORWARD CONTROL KIT installation Manual

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Filed Under (Harley Davidson) by admin on 15-03-2012

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1. Disconnect battery cable, negative (-) cable first. 2. Remove the left side rider footrest assembly. Save the footrest and fasteners for installation. Discard the remaining hardware. 3. From the kit, press hole plugs (8) into the screw holes on the frame where the stock footrest assembly was mounted. 4. Remove plugs from forward control frame mount (I) and discard. 5. Remove the foot shifter lever (A) and shifter peg (D). Discard the old foot shifter lever (A). Save the foot shifter lever hardware and shifter peg (D) for future use. 6. See Figure 2. Remove the primary chaincase cover (6) and primary chaincase housing (1). Refer to your model motorcycles Service Manual for removal procedures. NOTE See Figure 1. Before removing the gear shifter lever (1) ((H) in Table 1), it is necessary to mark the correct orientation of the lever. Using a marking tool, draw a location marking (4) on the end of the splined shaft (2) across from the casting split (3). This will allow the new gear shifter lever to be installed in the same orientation as the old lever. 5 3 4 1 2 is 02083 1. Gear shifter lever 2. Splined shaft 3. Casting split 4. Location marking 5. Lever bolt Figure 1. Gear Shifter Lever Orientation 7. After marking the gear shifter lever orientation, loosen the lever bolt (5) and remove the old shifter lever. Discard the old gear shifter lever but keep the lever bolt. From the kit, install the new gear shifter lever onto the splined shaft in the same orientation as the old shifter lever. Tighten the lever bolt to 18-22 ft-lbs (24.4-29.8 Nm)

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HARLEY DAVIDSON HAND CONTROL LEVER KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 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 a Harley-Dav- idson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) Brake Lever Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Do not remove handlebar clamp or switch housing assembly to remove brake lever. 1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A). Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a) 2. Place a 4 mm (5/32-inch) thick insert between the brake lever and the lever bracket. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1. 3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar. 4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly. 5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to the area where the master cylinder pushrod seats against the brake lever. DO NOT apply grease to the stop-light switch contact surface of the lever. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever

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HARLEY DAVIDSON SPORTSTER FORWARD CONTROL KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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

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Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 6. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is03193 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw (2) Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is03194 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove the exhaust to access the brake rod. Follow the instructions in the appropriate Service Manual. 3. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod INSTALLATION Install Forward Control Brake Pedal and Footrest Assemblies 1. See Figure 5 and Figure 6. At the lower front of the right frame downtube, remove the two screws securing the J- clip (B) to the frame. Discard the screws but save J-clip for installation. 2. Install the other end of the brake rod into the brake pedal assembly (8). Tighten to 84-144 in-lbs (9.5-16.3 Nm) . NOTE Assemble the brake pedal and footpeg clevis onto the footrest support bracket (as described in the next step) prior to mounting the support bracket to the frame. This will allow easier installation of the footrest mount clevis retaining ring (installed to grooved end of footrest mount clevis). 3. Slide the brake pedal (8) onto footrest mount clevis (11) then slide clevis into footrest/brake pedal support bracket (9). Align hole in the clevis with hole in the support bracket and install screw (6). Tighten the screw to 18-22 ft-lbs (24.4-29.9 Nm) . 4. Install the footrest mount clevis retaining ring (18) to the groove at the end of the footpeg clevis. 5. Position the J-clip (from Step 1) against the frame aligning the mounting holes. Mount the footrest/brake pedal support bracket (9) and J-clip to frame using the new screws (3). Tighten the bracket to 45-50 ft-lbs (61.1- 67.9 Nm) . 6. Obtain the brake rod (15) from kit and thread one end into the master cylinder bell crank. Tighten to 120-180 in-lbs (13.6-20.3 Nm) . 7. Install footpeg on clevis with spring washer (2). Make sure spring washer is positioned inside clevis (11) with the square edge toward the inside. Align holes and push clevis pin (7) from top down through hole in clevis. Secure clevis pin using the new retaining ring (17). 8. Install exhaust following the instructions in the appropriate Service Manual. Install Forward Control Shift Lever Assembly

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HARLEY DAVIDSON HEEL/TOE SHIFT LEVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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INSTALLATION NOTE The shift levers in these kits have opposite counterbored screw holes. When the toe and heel levers are positioned correctly, the socket head cap screws will be installed from the bottom of both levers. 1. Before removing the original shift levers, note the orientation. You may want to replace them at the same position and angle. NOTE The original equipment shift levers may have the socket head screws that secure the shift levers to the splined shifter shaft installed from the top or bottom, depending on your model motorcycle. 2. See Figure 1. Remove the original equipment shifter pegs (A) and retain for re-attachment to the new levers if desired. Remove the socket head screws (3) that clamp the shift levers onto the splined shifter shaft. Remove the original equipment shift levers. 3. First, position the toe shifter lever (1) so the counterbored screw hole is at the bottom. Slide the toe shifter lever onto the splined shifter shaft and position to the desired angle, aligning the screw hole with the notch on the shaft. 4. Install the heel shift lever (2) with the counterbore at the bottom. 5. Add a few drops of Loctite® 243 (blue) to the socket head screws (3), and insert the screws into the counterbored holes. Tighten to 24-26 ft-lbs (32-35 Nm) . 6. Install the shifter pegs onto the new shift levers. If using the original pegs, place a few drops of Loctite blue onto the screw threads prior to installation. Tighten the shifter peg screws. 7. Check for proper operation and clearance

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HARLEY DAVIDSON DYNA FLOORBOARD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-03-2011

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Installation SHIFTER ASSEMBLY (LEFT SIDE) 1. Remove highway footrest assembly, if equipped. Discard bracket, plate and mounting hardware. 2. Remove stock footrest assembly. 3. Remove stock (chrome) shift lever. Retain shift lever, peg, bolt and washer. 1 WARNING ┬« 1 of 5 Kit Number 50601-01 -J01921 2 of 5 Figure 1. Shifter Assembly (Left Side) Item Description Part No. 1 Bolt, 5/16-18 x 5/8 hex HD 2882W 2 Hex cap screw, 5/16-18 x 2.00 (2) 3023 4 Set screw, shaft cover 3231B 6 Assembly,shift lever 33704-01A 7 Assembly,adjustable shifter rod 33719-79B 8 Lever, shifter, machining, polish 33706-01 9 Assembly, shifter plate, polish 33700-01 10 Cover, shifter lever, rubber (2) 34619-85 11 Retainer,shift lever for 1996 to 2000 models 34639-93 Item Description Part No. 11ARetainer bracket, shift lever for 2001 and later models 34639-01 12 Cover, shifter shaft 34640-93 13 Washer, wave, overlap type (2) 34641-01 17 Socket head cap screw 4740A 25 Washer, 5/16″ (2) 6016 28 Washer. 5/16″ 6702 30 Nut, hex, locking, 5/16-18 7710W 32 Acorn nut, 5/16-24 7736 33 Hex jam nut, 5/16-24 7744 30 11 1 12 7 32 28 6 13 9 25 2 17 25 2 10 8 i03110.eps 33 4 11A ’96-2000 models 2001 and later models 4. See Figure 1. 1996 to 2000 models. Bolt shifter lever shaft retainer bracket (11) to the stock shifter lever with bolt (1) and nut (30). Do not tighten bolt at this time. 2001 and later models. Bolt shifter lever shaft retainer bracket (11A) to the stock shifter lever with bolt (1) and nut (30). Do not tighten bolt at this time. 5. Loosen the left rear crankcase bolt (at bottom of cylinder) and slide the slotted end of shifter lever shaft retainer bracket (11) onto the bolt, but beneath the washer. Tighten crankcase stud to 15-17 ft-lbs (20-23 Nm). 6. Place chrome cover (12) on shifter lever shaft (at primary case) and secure with set screw (5). NOTE Small wave washer (13) goes between foot shifter and bracket. 7. See Figure 1. Place small wave washer (13) on shifter lever (6) shaft. Coat shaft with Loctite Anti-seize and slide into bracket. 8. Install foot shift bracket (9) using screws (2). Tighten screws to 25-30 ft-lbs (34-41 Nm). 9. Place shifter rod (2) and washers (25) in position. Use short stud on shifter rod to secure shifter rod at the transmission end. Use Loctite 242 (blue) on stud before installing. 10. Install acorn nut (32) and washer (28) at foot shift end. Use Loctite 242 (blue) on acorn nut before installing

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HARLEY DAVIDSON XL HAND LEVER INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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These kits fit all 2004 and later XL Sportster® model motorcy- BRAKE LEVER INSTALLATION Removing the Brake Lever Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 1. 5/32 in. (4 mm) Cardboard Insert 1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See Figure 2. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. Save the pivot pin for re-use, discard the retaining ring. 3. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Installing the Brake Lever NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch

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