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HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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Victory V92SC Sport Cruiser COMFORT SPORT HANDLEBAR REMOVAL AND INSTALLATION

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Filed Under (Victory) by admin on 13-11-2010

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1. Remove wiring harness dart clips. 2. Disconnect clutch switch connector. 3. Remove 2screwsforclutch lever bracket clamp, remove clutch lever bracket from handlebar. 4. Remove screws for left handlebar switch assembly. Disconnect fast idle cable from lever. Remove switch assembly. 5. Grasp left grip end firmly. While twisting grip end back&forth, pull grip end off and discard. 6. Remove left grip by insertingathin screwdriver between the grip and handlebar end. Spray as mall amount of water/soap solution into the area between the grip and handlebar end. Aggressively twist the grip back-and-forth while simultaneously pulling the grip off. 1. Locate accessory handlebar. 2. Clean inside of throttle grip assembly and throttle cable flange grooves. Ill. 1. 3. Clean throttle grip area. Ill. 1. 4. Slide throttle assembly onto right handlebar end (cableshavenot been removed and should still be attached to the throttle tube). 5. Position the handlebar over the top of the triple clamp and reinstall using bolts removed instep 10. of handlebar removal. Torque to 30 ft. lbs. 6. Install right handlebar switch housing onto handlebar. NOTE: Make sure that locating pin of switch assembly aligns with hole in handlebars. 7. Install right handlebar switch housing screws, make sure locating pin properly aligns with hole in handlebar. Tighten screws to specified torque. 8. Install master cylinder and clamp, install screws. 9. Torque screws to specification. 10. Connect front brake switch wiring harness. 11. Install fast idle cable onto fast idle lever. 12. Clean inside of left grip and handlebar grip surfaces

HARLEY DAVIDSON CHROME HANDLEBAR CLAMP BOLT KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION Improperly aligned handlebars can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372a) NOTES Check that the handlebar is centered on the risers. To make sure that the handlebar is centered, verify that the knurled areas on the outboard side of each riser are equal. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact with the fuel tank occurs or the handlebars are not properly centered, see Figure 1. Slightly loosen the four upper clamp screws, and center the handlebar or raise the handlebar angle as necessary until proper clearance is obtained, then temporarily snug the screws, but do not fully tighten. 4 1 2 3 4 is00868 1. Upper clamp 2. Screw (4) 3. Handlebar 4. Handlebar risers (2) Figure 1. Handlebar Clamp Hardware 1. Remove and discard screws (2) that fasten upper clamps (1) to handlebar risers (4). Save washers under screw head for later use. 2. For Kit 94453-04: Select new chrome screws from the kit that match the length of the screws removed. For all other Kits: Select new chrome screws from the kit. 3. Slide washers previously removed onto screws, and thread screws through the upper clamps into risers. -J03586 1 of 2 4. If handlebar adjustments were made, snug screws but do not fully tighten. a. The bottom surfaces of upper clamps are offset, creating a gap between the clamp and riser on one side. b. Tighten clamps so the gaps appear to the rear of the handlebar, then tighten screw to 12-15 ft-lbs (16.3- 20.3 Nm). 5. If handlebar adjustments were not made, tighten screws to 12-15 ft-lbs (16.3-20.3 Nm). SERVICE PARTS

MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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HARLEY DAVIDSON SLOTTED HANDLEBAR RISER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Cover the fuel tank with a clean shop towel to prevent scratching. Damage to the finish could result. 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for re-assembly. Retain all additional hardware components that become dislodged from the riser when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers, and carefully allow the handlebar to rest on the fuel tank. 3. Obtain the new slotted risers (1) and hex head cap screws (2) from the kit, and the split lockwashers and hardware components removed in Step 1. NOTE The upper cup washer (A) must be oriented with the flat side up , and the lower cup washer (D) with the flat side down . The ground wire (G) and internal tooth lockwasher (H) are mounted to the right-side riser. 4. Refer to Figure 1 for the correct orientation and reassembly sequence. Install the new risers onto the upper fork bracket using the saved hardware and new screws. Snug the riser screws, but do not fully tighten at this time. 5. Center the handlebar on the risers. To make sure that the handlebar is centered, verify that the knurled areas on the outboard side of each riser are equal. 6. Position the new handlebar upper clamps (3) from the kit, and install with new hex socket head screws (4). Snug the upper screws, but do not fully tighten. Improperly aligned handlebars can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372a) 7. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is attained. 8. Tighten the upper handlebar-clamp screws as follows: a. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . b. Tighten the rear screws to 12-15 ft-lbs (16-20 Nm) . c. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . NOTE The gap between the upper clamps and the risers should be equal at the front and rear of the handlebar after tightening. 9. One at a time, remove the riser bolts installed in Step 4. Apply two drops of Loctite® 271 (Red) to the bolt threads and re-install. Tighten the riser bolts to 50-60 ft-lbs (68-81 Nm)

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HARLEY DAVIDSON HANDLEBAR GRIPS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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INSTALLATION Remove and Install the Left Grip 1. See Figure 1. Remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Loosen, but do not remove, the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lb (6.8-9 Nm) . 9. Tighten first the lower, then the upper switch housing screws to 35-45 in-lb (4-5.4 Nm)

HONDA VTX1300, VTX1800 R, C & S MODEL HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 27-12-2010

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1 .Lay a blanket folded several times over the fuel tank to protect it. 2. Notice on the 1800 models that there is a small punch mark on the handlebars located on the right hand, front side of the handlebars where the risers meet the top clamp/speedometer housing. This is to reference the handlebar position when re-assembling. On the 1300 models there is a punch mark on the forward facing side of the clamp, these must be installed the same way. 3. Loosen the two 19mm nuts holding the risers to the upper triple clamp (steering head). 4. Pry out the four chrome caps covering the handlebar bolts. Remove the four handlebar clamp bolts. (6mm allen wrench). While sitting on the motorcycle, pull the handlebars and upper clamp off of the risers. They may be slightly stuck and require some force to get free. Lay the handlebar and/or upper clamp/gauge assembly carefully on the blanket. 5. Remove the 19mm nuts and the risers from the triple clamp. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Place the thin flat washers provided into the recess at the top of the riser bolt holes on the triple clamp. Assemble the lock washers provided and then the original flat washers onto the bolts provided. Install the new risers onto the triple clamp and snug the bolts. 6. Re-install the handlebars and upper clamp/gauge assembly. ( Remember the punch marks) Tighten the front bolts first closing the gap at the front, and then tighten the rear bolts. Tighten the two 19mm riser-mounting bolts securely. Check for adequate clearance and proper routing of cables and hoses.

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Honda Motorcycle Na vigation Kit

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Filed Under (Honda) by admin on 28-11-2010

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Honda Motorcycle Na vigation Kit Honda Motorcycle Navigation Kit G e n e r i c A c c e s s o r i e s 2 0 0 8 For your peace of mind Honda Genuine Accessories are carefully designed, researched and stringently test ed tot he highest standards. And since they’re all Honda approved you’llknowthat they’rejustastoughand well made as your Honda motorcycle. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice. y e a r w a r r a n t y GENUINE ACCESSORIES Honda Motorcycle Navigation Kit Model Part Number Description RRP Remarks NAKED CBF 600 08A 40MER800B CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY CBF 600 08A 40MER800A CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY ON/OFF XL700V 08A 40MFF800 * CONTAINS NA VI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EARPH ONE, MANUAL, 08A 30MFF800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY XL 1000V 08A 40MBT800 CONTAINSNAVI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EAR PH ONE, MANUAL, 08A 30MBT800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY TOURERS/SPORT TOUR ERS DN-01 08A 40MEH800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, AND BATTERY -CONTAINS 08A 30MEW800 ADDITIONALSTE ERIN G HANDLE C LAMPS FORV ISU AL INTE GRAT ION OF THE COMPONENT NT700V 08A 40MEW800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, BATTERY

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HARLEY DAVIDSON "LIVE TO RIDE" HANDLEBAR GRIPS INSTALLATION MANUAL

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

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installation Do not lubricate the left grip of handlebar in any way before installation. This could allow grip to come off while riding which could result in loss of control of vehicle and death or serious injury. 1. Remove existing left handlebar grip by carefully cutting it away from the handlebar using a sharp blade or knife. Remove right grip/throttle sleeve assembly following instructions in appropriate Service Manual. After removal, make sure that left and right handlebar ends are clean and smooth. 2. Check that end caps are securely fastened to grips. Tighten screw inside grip to secure end caps. 3. Assemble new throttle sleeve to handlebar. Refer to appropriate Service Manual for detailed procedure. NOTE Surfaces to be glued must be clean, dry, and free from oil. If surfaces are not clean, dry, and free from oil, then the new application may not adhere as desired. Please observe the following WARNINGS when using the adhesive contained in this kit. FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWALLOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS METHYL ETHYL KETONE. Use only in well ventilated areas. Avoid contact with eyes, mucous membranes, and prolonged skin contact. KEEP OUT OF REACH OF CHILDREN. If swallowed, do not induce vomiting. Call a physician immediately. This product contains a chemical(s) known to the State of California to cause cancer, birth defects or other reproductive harm. 4. Liberally apply a coating of Harley-Davidson Adhesive (Part No. 99839-95) to the inside of left handlebar grip using the cotton swab. Make sure adhesive fully covers all inside surface area of the grip. Also, apply a coat of adhesive to the handlebar end. 5. Check how the rectangular pattern is oriented on the throttle (right) grip. Align pattern on left grip to match right grip and immediately push the new grip completely onto handlebar end. 6. Rotate the end caps so the “Live to Ride”text is positioned at the top of both grips. NOTE Do not hesitate when installing left grip or adhesive will dry before installation is complete. Allow 6-8 hours at 70°F to achieve full cure of the adhesive. Prior to starting engine, verify that the throttle control will snap back to the idle position when released. A throttle control that prevents the engine from automatically returning to idle can lead to a loss of control of vehicle which could result in death or serious injury. Cleaning

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