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HARLEY DAVIDSON CHROME REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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Kits 41017-00, 41026-00 and 41262-03 are designed for installation on 2000 and later XL, FXD and 2000-2002 Softail Model Motorcycles (except FXSTD and FLSTS). Kits 41260-03, 41261-03 and 41265-03 are designed for installation on 2003 and later Softail Model Motorcycles (except FXSTD and FLSTS). Kit Numbers 41017-00 and 41261-03 contain a16 inch chrome slotted rear wheel. Kit Numbers 41026-00 and 41260-03 contain a 16 inch chrome fatboy rear wheel. Kit Numbers 41262-03 and 41265-03 contain a 16 inch mirror chrome disc rear wheel. See Service Parts Illustration for kit contents. nstallation Do not re-use brake disc screws. New screws are provided for disc installation. Re-using original disc screws can result in torque loss and damage to rotor and/ or brake assembly. (00319a) Refer to the appropriate Service Manual for wheel removal and installation procedures. See Service Parts Illustration. This kit contains the necessary parts for wheel installation, however you will need to save the Axle, Axle Nut, Brake Disc, and the Drive Pulley with related hardware for reinstallation. NOTE The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Apply two drops of LOCTITE THREADLOCKER 262 (red) to each of the five sprocket mounting screws. Follow the bolt torque procedure in your service manual or, if installing an accessory hardware kit, in the I-sheet included with the hardware kit. 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 & Tire Cleaner Part Number 94658-98 applied with Harley Wheel & 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

CARE AND MAINTENANCE OF CHROME WHEELS

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Filed Under (Tips and Review) by admin on 16-02-2011

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Chrome-plated wheels are attractive and can remarkably change the appearance of your trike by reflecting light to base areas of your vehicle. We have piece together the following material to help you get many years of enjoyment from your wheels plated with chrome. •When washing your trike, start first with the wheels. Wash them when they are cool, not after a long drive. Never spray cold water on hot or warm wheels, this can result in permanent damage to their appearance. •Chrome-plated wheels should be washed with a mild soap and water frequently. It is important to take note that absolutely no ammonia-based or acid cleaning solutions are to be used on the wheel or the tires. •Use a washing mitt or a soft sponge. Never use any type of brush, abrasive pad or steel wool as these will scratch the finish. Rinse thoroughly. Do not allow soap, chemicals or water to sit on the surface and produce water spots. Dry your wheel with a soft non-abrasive towel. •Be careful around automatic car washes, due to their use of bristle brushes or acidic preparations that are used to remove dirt and debris from wheels. •Periodically, polish wheels with quality non-abrasive chrome polish. After polishing and/or cleaning it is a good idea to wax the exposed areas to seal the surface. •When possible, chrome-plated wheels should not be used in areas where salt and chemicals are used in winter weather. If chrome wheels are driven in winter months they should be cleaned every week. Chrome sealant is highly suggested for use on wheels that are driven in winter or better yet, remove your chrome-plated wheels during this time. •If you live near salt water or beaches, take extra attention to wash more frequently to remove ocean salts. Any build up of brake dust along with residue from coastal climate can damage the finish. •Proper attention should also be paid to the backside of the wheels when washing. Keep your investment safe; clean your wheels on a regular basis

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HARLEY DAVIDSON CHROME BATTERY COVER TRIM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVAL 1. See Figure 3. Remove button-head screw (A) that attaches battery cover (B) to battery tray (C). 2. See Figure 1. Remove battery cover by lifting it over the two tabs on the battery tray. NOTE The original equipment battery cover trim has four pinch tabs on the reverse side that attach it to the battery cover. 3. See Figure 2. Remove original equipment battery cover trim from battery cover by pushing the four pinch tabs out of the battery cover using a pliers or suitable tool. INSTALLATION 1. Place battery cover over the two tabs on battery tray (C) and attach it to battery tray with button-head screw (A). Tighten screw to 20-40 in-lbs (2.3-4.6 Nm). 2. Obtain chrome battery cover trim (1) from kit. 3. Using a 50/50 isopropyl alcohol/water solution, thoroughly clean the surface where the chrome trim will be installed. Let it dry completely. NOTE Test the trim mount fit prior to removing the adhesive backing from the chrome battery cover trim. 4. Remove adhesive liner from the chrome battery cover trim. NOTE The ideal temperature should be at least 60° F (16° C) for proper adhesion of the chrome trim on the battery cover. 5. Center and install chrome trim onto the battery cover. Apply firm pressure for one minute using a cloth to prevent scratching the battery cover and battery trim. 6. Let the adhesive cure for 24 hours at no less than 60° F (16° C)

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HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

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

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

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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 ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

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HARLEY DAVIDSON V-ROD CHROME TURN SIGNALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION Prepare the Motorcycle 1. Remove the right cover and the maxi-fuse. 2. Follow Service Manual instructions to remove the air box cover. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Follow Service Manual instructions given to remove the negative (-) battery cable from the negative (-) battery terminal. Remove the Existing Rear Turn Signals 1. See Figure 1. Insert a screwdriver into middle of hole of license plate light cover. Push forward to release tail lamp housing retaining clip. 2. See Figure 2. Identify the white left [19] (1) and black right [18] (2) 2 pin turn signal connectors. is 00231 Figure 1. Tail Lamp Housing 2 1 is00232 1. Left turn signal connector [19] (white) 2. Right turn signal connector [18] (black) Figure 2. Rear Turn Signal Connectors 3. See Figure 3. Press the button (1) and separate the pin terminal housing from the socket terminal housing. -J03601 1 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To release the socket terminal and wire, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. 6. See Figure 4. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket (3) and remove turn signals. 7. Repeat for the opposite turn signal. Install Chrome Rear Turn Signals 1. See Figure 5. Assemble a chrome turn signal assembly (1) to a chrome lamp support (2) by feeding the wire leads through the wire hole in the lamp support. 2. Feed the wire leads and conduit through the front hole in the license plate bracket and through hole in the support plate (4) towards the front of the motorcycle. 3. Thread the bolt (3) through the center hole in the support plate, through the center hole in the license plate bracket, and through the hole in the chrome lamp support into the chrome turn signal. 4. Tighten the bolt to 100-150 in-lbs (11.3-16.9 Nm). 5. Route the turn signal wires between the license plate bracket and the inner fender. Access the wires through the tail lamp opening in the outer fender. 6. See Table 1. Identify the left and right connector socket housings and match the socket terminated colored leads to the cavities in the socket housing which correspond to the colored leads in the pin housing

HARLEY DAVIDSON CHROME FOOTPEG BOLT KIT INSTALLATION MANUAL

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

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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 The bolts supplied in this kit are designed for a one-time installation only. If this kit is removed after initial installation, you must re-apply Loctite 243 (Blue) to the threads of the bolts. Kit Contents 3 1 3 is05122a Figure 1. Service Parts: Chrome Footpeg Bolt Kit Table 1. Service Parts Part Number Description (Quantity) Item 94128-01 Washer, chrome (2) 1 8023 Nut, chrome (2) 2 4233 Screw, TORX®, button head, chrome (2) 3 INSTALLATION 1. Remove existing nut and bolt securing footpeg to mount. Discard nut and bolt. 2. See Figure 2. Install chrome washer to bolt, then install bolt through mount and footpeg as shown. 3. Install nut to bolt. Tighten hardware to 10-16 ft-lbs (13.6- 21.7 Nm) . 4. Repeat Steps 1 through 3 for the opposite side

HARLEY DAVIDSON CHROME REAR BRAKE RESERVOIR COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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INSTALLATION 1. Remove and discard the screw and washer holding the rear brake master cylinder reservoir to the motorcycle frame. 2. See the Figure 1. Obtain the chrome screw (2) and washer (3) from the kit. Place the washer onto the screw threads. 3. Position the chrome rear brake reservoir cover (1) over the reservoir, lining up the holes. Fasten with the chrome screw and washer using the T27 TORX® key (6) from the kit. Tighten securely. 4. Slowly unscrew the original reservoir cap. Note the orientation of the reservoir gasket and the gasket collar, which may come off with the cap. Discard the original reservoir cap only. Set the gasket and collar aside for re-installation. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) 5. Refer to the Owner’s Manual and follow the procedure to check the brake fluid level. Fill as needed with DOT 5 SILICONE HYDRAULIC BRAKE FLUID. Do not reuse old fluid. Only use DOT 5 hydraulic brake fluid from a sealed container. 6. Set the reservoir gasket back onto the lip of the reservoir and position the gasket collar onto the gasket. 7. Carefully position the new chrome cap (4) over the reservoir and screw it on. Tighten securely. 8. Clean the indented top surface of the new cap with a 50- 50 mixture of isopropyl alcohol and water and let it dry. 9. Peel the paper backing from the Bar and Shield emblem (5). Turn the emblem to the desired orientation and press it firmly into place on the top of the chrome cap. After repairing 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.