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HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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2007 Harley-Davidson CVO Family: Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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1. Harley-Davidson reserves the right to discontinue models or change specifications at any time without incurring any obligations. Vehicle specifications may vary by country and region depending on local laws. Some models are not available i certain countries. 1. Harley-Davidson reserves the right to discontinue models or change specifications at any time without incurring any obligations. Vehicle specifications may vary by country and region depending on local laws. Some models are not available in certain countries. 1. Harley-Davidson reserves the right to discontinue models or change specifications at any time without incurring any obligations. Vehicle specifications may vary by country and region depending on local laws. Some models are not available in certain countries. 2. Measurement reflects 81.7 kg operator weight. 2. Measurement reflects 81.7 kg operator weight. 2. Measurement reflects 81.7 kg operator weight. 3. Recommended 91 octane or higher fuel (R+M)/2 (87 octane or higher for XL 883 models). Standard and optional fuel systems may vary by country and region. 3. Recommended 91 octane or higher fuel (R+M)/2 (87 octane or higher for XL 883 models). Standard and optional fuel systems may vary by country and region. 3. Recommended 91 octane or higher fuel (R+M)/2 (87 octane or higher for XL 883 models). Standard and optional fuel systems may vary by country and region. 4. Standard and optional wheels may vary by country and region. 4. Standard and optional wheels may vary by country and region. 4. Standard and optional wheels may vary by country and region. 5. Values shown are nominal. Performance may vary by country and region. 5. Values shown are nominal. Performance may vary by country and region. 5. Values shown are nominal. Performance may vary by country and region. 6. Security systems include the immobiliser and siren. 6. Security systems include the immobiliser and siren. 6. Security systems include the immobiliser and siren. 7. Availability of colours may vary from dealer to dealer and is subject to change without notice. 7. Availability of colours may vary from dealer to dealer and is subject to change without notice. 7. Availability of colours may vary from dealer to dealer and is subject to change without notice. 8. Model not available in all markets. 8. Model not available in all markets. 8. Model not available in all markets. 9. See motorcycle owner’s manual for complete details. 9. See motorcycle owner’s manual for complete details. 9. See motorcycle owner’s manual for complete details. 10. Inspections of certain systems and components are required at 4,000 km intervals. 10. Inspections of certain systems and components are required at 4,000 km intervals. 10. Inspections of certain systems and components are required at 4,000 km intervals.

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HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. 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. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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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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2007-2010 Harley Davidson Dyna EFI Tuner INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2012

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Remove the seat 2 Remove the left hand side cover (Fig. A). 3 Unplug the stock wiring harness connector from the ECM (Fig. B). 4 Move the data plug (Fig. B) out of the way to access bolt. 5 Remove the 3 bolts that hold the electrical box in place (Fig. B). 6 Slide the plastic box out from the frame. 7 Route the stock connector through to the back side of the electrical box (Fig. C). Fig. A Fig. B Fig. C Remove side cover Stock connector Stock connector Dat a plug Remove bolt Remove bolt s FM814 www .fuelmotousa .com 2007-20 1 0 Harley Davidson Dyna – FM EFI Tuner – 2 8 Lay the PCIII behind the electrical box temporarily. 9 Route the GREYconnector from the PCIII through the back of the electrical box and plug it into the ECM (Fig. D). 10 Connect the stock wiring harness to the BLACK connector of the PCIII. 11 Zip tie these connectors to the front side of the electrical box (Fig E). Make sure they are situated away from the rear exhaust pipe. Fig. D Fig. E PCIII connector Stock connector PCIII connector 12 Mount the PCIII to the underside of the stock ECM (Fig. F) using the supplied velcro. Make sure to clean both surfaces with the alcohol swab before attaching. Situate the PCIII so the USB and expansion ports point to the rear of the bike. This will allow you easier access to adjust the maps if necessary

2007 Harley Davidson Sportster 1200 Installation Manual

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Filed Under (Harley Davidson) by admin on 11-04-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Remove the ECM from the tray and remove the tray from the fender. You can reach underneath the fender to gain access to the release tabs for the tray. 4 Install the Dynojet tray into the rear fender . Make sure that all 3 location tabs are underneath the fender. 5 Lay the PCIII in the tray (Fig. B). 6 Install the stock ECM on top of the PCIII making sure that it is secured by the tray locking tabs. 7 Plug the GREYconnector from the PCIII into the ECM. 8 Route the PCIII harness on top of the GREY connector (Fig. C) and route towards the front of the bike. Fig. A Fig. B Fig. C 2007 Harley Davidson Sport ster 1200 – PCIII USB – 2 i817-51 1 www .powercommander .com Unplug Tray 9 Plug the BLACK connector from the PCIII into the stock wiring harness. Secure this connection with one of the supplied zip ties (Fig. D). 10 Run a zip tie behind the wiring harness (Fig. E). 11 Route the stock wiring harness as shown in Fig. E. Due to the lack of room on this bike this step needs to be exact or the install will not fit properly . Make sure that the harness coming from the GREYconnector is flush against the battery box. Acouple inches of this harness will be tucked underneath the frame

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2007 Harley-Davidson VRSC Family: Specifications

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Length (mm) 2455 2460 Overall Height (mm) 1100 1120 Seat Height – laden (mm) 2 660 660 Ground Clearance (mm) 127 127 Rake (steering head) 34° 34° Fork Angle 36° 36° Trail (mm) 115 115 Wheelbase (mm) 1715 1715 Fuel Capacity (litres) 18.9 18.9 Oil Capacity w/filter (litres) 4.3 4.3 Dry Weight (kg) 292 287 Engine 3 Liquid-cooled, Revolution® Liquid-cooled, Revolution® Displacement (cu. cm) 1130 1130 Bore x Stroke (mm) 100 x 72 100 x 72 Compression Ratio 11.3:1 11.3:1 Fuel System Electronic Sequential Port Fuel Injection (ESPFI) Electronic Sequential Port Fuel Injection (ESPFI) Exhaust System Chrome, slash-cut duals Chrome, straight-shot dual pipes Type Dunlop® Harley-Davidson Series, radial Dunlop® Harley-Davidson Series, radial Front D208F 120/70ZR-19 60W D208F 120/70ZR-19 60W Rear D419 240/40R-18 79V D207 180/55ZR-18 74W Machined slotted disc Machined slotted disc 19 x 3 in. 19 x 3 in. Machined slotted disc Machined slotted disc 18 x 8 in. 18 x 5.5 in. Primary Drive Gear, 64/117 ratio Gear, 64/117 ratio Final Drive Belt, 30/72 ratio Belt, 30/72 ratio Clutch 9-plate, wet 9-plate, wet Transmission 5-speed 5-speed 1st 10.98 10.98 2nd 7.38 7.38 3rd 5.88 5.88 4th 5.10 5.10 5th 4.57 4.57

HARLEY DAVIDSON BLADE FRONT WHEEL KITS INSTALLATION MANUAL

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

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

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-03-2012

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1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.

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