how to change handle bar bushings on a 1992 harley softail

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V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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HARLEY DAVIDSON TOURING DETACHABLE SISSY BAR UPRIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION NOTE The Detachable Sissy Bar Upright can be installed on either a two-point or four-point Docking Kit. 1. If not already in place, install the Detachable Docking Hardware Kit (either two-point or four-point) to the vehicle per the instructions in that kit. 2. See Figure 2. While standing behind the motorcycle, place the left-side and right-side front upright notches (with bushings in place) onto the docking points (A) inboard of the upper shock absorber mounts. Make sure the notch bushings (9) seat fully into the shock absorber docking points. 3. See Figure 2, arrows (D) and (E), and Figure 1. Position the rotary latches (4) over the rear docking points (3). Check to be sure the upright sides (1) and latches fit into the neck (7) of the rear docking points as shown. This may require some gentle squeezing or spreading of the sissy bar upright sides. NOTE After installing the sissy bar upright, check to be sure the sissy bar is secure. The front and rear docking points must be fully engaged. See Figure 1 for correct engagement. 4. Push the rear of the sissy bar downward and close the latches by pressing the latch lever as far forward as it will go. You will hear a “CLICK” when the latch is in place. If the latch does not easily close, do not force. Check the sissy bar alignment again, as described in steps 2 and 3. 5. To remove the sissy bar upright, press the release button (G) on each side and pull the latch levers back. Carefully lift the rear of the sissy bar up and pull the upright out of the front docking points

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HARLEY DAVIDSON NARROW CHROME DIRECTIONAL BAR INSTALLATION INSTRUCTIONS

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

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This kit is designed for installation on 1986 and later FLST®, FLSTC®, FLSTN®and 1991 and later Touring models. (Except 2004 and later FLHRS®and FLTR®) NOTE: Will not fit when equipped with Flat Lens Turn Signal Module (Part Number 91699-99A). Installation 1. Disconnect turn signal wires. For 1999 and later models: See Figure 1. Remove taillight cover and disconnect turn signal wires at connectors shown in illustration. For 1998 and earlier models: Disconnect turn signal wires at connectors located in directional bar. On 1994 and later models there are two wires for each turn signal lamp. Earlier models have only 1 wire per lamp. 2. Remove existing directional bar from motorcycle and save hardware for re-installation. If the turn signal connector is too large to be removed from the directional bar, remove the wires from the connector as follows: Bend back the connector latches on the sides of the connector slightly to free the secondary lock. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing. With a paper clip sharpened to a chisel point, insert the paper clip into the connector housing cavity until it stops. Pivot the end of the paper clip and gently tug on the wire to pull the terminal from the cavity. Do not tug on the wire until the tang that holds the terminal in the cavity is released. Take your time, a few tries may be required before you develop a feel for releasing the terminal from the connector. 3. Remove screws that mount turn signals lamps to existing directional bar. Remove lamps and turn signal wires (with their attached connector halves) from existing bar. 4. Position directional bar in mounting location at rear fender and secure bar to motorcycle using original hardware removed in step 2. Route turn signal wires from motorcycle back into directional bar, or up to taillamp (if 1999 and later model) and mate connectors. If the wires were removed from the connector in step 2, insert the terminal ends of the wires into the connector until they snap in place, then mate connector halves.

Harley-Davidson FXWG, FXST (all except FXSTS), FXDWG Light Bar INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2012

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1. Put a pair of male and female clamp halves together just above the lower triple-clamp. Squeeze the ends of the clamp together with a pair of pliers. Diagram A. 2. Have an assistant position the Light Bar Assembly so the lightbar bracket is to the outside of the clamp assembly. Make sure the wires from the Light Bar Assembly are below the lower triple clamp. Diagram B. 3. Insert a Screw through the clamp and Light Bar Assembly mounting bracket and thread on an Acorn Nut. 4. Hold the Light Bar Assembly in place in front of the lower triple clamp, assemble and attach the remaining clamps. 5. With all four clamp assemblies in place, tighten the clamping screws and nuts to 15 ft. lbs. (21 Nm). Refer to the service manual to gain access to the wire harness inside the fuel tank tunnel or inside the frame backbone. Also, verify the appropriate color wires for hook-up of the passing lamps and turnsignals and running lights. Route the wires from the Light Bar Assembly, around the lower triple- clamp, and up to the frame backbone. Secure the wires so they cannot become pinched when turning the fork. A. The short black wires from the Light Bar Assembly connect to the wires powering the running lights. B. The short red wires from the Light Bar Assembly connect to the wires powering the turnsignals. C. The long blue wires from the Light Bar Assembly connect to the wire powering the headlight low beam. After the wires are connected, verify the operation of the passing lamps, running lights and turnsignals. Correct any connection problems before reassembling the motorcycle. Reinstall the fuel tank. Check all fasteners used during this installation for tightness

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HARLEY DAVIDSON SISSY BAR MOUNTED AUXILIARY BRAKE AND TAIL LIGHT INSTALLATION INSTRUCTIONS

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

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These kits fit 1999 and later XL models, 1996 and later Dyna™ and 1996 and later Softail models (except 2006 FXSTC) equipped with a Medallion Plate-Style Sissy Bar Upright. Will not fit with Backrest Pads that have mounting brackets that match the contour of the sissy bar medallion. Will not fit with sissy bar mounted storage bags INSTALLATION 1. Follow the instructions in the Service Manual to remove the seat. 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) 2. Disconnect battery cables, negative (-) cable first. 1 2 is 01457 1. Adhesive mounted medallion 2. Push nut mounted medallion Figure 1. Medallions 5 2 1 3 4 is 01458 1. Screw 2. Screw (2) 3. Backrest bracket 4. Backrest pad 5. Mounting hole spacing (center to center) Figure 2. Backrest Pad and Bracket -J03063 1 of 5 Remove the Backrest Pad NOTE Medallions are attached to a medallion plate between the uprights of the sissy bar using either adhesive or push nuts. 1. See Figure 1. Remove and retain any existing medallion. Adhesive Mounted Medallion (1): Carefully pry the medallion (1) from the plate. Remove any adhesive residue from the back of the medallion and the sissy bar medallion plate. To avoid contaminating the adhesive backing, place the medallion in an area away from dirt and debris. Push Nut Mounted Medallion (2): Carefully pry the edge of the medallion until the medallion is free of the push nuts. 2. See Figure 2. Remove and retain the screw (1) that secures the backrest pad to the plate. 3. Remove and retain the two screws (2), backrest bracket (3) and backrest pad (4). Install the Light Assembly 1. See Figure 3. Clean the front of the medallion plate (2) with a 50/50 solution of isopropyl alcohol and water. 2. Peel the adhese bracket kit (Part Number 59545-04) and sandwich the light assembly between the bracket frame and the medallion plate. The bracket clamps will fit around the back of the sissyive backing from the adhesive tape located on the light assembly (1). Fit and hold the light assembly to the front of the medallion plate (2). 3. See Figure 6. For 2.55 inch (64.8 mm) center to center mounting hole backrest pads, use th bar arms.

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HARLEY DAVIDSON SISSY BAR UPRIGHT KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Install sissy bar upright kit following the appropriate side- plate instruction sheet. 2. If using sissy bar upright with backrest pad, install pad before applying medallion. 3. Clean surface of sissy bar upright using a 50/50 isopropyl alcohol/water solution. Allow surface to dry thoroughly before continuing. NOTES Test placement of medallion on sissy bar upright before installation. Do not remove adhesive backing until ready to apply. The ideal temperature should be at least 60° F (16° C) for proper adhesion of the medallion on the sissy bar upright. 4. Peel off adhesive backing on bar and shield logo medallion (1) and apply to sissy bar upright (2). Press firmly in place for 10 to 15 seconds. 5. Allow the adhesive to cure for 12 hours at no less than 60° F (16° C). 6. Refer to appropriate sideplate instruction sheet for torque specifications. SERVICE PARTS

Harley Davidson Softail Sideshots Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. On FLSTN, FLSTF, FLSTH and FLSTC loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heat shield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (Not necessary on 2000- up models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head 5. Remove the bolts attaching the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. On pre 2000 models go to step #9, on 2000-up models go to step #10. 9. Remove the right passenger foot peg bolt. Position the motorcycle on the side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt, remove the bolt and stock mounting bar. Reinstall the pivot bolt and torque to 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″ x 3″ Allen bolt and 1-5/8″ length spacer (supplied). 10. Using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″ x 2 1/2″ Allen bolt and 3/4″ length spacer (supplied). 11. The bolts and spacers used in the above steps may also be used on all Softail models to space the right rear foot peg away from the exhaust. 12. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers (save for reuse). NOTE: If circlips look bent or twisted replace them with new circlips.

HARLEY DAVIDSON SOFTAIL Shortshot Exhaust System REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 17-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. On FLSTC, FLSTF, FLSTN and FXSTS loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heatshield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (This step is not necessary on 2000 models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. 9. Park the motorcycle on its side stand. Remove the right side 1/4″-20 bolt which holds the lower fender in place. The fender will flex out of the way allowing the removal of the right passenger foot peg bolt. Position a floor jack under the right hand frame tube of the motorcycle below the swing arm pivot bolt. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Set the mounting bar aside. Replace the pivot bolt and torque it between 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″-20 x 3″ bolt and an 1 5/8″ long spacer (supplied). 10. On 2000 year models, using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″-16 x 2 1/2″ bolt and 3/4″ length spacer (supplied). 11. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted replace them with new circlips. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Vance and Hines recommends you replace your exhaust gaskets with Sceamin’ Eagle gaskets part number 17048-98. 2. Install the mounting bracket to the frame, by aligning the two 3/8″ holes in the bracket with the two holes in the frame below the right rear footrest, using the two 3/8″-16 x 3/4″ flange head bolts (supplied), do not tighten at this time. When the bracket is mounting correctly, it should bend out and away from the motorcycle, with the four holes of the bracket toward the front of the motorcycle. 3. Install the circlips and flanges from the stock system on to both of the new head pipes

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HARLEY DAVIDSON FLSTC SOFTAIL SADDLEBAG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Additional Fitment Information Detachables NOTE If motorcycle has not been altered from fixed saddlebag hardware to accessory mounting detachable docking points. the separate purchase of Turn Signal Mounting Bar (Part Number 68611-98) is required for sufficient lock clearance. This kit is available at your Harley-Davidson Dealer. Installing these saddlebags on models equipped with a detachable sissy bar or detachable luggage rack requires the additional purchase of mounting hardware kit as follows: Hardware Kit Fitment 53075-03 2003 and later FLSTC models with detachables 53009-03 1987 through 2002 FLSTC models with detachables See Service Parts Page for kit contents. Additional weight can affect motorcycle stability, handling characteristics, and safe operating speed. Do not exceed 7 lbs. (3.18Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury. Wide Tire If a wide tire kit has been installed, utilize the hardware and installation instructions found in that kit to reorient the fasteners to come from the inside to the outside of the finder. Button head screws from wide tire kit must be installed from the inside out, with the button heads on the inside of the fender. Failure to do so could result in bolt contacting tire, which could result in death or serious injury. Installation NOTE A Service Manual for your vehicle is available at your Harley-Davidson Dealer. 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect the negative (-) battery cable first. If positive (+) cable should contact ground with the negative (-) cable connected, the resulting sparks may cause a battery explosion which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Following instructions in applicable Service Manual, remove original saddlebags from supports. Install Turn Signal Mounting Bar If motorcycle is not equipped with accessory mounting detachable docking points, install Turn Signal Mounting Bar (Part No. 68611-98) following instructions provided with the kit. See Figure 1

HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

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