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HAR:EY DAVIDSON FLHR/C/S (Road King) FRONT END LOWERING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Removal (Left and Right Forks) 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to Touring Model Service Manual and remove front wheel, fender and brakes. 3. Refer to Touring Model Service Manual and remove headlamp nacelle. 4. Loosen fork cap bolt from fork tube plug at top of fork tube, but do not remove. 5. See Figure 1. Standing at front of vehicle, loosen pinch bolt (with lockwasher) on right side of lower fork bracket, but do not remove. 6. Spray glass cleaner on fork tube above the rubber fork stop. After lubricating surfaces, move fork stop up fork tube until it contacts bottom of upper fork bracket. 7. Holding fork slider to prevent fork from dropping, remove fork cap bolt from fork tube plug. Slide fork tube down and out of upper fork bracket, fork stop, lower fork bracket and slider cover. 1 WARNING 1 WARNING 1 WARNING 1 of 5 ® Kit Number 54614-05 Figure 1. Loosen Pinch Bolt on Lower Fork Bracket i04808 1 Fork cap bolt 2 Fork stop 3 Pinch bolt 8. Thread fork cap bolt back into fork tube plug to prevent loss of oil while handling. 9. Move forks to bench area. Place suitable drain pan on floor beneath vise. 10. Repeat Steps 2-6 to remove left fork. Left And Right Fork-Disassembly 1. Remove nuts, lockwashers, flat washers and axle holder from studs at end of fork slider. 2. See Figure 2. Obtain FORK TUBE HOLDER (Part Number HD-41177) and proceed as follows: a. Clamp end of tool in vise in a horizontal position with plastic knobs facing toward you. b. See Figure 3. With the fork cap bolt topside, clamp fork tube between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. 3. Remove fork cap bolt from fork tube plug. Remove quad ring seal. Save bolt but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug from fork tube. Be aware that fork tube plug is under spring pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove 6mm screw from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring. 11. Remove and discard damper tube. 12. Remove wear ring and rebound spring. Discard rebound spring. Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted. 13. Using pick tool, remove retaining clip between fork slider and fork tube. 14. Remove fork tube from fork slider. NOTE To overcome any resistance, use the fork tube as a slide hammer, that is, first push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. 15. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing. 16. Remove the lower stop. Right and Left Fork-Assembly Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. 1. See Service Parts Illustration. Obtain new Damper Tube (Item 7, Part Number 46532-04) from kit. Obtain new Rebound Spring (Item 8, Part Number 46273-02) from kit and install on opposite end. Install wear ring removed in step 12. 2. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube. Install lower stop at end of damper tube. 3. Install fork slider in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (14) (Part Number 45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube. 5. Slide slider spacer down fork tube until it contacts slider bushing.

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HARLEY DAVIDSON TOURING FRONT LOWERING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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REMOVAL 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to the appropriate Service Manual and remove the front forks. 3. Move forks to bench area. Place suitable drain pan on floor beneath a vise. INSTALLATION Fork Disassembly 1. See Figure 6. Remove nuts (U), lockwashers (T), flat washers (S) and axle holder (R) from studs at end of fork slider. 2. See Figure 1. Obtain FORK TUBE HOLDER (HD-41177) and proceed as follows: a. Clamp end of tool in vise (1) in a horizontal position with plastic knobs facing toward you. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 6 for Steps 3-17. 3. Remove fork cap bolt (A) from fork tube plug. Remove quad ring seal. Save bolt but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug (B) from fork tube (G). Be aware that fork tube plug is under spring pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring (1) from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove screw and washer (Q) from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring. 11. Remove and save blow valve (E). 12. Remove damper tube (2). 13. Remove rebound spring (F) from damper tube. 14. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 15. Remove fork tube (G) from fork slider. Slide fork tube gently in a slide hammer motion against the slider to remove the seals and bushing from slider. 16. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). 17. Remove the lower stop (L). Fork Assembly NOTE Refer to Figure 6 for the following procedure. 1. Obtain new Damper Tube (2) from kit and install rebound spring (F) over the lower end. 2. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube (G). Install lower stop (L) on the lower end of damper tube. 3. Install fork slider (O or N) in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (K) (45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing (K) down fork tube. 5. Slide slider spacer (J) down fork tube until it contacts slider bushing. 6. Obtain new fork oil seal (I) (45875-84A, not included). Coat fork oil seal ID with clean fork oil. With the lip garter spring side facing down (toward the fork slider), slide oil seal down fork tube until it contacts slider spacer title_tag=

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HARLEY DAVIDSON FX SOFTAIL FRONT LOWERING SUSPENSION KIT INSTALLATION MANUAL

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

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REMOVAL 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to the appropriate Service Manual and remove the front forks. 3. Move forks to bench area. Place suitable drain pan on floor beneath a vise. INSTALLATION Fork Disassembly 1. See Figure 6. Remove nuts (T), lockwashers (S), flat washers (R) and axle cap from studs at end of fork slider. 2. See Figure 1. Obtain FORK TUBE HOLDER (HD-41177) and proceed as follows: a. Clamp end of tool in vise (1) in a horizontal position with plastic knobs facing toward you. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 6 for Steps 3-17. 3. Remove fork cap bolt (A) and spacer (O) from fork tube plug (B). Remove quad ring seal (D). Save bolt and spacer but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug (B) from fork tube (G). Be aware that fork tube plug is under spring -J03923 1 of 4 pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring (1) from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove screw and washer (Q) from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring (1). 11. Remove dust cover (E). 12. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 13. Remove fork tube (G) from fork slider. Slide fork tube gently in a slide hammer motion against the slider to remove the seals and bushing from slider. 14. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). NOTE The lower stop (L) may come out with the damper tube or remain in the slider tube. Ensure that the lower stop is removed from the slider tube. 15. Remove the lower stop (L). 16. Remove damper tube (2) from fork tube. 17. Remove rebound spring (F) from damper tube. 18. Repeat Steps 1-17 for the opposite side fork assembly. Fork Assembly

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 39 mm Front Spring Lowering Kit INSTALLATION PROCEDURE

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Filed Under (Harley Davidson) by admin on 07-04-2012

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1. Support the motorcycle so the front wheel is off the ground. Next remove the front wheel and fender. Remove the fork cap nuts and loosen the lower triple clamp pinch bolts. Remove the front brake caliper. Some models have a tapered end to the fork tube. Extra effort will be required to remove the tube from the crown. Loosen the top fork cap 1 to 2 revolutions. Use a soft wood block or similar tool (that will not mark fork cap finish) and tap down with mallet to loosen fork tube from its tapered fit in top steering crown. Make sure fork pinch bolts are loose. To completely remove fork of this style, unscrew the fork cap entirely. 2. Slide both fork assemblies out of the triple clamps. Unscrew the top fork tube plugs. Remove the plugs and fork springs. CAUTION: Fork caps are under spring pressure and could cause serious injury. Drain the fork oil by turning the fork assemblys upside-down. 3. Next, bottom the fork tube into the fork leg. DO NOT extend the tube while you remove the allen bolt on the bottom of the fork leg. Turn the assembly upside-down and shake the damper rod and rebound spring out of the fork assembly. Again, DO NOT extend the tube during this. Extending the tube could dislodge the internal bottoming cone, which fits on the end of the damping rod, making it very difficult to reinstall the damper rod without complete fork disassembly. 4. FOR 1″ REDUCTION IN FORK LENGTH: You must first measure the length of the O.E.M. rebound spring. Depending on the model of the motorcycle, the length will either be 1″ or 2″ long. A. If you currently have a 1″ rebound spring, you need to replace it with the 2″ long LA Choppers rebound spring (included in the kit), then reinstall the damper rod in the fork tube. B. If you currently have a 2″ rebound spring, you will need to add the 1″ long spacer, then reinstall the damper rod in the fork tube.

Street Fork Spring Installation Instructions

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Filed Under (Tips and Review) by admin on 13-02-2011

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1. Remove fork springs according to instructions contained in your shop manual. For maximum performance we highly recommend that the forks be thoroughly cleaned, inspected and new fork oil installed. Note: If your motorcycle comes equipped with two fork springs in each leg (long & short), remove and discard both springs and the flat washer between the springs. If a stock spacer exits, remove it. If there is a short spring on the damper rod, do not remove it! 2. Use the recommended fork oil viscosity as noted in your owners manual with the following exceptions: GL1100 20 weight, GL1200/1500 15 weight required. See fine tuning for more in- formation. Fork oil level/volume should be checked according to the steps outlined in your authorized shop manual. Measurement of your fork oil by level is the preferred method. However, some manuals only specify a volume measurement. Due to the design of a progressive wound fork spring it will displace more oil thus requiring a maximum oil level of 5.5″ (140mm). Caution: This is not a recommendation, it is only a precautionary statement. If your manual specifies an oil level higher than 5.5″ (140mm) set the oil level at 5.5″ (140mm). (Oil level is the distance from the top of the fork tube to the top of the oil with the fork completely collapsed and the fork spring removed see figure 1.) This measurement can be made by using either one of the Progressive Suspension Fork Oil Level Adjusters (FOL-1 or FOL-2). 3. Install your new fork springs into the forks. Mechanically, it makes no difference which way the springs are installed. Some manuals will state; install the spring with the close wound end towards the bottom. This is done because sometimes there will be less spring noise. The springs will perform exactly the same regardless of which direction they are placed. Check the spacer length requirement for your motorcycle in the enclosed supplement. If not listed, you must calculate the pre-load. What is pre-load? Pre-load is the distance the spring compresses when the fork cap is installed. You may or may not utilize a spacer to achieve proper pre-load. The spacer in itself is not “pre-load”. It just helps to achieve it. Why is pre-load important? It determines the proper ride height which in turn affects how the bike handles.

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HARLEY DAVIDSON PREMIUM SUSPENSION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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REMOVAL Front Fork Assembly 1. Refer to the XR model section of the service manual and remove the front forks. INSTALLATION Front Fork Assembly 1. Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. 2. See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85- 11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). is06083a Figure 1. Fork Installation Height Measurement. NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. 3. Install pinch screws to upper and lower fork brackets. 4. Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). 5. Tighten pinch screws to 30-35 ft-lbs ( (40.7-47.5 Nm)) See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. 6. Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. REMOVAL OEM Rear Shock Absorbers 1. Refer to the XR model section of the service manual and remove the rear shock absorbers. INSTALLATION Rear Shock Absorbers 1. See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. is06142 Figure 3. Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c) Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a) NOTES Damping is set at the factory for the average solo rider under normal riding conditions. The rider may make adjustments to compensate for individual riding styles and varying road conditions. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully. The front and rear preload setting will need to be adjusted for the rider’s weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). If the preload adjustment is correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload. The following tools are needed to make suspension adjust- ments. • 5 mm hex key (front fork preload adjustment tool). • Spanner wrench with extension handle (shock absorber preload adjustment). • Screw driver (front fork damping adjustment). 1. Front fork preload adjustment: a. See Figure 4 and Table 1. Using the 5 mm hex key, turn the preload adjuster counterclockwise until it stops. This is the minimum preload setting. b. Turn the preload adjuster clockwise the recommended amount specified for the rider weight

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

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HARLEY DAVIDSON DETACHABLE QUARTER FAIRING AND DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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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 If your motorcycle has directional lights mounted on the upper fork bracket they must be relocated to the bottom fork bracket. Some models have front directional lights equipped with three wires, the third black wire is a ground wire. Check to determine how many wires are connected to the front directional lights and follow the following procedure that applies. Ifdirectional lights are not mounted on the upper fork bracket proceed to “ASSEMBLING FAIRING”. Relocating Two Wire Directional Lights 1. Support motorcycle on a center stand such that front wheel is raised slightly off the ground. 2. Remove fork tube pinch screw from right side of lower bracket. 3. Cut wires connected to right directional light about 2 in. away from directional light body. 4. Remove fork tube pinch screw from right side of upper fork bracket. (This is the screw that secures the right directional light.) 5. Install right directional light on right side of lower fork bracket using pinch screw removed in step 4. Install pinch screw removed in step 2 into right side of upper bracket. Tighten both pinch screws to 30-35 ft-lbs. 6. Repeat steps 1 through 5 to relocate left directional light. NOTE Fork tubes may slide downward within fork brackets. If this occurs, front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures. 7. Connect the right directional light as follows: Strip approx. 5/16 in. of insulation from the wires cut in step 3. 8. Crimp solderless connectors from kit on two wires coming from motorcycle. 9. Split one end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 10. Slide a piece of shrink tubing from kit over each of the wire ends stripped in step 9 and crimp the wires into the terminals installed in step 8. Make sure you connect the silver and copper colored wires to like colored wires. NOTE Polarized wire is used in this application to ensure correct wiring. One wire is silver, one is copper colored. Wire colors of spliced wire must match wire color of original directional wire leads. 11. Cut polarized wires to the length required for connection to the wires at the relocated directional light. Make certain you leave enough slack in wires to allow routing the harness along the fork tube. 12. Split remaining end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 13. Slide heat shrink tubes over the two wire end. 14. Strip 5/16 in. of insulation from wires connected to directional light and connect like colored wires at directional light with connectors from kit. 15. Slide heat shrink tubing over connectors installed in steps 10 and 14. Activate shrink tubing with heat gun or hair dryer.

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Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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