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HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

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HARLEY DAVIDSON SOFTAIL LEFT SIDE LEATHER TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Installation While handling and installing tool box, be careful not to scratch surface. 1. See Service Parts Illustration. Install tool box (1) to mounting bracket (6) using button head screws (2) and washers (5). Screws (2) should be inserted through mounting holes on inside of tool box (1) and then inserted through bracket (6) holes and threaded into weld nuts attached to bracket. 2. Remove and save the two screws that secure left rear fender support to motorcycle frame. 3. Remove two bolts, nuts, and washers that secure debris deflector to motorcycle frame. This will allow you to move debris deflector out of the way when installing new passenger footpeg support bolt. Save hardware for reinstallation. 4. For 1990 to 1999 Softails: If tool box is being installed with passenger footpeg, remove the hex head bolt and left passenger footpeg. Retain footpeg and lockwasher for reinstallation. Discard bolt . If tool box is being installed without passenger footpeg, remove hex head bolt and left passenger footpeg. Discard footpeg. Retain bolt and lockwasher. For 2000 and later Softails: See page 3 . Remove footrest from clevis. Remove clevis from frame by removing cap screw from center of clevis. If tool box is installed with footpegs, keep all hardware. If toolbox is to be installed with footboards, discard hardware. 5. Slide top of mounting bracket (6) between rear fender support and frame. Align top holes in bracket with fender support holes. Align lower bracket hole with footpeg mounting hole in frame. Install the two screws, removed in Step 2, in fender support. Do not tighten screws at this time. 6. For 1990 to 1999 Softails: Place lockwasher retained in step 4 on footpeg support hex head bolt (3) from kit. CAUTION 1 of 3 For 2000 and later Softails with footpegs: Install kit 49352-00 according to instructions included in this kit. Footpeg must fold up at a 45°angle (from vertical) toward rear of motorcycle. This angle allows footpeg to fold up if, by accident, it strikes the ground surface when making a sharp turn. Failure to set footpeg to the proper fold-up angle could result in death or serious injury. 7. For 1990 to 1999 Softails: Position footpeg so it folds up and back at a 45°angle. Install bolt (3) from kit through frame, tool box bracket (6), and spacer (4), into footpeg, as shown. NOTE If vehicle is equipped with saddlebag support bracket, Part No. 90346-90 or 90346-94, position saddlebag support bracket between tool box bracket and spacer.

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HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. 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. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

HARLEY DAVIDSON SPORTSTER LEATHER SADDLEBAG KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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SADDLEBAG INSTALLATION 1. See Figure 3. Remove the rear shock absorber bolt (Figure 1, Item 1). Position the 0.531 x 0.75 x 0.25 inch spacer (7) and the front saddlebag bracket attachment hole over the rear shock absorber bolt location. Secure with the 1/2- 13 x 3.75 inch screw (5). 2. See Figure 3. Position the 0.325 x 0.75 x 0.25 inch spacer (8) and the rear saddlebag attachment hole over the second hole on the rear of the fender, fender support cover, and relocation pad. From the underside of the fender, insert a 5/16-18 x 3.00 inch screw (6) and secure with locknut (10). Tighten locknut (10) to 24-27 ft-lbs (32.5-36.6 Nm) . 3. Tighten the front screw (5) to 21-27 ft-lbs (28.5-36.6 Nm) . 4. See Figure 3. Assemble an isolator washer (12) onto an isolator bushing (13). Place a screw (15) through the bushing. 5. Place the screw and bushing assembly into the top hole inside the saddlebag back. 6. See Figure 3. Push a saddlebag isolator (14) over bushing with cone shape toward saddlebag. 7. Place saddlebag in position on bracket and insert the new screw (15) into the bracket. Do not tighten. 8. Repeat steps 4 through 7 for remaining holes. With all isolators in place, tighten screws to 96-120 in-lbs (10.8- 13.6 Nm) . 9. Repeat Steps 1 through 8 for the opposite saddlebag. 10. Raise rear wheel until the rear shock absorbers align with shock absorber mounting holes on the swingarm. Support the wheel to prevent it from falling during the following step. 11. See Figure 1. Attach rear shock absorber to swingarm by installing bolt (1), washer (2) and nut (4). Tighten bolt to 45-50 ft-lbs (61.1-67.9 Nm) . Repeat step on opposite side of motorcycle. INSTALL REFLECTORS Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) 1. See Figure 3. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Mark hole location. 2. Using appropriate tool, make two 3/16 in. holes in sad- dlebag. 3. Install reflector mount (3) on saddlebag using two pushnuts (2). 4. Remove adhesive backing from reflector (4) and install on mount. 5. Repeat steps 1 through 4 for the opposite saddlebag. INSTALL SEAT After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1. See Service Manual instruction to install the seat

HARLEY DAVIDSON DASH PANEL EXTENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the seat. 2. See Figure 1. Loosen the two socket head screws on the instrument panel console. Raise the console enough to access the two pushnuts holding the upper end of the leather insert. Remove and discard the pushnuts using pliers or a blade-type screwdriver. 3. Remove and discard the phillips head screw (3) and washer (4) securing the lower portion of the leather insert to the fuel tank. Remove the leather insert and discard it. 4. Obtain the dash panel extension (1) and the dash panel extension trim (2) from kit. Place the dash panel extension on the dash panel extension trim making sure the panel is centered and fits cleanly into the lips on both sides of the trim. 5. Gently lift up on the rear of the instrument panel console and install the dash panel extension with the rubber dash panel extension trim underneath, butting the two together. Make sure the rubber dash panel extension trim is aligned with the dash panel extension. Finger tighten the two socket head screws to hold down the instrument panel temporarily in place. NOTE The console rubber trim from a stock vehicle may need to be trimmed slightly to assure proper fit. NOTE When performing the next step, note that proper alignment is achieved when space is eliminated between the instrument panel console and/or between the dash panel extension trim piece and the fuel tank. Due to variances in fuel tank and instrument panel console fitments, the foam pads are used on “as needed” basis to achieve proper alignment. It may be necessary to experiment a few times using various combinations of pads to achieve the desired alignment. In some cases, pads may not be necessary while in others, it may be necessary to use all with one stacked above another. 6. Observe the overall fitment of the panels over the tank and determine whether the foam pads will be necessary to achieve the desired alignment. 7. If necessary, remove the dash panel extension assembly. Peel the adhesive backing and install the needed foam pads (5) to the raised areas extending from the front of the dash panel extension as shown. Re-install the panel. 8. When the proper alignment between the new kit and the fuel tank is achieved, tighten the rear mounting screw (3) with the washer (4) to the speed nut located on the tab at the rear of the fuel tank. 9. Tighten to 18-24 in-lbs (2.0-2.7 Nm). 10. Tighten the instrument panel console?s two socket head screws to 18-24 in-lbs (2.0-2.7 Nm). 11. Install the seat

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HARLEY DAVIDSON TOUR-PAK KIT INTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Remove the rubber mat from the bottom of the Tour-Pak. 2. See Figure 1 and Table 1 to determine the proper hole configuration to attach the Tour-Pak to your luggage rack. Holes will be drilled as explained in Step 3 in the hole location for your luggage rack. Table 1. Luggage Rack and Hole Configurations Hole Configura- tion Luggage Rack C (3 holes) Stock 1997 B (4 holes) Detachable luggage rack 53107-96 A (5 holes) Luggage rack 53118-97A and luggage rack 53118-98 A (5 holes) Stock 1998 and later racks A (5 holes) Detachable Tour-Pak rack 53276-04 B (4 holes) Solo detachable Tour-Pak rack 53655-04 B (4 holes) Detachable Tour-Pak rack 53066-00B B (4 holes) Solo detachable Tour-Pak rack 53559-04A A (5 holes) Solo detachable Tour-Pak rack 53260-02 -J03631 1 of 3 B 1 A C 2 2 2 is00163 1. Front of motorcycle 2. Bottom view of Tour-Pak interior (rubber mat removed) Figure 1. Hole configurations for Tour-Pak attachment NOTE Drilling holes in Tour-Pak without wood underneath each hole site may result in the leather becoming damaged during the drilling process. 3. Place blocks of wood underneath the Tour-Pak where the holes will be drilled to prevent damage to the leather while drilling. Use the pre-drilled holes in the metal base as a guide and carefully drill the holes through the leather in the proper location using a 11/32 inch drill bit. 4. See Figure 2. For detachable luggage racks (53107- 96, 53066-00B and 53276-04): Install black cover tube to the front bar (1) of the luggage rack, as shown. This tube is used to provide a cleaner look. The black cover tube is not for use with other luggage racks. 5. Attach Tour-Pak to rack using the mounting screws provided in the Luggage Rack kit. Put bolt through from inside of Tour-Pak. Tighten screws to specifications found in the Luggage Rack kit. 6. Place the black rubber mat on the bottom of the Tour-Pak. 7. If luggage rack was removed, reattach to motorcycle according to kit instructions or Service Manual instructions

HONDA GL1500CD/ VALKYRIE Specifications

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Filed Under (Honda) by admin on 29-01-2011

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position when it comes to the environment. We continue to develop low-emission technologies for our current and future motorcycles, ATVs, scooters and personal watercraft. We already produce models that exceed the stringent 2008 CARB emissions requirements years ahead of schedule. And that’s the kind of performance everybody can appreciate. BE A RESPONSIBLE RIDER. Riding a motorcycle is an exercise in responsibility—to yourself, to others, to the environment and to the sport. So remember, wear a helmet, eye protection and protective clothing whenever you ride. Never ride under the influence of drugs or alcohol, and never use the street as a racetrack. Inspect your motorcycle before riding, read your owner’s manual, and see your local Honda Dealer concerning reimbursement through the Honda Rider’s Club of America™for Motorcycle Safety Foundation (MSF) rider training.* Always obey local laws, use common sense, and respect the rights of others when you ride. Make sure you have a proper license when riding on public roads, and never modify your motorcycle’s exhaust system. 03 SPECIFICATIONS ACCESSORIES VALKYRIE Log on to our website at honda.com for more information about Honda Genuine Accessories . On a bike like the Valkyrie, you can never have too much chrome. And that’s precisely why we offer our Chrome Sidecovers and Chrome Swingarm-Pivot cover to help really brighten up these areas. Here’s one of our most popular Valkyrie accessory options. These Leather Saddlebags look great, hold plenty, and match some of the other leather accessories we have available. Got a long trip planned, or is winter right around the corner? Then make sure you take a look at-or should we say take a look through-a Honda Genuine Accessories Windshield for your new Valkyrie. GL1500CD 1520cc liquid-cooled horizontally opposed six-cylinder with belt-driven overhead camshafts Six 28mm constant-velocity carburetors 71.0 x 64.0mm Solid-state digital Five-speed constant-mesh Shaft 150/80R-17 radial 180/70R-16 radial Dual-disc with twin-piston calipers 28.9 inches 66.5 inches 5.3 gallons, including 1.1 gallon reserve 681 pounds Black Windshield, leather saddlebags, chrome exhaust tips, chrome rear carrier, CB transceiver kit, passenger CB talk switch, studded backrest pad, studded main seat, studded rear seat, deluxe backrest pad

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2010 Honda CBR125R Track Day and School

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Filed Under (Honda) by admin on 01-11-2011

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A. Rookie Racers who wish to take this Officially Sanctioned School in preparation for their
participation in the 2010 Honda CBR125R Challenge held in conjunction with the 2010 Parts
Canada Superbike Championship (opening double header National round for the CBR125R
Challenge is May 27-30 at ICAR, Mirabel, north of Montreal, Quebec).
B. Current, licensed CBR125R series racers looking for track time in preparation for the upcoming
National series. Series AMB Scoring transmitters will be available for racer use at the venue.
C. Street riders who would like to try their stock CBR125R machines in a controlled environment;
Requirements:
1. Participants must be 18 years of age, or accompanied by an officially recognized parent or
guardian. The minimum age for participants is 13 – proof of age and ID are required. All
participants will be required to sign a release, waiver and minor permission Forms where
applicable. ID is required.
2. Participants must use a Snell 2005 or newer standard full face helmet, full race leathers (or
leather jacket with textile riding pants, zipped together), leather gloves and leather motorcycle
boots of at least eight inches in height.
3. Headlights and turn signals must be taped in case of breakage; mirrors must be removed.
Technical staff will be on hand to assist participants, and Orion Motorsports will provide Pirelli
tire sales, service and installation at the track during the da

2010 Toyota Motorsports/ TRD USA Contingency Award Program

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Filed Under (Toyota Manuals) by admin on 29-09-2011

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To enroll in the program, complete the registration form included in the enclosed material and mail, fax or e-mail it to TRD per the instructions at the bottom of the form. Contact personnel are listed on the attached 2010 Contingency Award Guidelines sheets. These people are available to assist you throughout the year. Parts Ordering: If you are planning to order Toyota parts during 2010 you must supply us with your Visa or Master Card credit card number at the time you register in the program. There is a line on the registration form for this number. See the attached Parts Ordering Guidelines for detailed information on how to order parts. TRD is looking forward to working with each of you, and we wish you a very successful year with your racing program

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Removal and Fitting of Tyres

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Filed Under (Tips and Review) by admin on 17-11-2010

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General Advice Tyres are the only parts of the motorcycle which are in contact with the road. Safety in acceleration, braking, steering and cornering all depend on a relatively small area of road contact. It is therefore of paramount importance that tyres should be maintained in good condition at all times and that when the time comes to change them suitable replacements are fitted. The original tyres for a motorcycle are determined by joint consultation between the motorcycle and tyre manufacturers and take into account all aspects of operation. It is recommended that changes in tyre size or type (construction) should not be undertaken without seeking advice from the motorcycle or tyre manufacturers, as the effect on motorcycle handling, safety and clearances must be taken into account. The tyre industry has long recognised the consumer’s role in the regular care and maintenance of their tyres. The point at which a tyre is replaced is a decision for which the owner of

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