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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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HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.

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HARLEY DAVIDSON DETACHABLE TOUR-PAK KIT FOR ELECTRA GLIDE CLASSIC INSTALLATION MANUAL

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

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INSTALLATION Install Docking Kits and License Plate Holder 1. Install Rear Detachable Docking kit. Refer to the instruction sheet provided with kit. 2. Install Touring Detachable Tour-Pak Rack. Refer to the instruction sheet provided with kit. 1 4 2 3 is03989 1. License Plate Holder 2. Red Reflector 3. Original Equipment Screws 4. Original Equipment Bottom Support Tube Figure 2. Install License Plate Holder 3. See Figure 2. Install the new license plate holder (1) to the bottom support tube (4) using screws (3) saved from prior step. 4. Remove adhesive backing from red reflector (2) and carefully center and align it with the bottom edge of the license plate holder (1) and press firmly into place. -J03930 1 of 4 MOUNTING ANTENNA RELOCATION BRACKET 1. See Figure 6. Assemble joint assembly (9) to antenna mounting bracket (6) using lock washer (5) and 2 hex nuts (4). Tighten hardware securely. 2 1 5 4 3 is03992 1. Rear Docking Point 2. Docking Point Support Bracket 3. Antenna Mounting Bracket 4. Antenna/Cable Adapter 5. Rear Docking Point Screw and Locknut Figure 3. Relocated Antenna Bracket and Cable 2. See Figure 3. Install assembled antenna bracket (3) by removing screw and locknut (5) securing left rear docking point (1) to docking support (2). Install bracket as shown and reinstall rear docking point screw and locknut. Tighten screw and locknut to 15-19 ft-lbs (20.3-25.7 Nm) . 3. Thread antenna/cable adapter (4) onto joint assembly. ROUTING ANTENNA CABLES 1. See Figure 4. Gently remove left side cover (1) by pulling from frame tubes (no tools required). 2. Connect original antenna cable (not shown) to bottom of joint assembly. 3. Route antenna cable/wiring between left frame rail and fender. 4. See Figure 5. Attach cable to docking point support bracket in location (1) using short cable strap. 5. See Figure 4. Coil excess antenna cable/wiring (2) and use long cable strap (3) to fasten cable to frame under left side cover (1) with vehicle wiring harness. 6. See Figure 6. Cap unused wiring connector with connector housing (10).

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HARLEY DAVIDSON DYNA DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION Installing the Front Docking Point To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Remove the seat and disconnect the negative (-) battery cable. NOTE To keep the fender aligned, complete ALL the following procedures on one side of the motorcycle before starting the other side. 2. See Figure 1. Remove the stock fender support bracket. Position new rear fender mounting bracket from kit (5) into position. 3. Apply Loctite 243 (Blue) to button head bolt (2) prior to installation. Place the tapered side of front docking point (1) against the strut cover. Insert button head bolt (2) through the docking point, fender support and fender. Tighten to 12-18 ft-lbs (16.3-24.4 Nm) . 4. If used without saddlebags, install rear docking point (3) and recess cover (4) according to instructions in Part Number 53968-06C, Directional Relocation Kit. If used with saddlebags, mount rear docking point according to instructions with saddlebag kit. MAINTENANCE NOTE In time, the docking points may wear causing the mating luggage rack or sideplates to become loose. The fit may be tightened using the following procedure. If any fasteners with Loctite are loosened, then the fasteners must be removed, cleaned of existing Loctite and re-installed with new Loctite. 1. Loosen the docking hardware. 2. Rotate the docking points clockwise approximately 45°. 3. Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures. This procedure can be repeated up to 3 times before replacement of the docking points is recommended.

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HARLEY DAVIDSON FLSTC & FLSTS DOCKING HARDWARE WITH SADDLEBAG SUP- PORTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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The rear docking points in kit part number 90366-03 provide the rear mounting points for the Solo Rack. The rear mounting points from this kit ( 53931-03A ) will need to be installed to provide the clearance for the Solo Rack to be mounted. Table 2. Turn Signal Relocation Kit Requirement Turn Signal Relocation Kit Required Accessory Part Number 2003 and later FLSTC Not required 53815-00 Detachable Sideplates Not required 53066-00A Detachable Tour Pak Rack REMOVAL FLSTS Saddlebag Assembly Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Repeat steps 1 – 2 on the other side of the vehicle. FLSTC Saddlebag and Fixed Mount Sissybar Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts, but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Remove and discard fixed mount sideplates. Retain sissy bar for use with detachable sideplates. 4. Repeat steps 1 – 3 on the other side of the vehicle. 1 is06914 1. Saddlebag support studs Figure 1. Original Equipment Hardware (FLSTS model shown) INSTALLATION Docking Hardware Installation – For Detachable Sideplates or Tour-Pak Rack NOTE See Figure 15. The rear docking point (8) is wider than the front docking point (2). -J02425 1 of 5 1. Place front docking point (2) on front stud (1), with countersunk end of docking point facing fender support. 2. Place spacer (6) for side plates or mid docking point (for detachable sideplate kit) on rear stud (1). 3. Place rear docking point (8) on bolt (7), with countersunk end facing fender support. 4. Insert front stud (1) through front docking point (2), fender support and into bracket underneath fender as shown. 5. Insert rear stud (1) through fender support and into bracket underneath fender as shown. 6. Install bolt (7) through fender support and into bracket underneath fender as shown. 7. Tighten front and rear studs (1) and bolt (7) to 27 ft-lbs (37 Nm) . 8. Repeat steps 1-7 on the other side of the vehicle.

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HARLEY DAVIDSON FOUR-POINT DETACHABLE DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 3. Remove the screw (A) retaining the rear of the chrome cover to the rear frame extension on each side of the vehicle. 2. Place a washer (7) over the threads of each of the larger TORX® head screws (6) from the kit. Apply 2 or 3 drops of Loctite 262 Threadlocker and Sealant – Red to the threads of each screw. Install the screws through the docking plates (1) and fender covers, and into the threaded holes in the frame extensions on each side of the vehicle, and tighten to 17 ft-lbs (23 Nm) . NOTE See Figure 1. The docking points must be attached to the docking plates (2) with the chamfer (1) facing the plate and the flat side facing out. 1 2 is05506a 1. Docking point chamfer (bevel) 2. Mounting plate Figure 1. Docking Point Installation 3. See Figure 3. Slide a spacer (2) onto the longer pin (B) of each docking plate. Install the four docking points (3), chamfer end first, onto the long and short docking plate pins using the washers (5) and smaller TORX screws (4). Tighten to 10.5 ft-lbs (14.2 Nm) . NOTE Protective tape must be installed to the rear saddlebag mounting bracket to prevent damage to the saddlebag finish when the lid is opened. 4. See Figure 2. Apply protective tape (2) to the rear mounting bracket (1) on the saddlebag in the location shown. Repeat for the other side. 2 1 is05533 1. Rear saddlebag bracket (2) 2. Protective tape %lengthT=0

HARLEY DAVIDSON XL DOCKING HARDWARE/ DIRECTIONAL RELOCATION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION 1. See Figure 2. Following directions supplied with saddlebags to relocate rear turn signals, but also use the following exceptions to install the parts contained in this kit: •Use turn signal studs (4) in place of hex bolts supplied with saddlebags. The longer studs are required to accommodate the rear docking points. •On each side, insert relocation pad plate (3), saddlebag mount spacer (12), rear docking point (2), and docking point spacer (11) between relocation pad (supplied with saddlebags), and fender support cover as shown. •Use 4-inch long cap screw (5) in place of hex bolts supplied with saddlebags. The longer cap screws are required to accommodate the rear docking points. •The turn signal wires should be routed under the fender support cover back to the connectors they were removed from following the directions supplied with saddlebags. 7 1 14 2 12 6 9 3 1 11 4 10 8 16 17 15 18 5 13 is03490a 1. Locknut, 5/16-18 inch (3) 2. Rear docking point 3. Relocation pad plate from saddlebag kit 4. Turn signal stud 5. Cap screw, 5/16-18 x 4 inch 6. Spacer from saddlebag kit 7. Turn signal wire 8. Fender support cover 9. Cap screw, 5/16-18 x 2-1/4 inch 10. Front docking point 11. Docking point spacer 12. Saddlebag spacer 13. Washer, 1/4 inch 14. Locknut 1/4-20 inch 15. Cap screw, 1/2-13 x 3-3/4 inch 16. Spacer 17. Saddlebag support 18. Stock washer Figure 1. Installation shown on 2000 model On 1999 and earlier models: See Figure 2. Before mounting saddlebag supports, remove acorn nut from upper shock mount, and install washer (7), and shock mount spacer (8) as shown. Tighten upper shock mount spacer to 21-35 ft-lbs (28-47 Nm). This will properly space out the saddlebags to accommodate the docking points. On 2000 models: See Figure 1. Before mounting saddlebag supports remove button screw from upper stock mounts, and proceed to Step 2.

HARLEY DAVIDSON XL DETACHABLE UPRIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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INSTALLATION Install Docking Point Kit Install the docking point kit following the instructions in that kit. Passenger Upright Installation 1. See Figure 1. Stand behind the motorcycle, and place (10) the front upright notches (2) into the front docking points (3). 2. See Figure 2. Check for correct notch engagement. NOTE Failure to correctly engage the sideplate notches to the docking points may result in damage to the rear docking points. 3. See Figure 1. Push (11) the rotary latches (4) into their most forward position. Align the latches over the rear docking points (7), making sure the latches and rear notches (6) fit into the neck (8) of the rear docking points. NOTE This may require some gentle squeezing or spreading of the upright sideplates. 4. Push downward (12) on the sideplates, and close the rotary latches by pulling (13) the latch levers as far back as they will go. A click will be heard when the latch is in place. If the latch does not close, do not force it. 2 12 3 7 4 1 5 9 10 5 7 8 6 4 13 11 is06182a 1. Upright 2. Front notch 3. Front docking point 4. Rotary latch 5. Release button 6. Rear notch 7. Rear docking point 8. Rear docking point neck 9. Fender support bracket 10. Place front notches into front docking points 11. Push latches forward 12. Lower rear notches onto rear docking points 13. Pull rearward to close latches Figure 1. Detachable Upright

HARLEY DAVIDSON DYNA DOCKING HARDWARE FOR FXDX WITH WIDE TIRE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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Installation NOTE Perform the following procedures on one side of the motorcycle until instructed to go to the other side. To keep fender in alignment the front docking point will be mounted first. INSTALLING DOCKING POINTS NOTE Save the acorn nuts and washers removed from the fender support bracket for use when installating docking points. 1. Loosen and remove the acorn nuts, washers, and screws from the fender support (right-hand) bracket. Save the washers and acorn nuts for docking point installation. Discard screws. 2. Obtain 1 plastic bushing, labeled 01, from a bushing set. 3. Place the bushing (4) (beveled side out) into the front support hole as shown in Service Parts illustration. 4. Place the countersunk side of the front docking point (2) so that it engages bushing (4). 5. From underneath (inside) the fender, insert hex-head screw (1) through fender, support bracket and front docking point (2). 6. Install washer (7) split lockwasher (5) and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 7. Obtain another plastic bushing, labeled 01 , from the bushing set. 8. Place bushing (4) (beveled side out) into the the rear support hole as shown in Service Parts illustration. 9. Place the countersunk side of the rear docking point (3) so that it engages bushing (4). 10. From underneath (inside) the fender, insert hex-head screw through fender, support bracket and rear docking point (3). 11. Install washer (7) split lockwasher (5)and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 12. Repeat procedures 1 through 11 for opposite (left-hand) side of the motorcycle. NOTE In time docking points may wear, causing the sideplates to become loose. The fit may be tightened using the following procedure. 1. Loosen docking hardware. 2. Rotate docking points clockwise approximately 45°. 3. Tighten docking hardware to the appropriate torque values. Repeat as often as required, up to 3 times

HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. 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 your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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