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Harley-Davidson BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-04-2012

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1) Remove the primary chain case cover. Refer to your Factory Service Manual for this procedure. 2) Remove the compensating sprocket nut with a 1-1/2″ socket. A ½” impact gun is best for this task. *) Remove the 1-3/16″ clutch nut. This is a left handed nut so loosen it by turning it in the clockwise direction (as viewed from the left side of the motorcycle). 4) With one hand on the compensating sprocket and one on the clutch assembly, remove the primary drive assembly (compensating sprocket, primary chain, tensioner assembly, and clutch as shown in figure a and set it on a clean surface. 5) Flip the adjuster shoe bracket on the chain tensioner assembly. figure b shows the stock orientation of the adjuster show and bracket. Figure C shows the adjuster show bracket flipped 180°. To flip the shoe bracket, remove the two ¼-28×2 bolts that hold the bracket assembly together. This will allow you to separate the chain tensioner assembly components from the primary chain. Flip the bracket around as shown in figure c . PAGE 4 Figure B Figure A BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS 6) install the new compensating sprocket, chain, and clutch onto the motor sprocket shaft and the transmission input shaft. The flipped chain tensioner assembly (as shown in figure c ) is not ‘captured’ on the primary chain like the stock configuration. Loosely install the chain tensioner assembly onto the anchor plate bolt. Tighten the compensating sprocket nut to 157+ 7 ft-lbs and the clutch hub nut to 75+ 5 ft-lbs using red Loctite on the threads.

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HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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Harley-Davidson Softail Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 02-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the fasteners that secure the seat. Remove seat. 6. Disconnect negative Battery Terminal. 7. Remove the Saddle Bags. And their hardware. If equipped. 8. Loosen Muffler Clamp on both Mufflers and other attaching hardware. Remove and discard both Mufflers. 9. Loosen the 4 exhaust stud nuts and save. Remove and discard head pipes and exhaust gaskets. 10. Disconnect the Rear Lamp Wiring Harness. 11. Remove any fasteners from Electrical Box. 12. Remove and discard Rear Fender, Fender Support and fasteners. NOTE: 2008-Current various models. Remove ECM from Fender and save nuts. 13. Drain all Brake Fluid from the Rear Brake System. 14. Un-clamp Rear Brake Line from the frame and Rear Fork. 15. Remove and discard both Banjo Bolts and Crush Washers from the Rear Brake Caliper and the Rear Brake Master Cylinder. 16. Remove Brake Light Switch from the Brake line, Save for reassembly. 17. Remove the Torx screw from the Brake Line bracket, Save the Torx screw for reassembly. 18. Remove and Discard Brake Line. 19. If Lower Controls option. Remove and Discard right and left floorboards/foot pegs, brake pedal, shifter, and shift linkage. Remove and Discard Passenger Foot pegs or Floorboards and their mounts. Then skip to step 24. 20. If Lower Controls Not purchased. Continue. 21. Remove acorn nut from Shift Linkage. 22. Remove 3 fasteners from Drivers Floorboard and remove. 23. Remove and discard Jiffy Stand. 24. Remove the Primary Cover by first removing the top and rear inspection cover screws. 25. Continue by removing remaining fasteners. 14 total. 26. Remove and discard Primary Cover Gasket. 27. Clean residual gasket material from both surfaces. 28. Loosen the Top Center Nut on the Primary Chain Adjuster. Lower the Primary Chain Adjuster until it rests flat on the Inner Primary Cover. 29. Remove the Clutch Lifter Retaining Ring from the Clutch Basket. Remove Clutch Lifter Assembly. 30. Using the Primary Drive Locking Tool. Loosen the Compensating Sprocket Nut. 31. Using the Primary Drive Locking Tool. Loosen the Clutch Hub Main shaft Nut. WARNING: This nut is LEFT HAND threaded. 32. Remove the Primary Drive Locking Tool, Compensating Sprocket Nut, and Clutch Hub Main shaft Nut. 33. Remove the Sprocket cover and Sliding Cam from the Crank Shaft Extension. 34. Remove the Clutch Assembly, Primary Chain, Compensating Sprocket, and Crank Shaft Extension in one assembly.

HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

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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 LIGHTED MIRRORS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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REMOVAL Prepare for Service Touring Models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG and MAXI-FUSE in Service Manual. Softail and Dyna Models: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 1. Remove seat according to the instructions in the Service Manual. 2. Disconnect battery cables, negative (-) cable first. 3. Remove fuel tank according to the instructions in the Service Manual. Sportster Models: Remove left side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. V-Rod Models: Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. Remove Existing Mirrors Touring and Softail (Except FXSTD, FLSTF) Models Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. Right side: See Figure 2. Remove acorn nut (1), star washer (2), and existing mirror (3) from front brake hand control assembly. Discard star washer and mirror but save acorn nut. 2 1 3 is03431 1. Acorn nut 2. Star washer 3. Mirror, left Figure 1. Remove L.H. Mirror (Except Sportster) 2 1 3 is03432 1. Acorn nut 2. Star washer 3. Mirror, right Figure 2. Remove R.H. Mirror (Touring, Softail – Except FXSTD, FLSTF) Dyna, FXSTD, FLSTF, and VRSC Models 1. Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. 2. Right side: See Figure 3. Loosen ball stud clamp (1) to remove directional lamp assembly (2). Remove retainer (3), star washer (4), and existing mirror (5) from front brake hand control assembly. Discard star washer and mirror but save remaining parts. 2 5 3 1 4 is03428 1. Ball stud clamp 2. Directional lamp assembly 3. Retainer 4. Star washer 5. Mirror, right Figure 3. Remove R.H. Mirror (Dyna, FXSTD, FLSTF, VRSC) Sportster Models Left side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (3) from clutch hand control assembly. Discard washer and mirror but save locknut. Right side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (4) from front brake hand control assembly. Discard washer and mirror but save locknut. 3 2 1 2 1 4 is03414 1. Locknut (2) 2. Washer (2) 3. Mirror, left 4. Mirror, right Figure 4. Remove Mirrors (Sportster) INSTALLATION Install Lighted Mirrors Touring and Softail (Except FXSTD, FLSTF, FXSTS, FLSTS) Models 1. Left side: See Figure 5. Install mirror stem (1) through clutch hand control assembly.

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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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HARLEY DAVIDSON HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. 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 A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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HARLEY DAVIDSON STEERING HEAD WASHER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 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. 1. See Figure 1. Remove the fork stem cap (1). Bend the lockwasher (2) tab away from the steering stem nut (3) and remove the fork stem nut and lockwasher. Discard the lockwasher. NOTE Always tighten the steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm) before measuring fall away. Lubricate threads of nut with a small amount of clean engine oil. Avoid applying oil to the mating surfaces of the steering stem nut (3) and the new hardened washer from the kit. 2. Install the new hardened washer from the kit (2) and steering stem nut (3). Tighten steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm). 3. Check fall away following the instructions in STEERING HEAD BEARINGS BEARING ADJUSTMENT (FALLAWAY) in an appropriate Service Manual, however, tighten the steering stem nut (3) to 70 – 80 ft-lbs . Adjust adjusting nut (5), if necessary per instructions. 4. Install fork stem cap (1).

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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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