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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

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2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 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. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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HARLEY DAVIDSON DYNA AND SPORTSTER Chrome Front Wheel Spacers INSTALLATION ISNTRUCTIONS

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

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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Filed Under (KTM) by admin on 12-11-2010

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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HARLEY DAVIDSON FL SOFTAIL PROFILE LOW FRONT SUSPENSION KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-11-2010

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Fork Spring Removal 1. Elevate and support the vehicle so the front tire is off the floor and the forks are fully extended. 4 9 3 1 10 11 2 5 6 7 8 is04004 1. Slider tube cap 2. Spacer washer 3. Oil seal 4. Clamp bolt and washer 5. Fork tube plug 6. O-ring 7. Fork spring 8. Tight-wound end of spring 9. Fork slider tube 10. Fork slider 11. Drain screw and washer Figure 1. Front Fork NOTE Remove the brake caliper from the fork slider. DO NOT remove the brake line from the caliper. 2. Remove the front wheel. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. 3. Remove the front fender. See FRONT FENDER in the Service Manual. 4. See Figure 1. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side. Save the cap and spacer. The oil seal can be discarded. 5. Loosen the clamp bolt (4) and pull the fork from the brackets. 6. Repeat Steps 4 and 5 for the other fork side. -J00280 1 of 4 Wear saf ety glasses or gog gles when ser vicing f ork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) NOTE Be careful not to damage the O-ring. 7. See Figure 1. Remove the fork tube plug (5) and O-ring (6). Pull the spring (7) out of the slider tube (9). Remove the drain screw and washer (11), and drain the fork. Reinstall the drain screw and washer, and tighten to 52-78 in-lbs (5.9-8.9 Nm). 8. Repeat Step 7 for the other fork side. NOTE The Profile® Low Front Suspension Kit requires a different amount of H-D TYPE E FORK OIL than is listed in the Service Manual. NOTE Measure the oil level from the top of the fork tube with the fork spring removed and the fork fully compressed. 9. See FRONT FORK OIL in the Service Manual, but substitute the measures below. Fill the forks with Harley- Davidson TYPE E FORK OIL: • 1986 through 1999 models: •11.7 oz (345 cc) of oil, or •5.2 inch (132 mm) from top of oil level to top of tube. • 2000 and later models: •13.4 oz (396 cc) of oil, or •4.1 inch (104 mm) from top of oil level to top of tube. Fork Spring Installation 1. Insert a new Profile Low spring (7) from the kit into each slider tube (9), with the tight-wound portion (8) toward the bottom of the fork slider. NOTE Be careful not to damage the O-ring. 2. Install the fork tube plug (5) and O-ring (6) assembly into the slider tube and tighten securely. Be sure that one flat on each fork tube plug faces toward the inside of the fork. 3. Insert both fork side assemblies up through the slider covers, the fork stem and bracket, and the upper bracket. 4. Obtain two new oil seals (3), H-D Part Number 45733-48, and the spacer washers (2) and slider tube caps (1) saved earlier. Place an oil seal, followed by a spacer washer, onto each fork tube plug. 5. Insert the threads of a slider tube cap through each washer and seal, and into the fork tube plugs. Tighten to 40-60 ft- lbs (54.2-81.3 Nm). 6. Tighten the fork stem bracket clamp bolts (4) to 30-35 ft- lbs (40.7-47.5 Nm). 7. Install the front fender. See FRONT FENDER in the Service Manual. Install the front wheel and brake caliper. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. Jiffy Stand Removal/Installation 1. Move the jiffy stand to the retracted (up) position. Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c) 2. See Figure 3. Unfasten the jiffy stand leg spring (A) from the vehicle. Remove the hex bolt (B), lock washer (C), flat washer (D) and leg stop (E) from the threaded end of the jiffy stand leg. Discard the jiffy stand leg, but retain all other components. 3. Clean and inspect the jiffy stand attaching parts and mounting bracket for wear or damage. If parts replacement is necessary, refer to the Jiffy Stand section of your Service Manual for replacement procedures

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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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HSR Carburetor Total Kits Installation Instructions

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

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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Filed Under (Harley Davidson) by admin on 16-04-2012

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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HARLEY DAVIDSON BLADE FRONT WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION 1. 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. or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. 2. See Figure 2. Install valve stem assembly (L) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. • For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. • For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. • For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08: • Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side. • For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. 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. 4. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. 5. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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