removing a compensator on a dyna harley

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HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 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. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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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 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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HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. 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) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so 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

HARLEY DAVIDSON DYNA GLIDE CUSTOM SEAT KIT Installation Instructions

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

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Installation When performing the following procedures, be careful not to scratch painted surfaces (fender, tank, etc.) with metal tabs on seat. 1. Remove existing seat from motorcycle. Keep lockwasher and screw. 2. Remove existing grab strap and all attaching hardware. 3. Install new grab strap onto motorcycle at same location old grab strap was removed (re-use existing hardware). 4. On all models, except FXDWG , install existing stock rear bracket onto seat using stock hardware. On FXDWG models, install the new rear bracket, 52152- 97 onto the seat using the stock hardware. 5. Position new seat on motorcycle. Be sure bracket on front of seat fully engages seat mounting tab on frame. NOTE On rear fenders of 1997 -2003 models, a captive nut secured with a plastic retention washer has replaced the previously used weld nut. Do not remove the plastic retention washer unless the captive nut is damaged and must be replaced. The plastic retention washer also prevents seat bracket from contacting paint on fender. Therefore, no nylon washer is required between bracket and fender on 1997 – 2003 models. 1996 DYNA MODELS ONLY Secure seat with stock screw, stock lockwasher and place stock nylon washer between seat bracket and fender. 1997 – 2003 DYNA MODELS Secure seat with stock screw and stock lockwasher.

2004-2005 Harley Davidson Dyna EFI Tuner Installation Manual

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Filed Under (Harley Davidson) by admin on 14-04-2012

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1 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 the box and into the small opening in the frame (Fig. C). Fig. A Fig. B Fig. C Remove side cover Stock connector Stock connector Data plug Remove bolt Remove bolts FM810 www. fuelmotousa.com 2004-2005 Harley Davidson Dyna – FM EFI Tuner – 2 8 Plug the black connector of the Power Commander into the stock wiring harness connector (Fig. D). 9 Route the grey connector of the Power Commander through the box and plug it into the ECM. 10 Install the Power Commander against the rear part of the electrical box. Make sure to clean both surfaces with the alcohol swab first. Use the supplied velcro to attach the Power Commander. 11 Bolt the box back into place. 12 Reinstall the seat. Fig. D Fig.

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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

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HARLEY DAVIDSON DYNA STREET PERFORMANCE SLIP-ON ACCESSORY MUFFLERS INSTALLATION MANUAL

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

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PRODUCT INFORMATION Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

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HARLEY DAVIDSON DETACHABLE DYNA SIDEPLATE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Additional Parts Required The appropriate docking hardware and possibly a directional relocation kit must be installed prior to installation of this side- plate kit. These kits must be purchased separately from a Harley-Davidson Dealer. Table 1. Docking Hardware Kits Model Year Docking Hardware Kit FXDWG 53964-06 only Table 2. Directional Relocation Kits Model Year Docking Hardware and Directional Relocation Kit All except FXDWG 53961-06 and 53968-06 If mounting this kit with Saddlebags, part number 53968-06 is not required. Loctite® 262 (red), Part Number 94759-99, is available from your Harley-Davidson Dealer. Kit Contents Table 3. Kit Contents Part Number Description (Quantity) 52869-06 Side Plate, detachable, right 52870-06 Side Plate, detachable, left 94592-98 Button head screws (4) SISSYBAR INSTALLATION 2 3 1 4 1 is 01079 1. Sideplate 2. Sissybar 3. Buttonhead screw 4. Rotary latch Figure 1. Detachable Sissybar Sideplate Assembly See Figure 1. Install new or existing sissybar (2) to detachable sideplates (1) using four buttonhead screws (3). Apply Loctite® 262 (red) to screws before installation. Tighten screws to 96- 120 in-lbs (11-14 N-m)

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