how to install battery side cover clips on 04 sportster

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HARLEY DAVIDSON CHROME BATTERY COVER TRIM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVAL 1. See Figure 3. Remove button-head screw (A) that attaches battery cover (B) to battery tray (C). 2. See Figure 1. Remove battery cover by lifting it over the two tabs on the battery tray. NOTE The original equipment battery cover trim has four pinch tabs on the reverse side that attach it to the battery cover. 3. See Figure 2. Remove original equipment battery cover trim from battery cover by pushing the four pinch tabs out of the battery cover using a pliers or suitable tool. INSTALLATION 1. Place battery cover over the two tabs on battery tray (C) and attach it to battery tray with button-head screw (A). Tighten screw to 20-40 in-lbs (2.3-4.6 Nm). 2. Obtain chrome battery cover trim (1) from kit. 3. Using a 50/50 isopropyl alcohol/water solution, thoroughly clean the surface where the chrome trim will be installed. Let it dry completely. NOTE Test the trim mount fit prior to removing the adhesive backing from the chrome battery cover trim. 4. Remove adhesive liner from the chrome battery cover trim. NOTE The ideal temperature should be at least 60° F (16° C) for proper adhesion of the chrome trim on the battery cover. 5. Center and install chrome trim onto the battery cover. Apply firm pressure for one minute using a cloth to prevent scratching the battery cover and battery trim. 6. Let the adhesive cure for 24 hours at no less than 60° F (16° C)

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

HARLEY DAVIDSON DYNA BATTERY COVER INSTALLATION MANUAL

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

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INSTALLATION 1. Remove 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. 3. Follow instructions in applicable Service Manual to loosen and lower battery tray. 4. Remove top and side covers and discard. 5. See Figure 1. Install cover from kit as follows: a. Align bottom of cover with tray (2) making sure that three clips on bottom properly seat (center) on both sides of retaining lip (6) at the base of the battery tray. b. Position top of cover (5) under the frame tube. 6. Raise tray and cover following instructions in Service Manual and tighten bolts (3,4) securely. 5 3 2 1 4 6 is 01648 1. Battery 2. Battery tray 3. Upper mounting bolt 4. Lower mounting bolt 5. Battery cover 6. Retaining lip Figure 1. Battery Cover and Mounting Hardware 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) 7. Connect battery cables, positive cable first. 8. Install seat

HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

HARLEY DAVIDSON DERBY COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits are designed for installation on all 1999 and later 1340 Evolution and Twin Cam equipped models.INSTALLATION For models equipped with left side exhaust pipe: Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) NOTE Remove clutch inspection (derby) cover with motorcycle upright, not on side stand. If cover is removed with motorcycle on side stand, primary fluid will leak out of primary chaincase. 1. On models so equipped, remove the left-side passenger footboard. Using a T27 TORX® drive head, remove the derby cover from the primary chaincase. Discard the derby cover and fasteners. NOTE The gasket between the clutch inspection cover and the chaincase cover must be removed and all oil must be wiped from the gasket and groove in chaincase cover each time the cover is removed. 2. Remove the gasket from the groove in the chaincase cover and mounting surface. 3. Inspect gasket for tears or damage. Replace as required with gasket 25416-99C (sold separately). NOTE If installing the Derby cover on a 2006 and later Dyna, 2007 Softail, or 2007 Touring model, the original equipment gasket must be discarded and replaced with Derby Cover Gasket 25416-99C (sold separately). 4. To avoid punching holes in the clutch inspection cover gasket or enlarging the existing holes, install the new derby cover and gasket as follows: a. Align the triangular shaped hole in the gasket with the top hole in the derby cover. Be sure the rubber molding and the words “towards clutch” face the motorcycle. b. See Figure 2. Place a washer (2) from the kit onto the threads of one of the new screws (3). Insert the screw threads through the top hole in the derby cover, and carefully thread it all the way through the triangular shaped hole in the gasket. Do not push the screw through the hole. c. Hang the derby cover on the primary chaincase cover flange by starting the top cover screw. d. Start the remaining four screws and washers. 5. Install gasket (part number 25416-99C) and derby cover (1) on primary chaincase cover using screws and washers from the kit. Tighten screws to 84-108 in-lbs (10-12 Nm) in the sequence shown in Figure 1

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