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HARLEY DAVIDSON FRONT AND REAR FENDER TIP TRIM INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation GENERAL The original equipment (stock) fender tip lamp assemblies must be removed and the wire(s) must be unplugged or removed as specified in the following instructions. FRONT FENDER TIP REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1994 AND LATER FLT MODELS 1. Refer to the applicable FLT Service Manual. Remove headlamp assembly with housing. 2. Locate the 3-place connector [32 in wiring diagram] through which 12vdc and electrical ground are connected to the fender tip lamp assembly. The connector locations are as follows: FLTC Ultra: Under fuse and circuit breaker block FLHT/C/C-U: On bottom of left outer fairing bracket FLHR: On left front above air suspension valve NOTE Before disassembling the connector in the next step, refer to the applicable wiring diagram and check wire colors and connections to assure that connector [32] has been located. 3. Refer to the “DEUTSCH ELECTRICAL CONNECTOR” section in the FLT Service Manual and remove the leads, connected to the fender tip lamp, from the socket half, connector [32B]. 4. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 5. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wires connected to lamp assembly. 6. Reach under left side of fender and gently pull wires through rear hole in left side of fender and then through clips on left side of fender and finally through front hole and out of trim strip. REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1993 AND EARLIER FLT MODELS, FLSTC AND FLSTN 1. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 2. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wire connected to lamp assembly. 3. Unplug wire connector located about 3 in. from lamp assembly. Cover the socket half of connector (connected to motorcycle wiring) with electrical tape. INSTALLING FRONT FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in fender and guide outer ends of fender tip trim into trim strips on sides of fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs . REAR FENDER TIP REMOVAL OF STOCK REAR FENDER TIP LAMP ON ALL MODELS Follow steps 1 through 3 given above for “1993 AND EARLIER FLT MODELS, FLSTC & FLSTN” INSTALLING REAR FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in rear fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs

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HARLEY DAVIDSON HERITAGE CHROME FRONT FENDER RAIL INSTALLATION MANUAL

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

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INSTALLATION NOTE See Figure 1. Be careful not to crack plastic fender lamp lens (2) or chrome plate when removing lens. 1. Remove fender lamp light lens (2) by placing screwdriver in slot in top of lens and carefully prying cover loose. Retain lens and gasket for later installation. 2. Loosen four hex socket head screws (1) which attach fender (4) to fender mount. 3 2 4 1 is03805 1. Fender mount screws (4) 2. Fender lamp light lens 3. Fender Rail 4. Fender Figure 1. Installed Front fender Rail NOTE When installing fender rail (3), be sure fender rail supports are inside of fender. 3. Place fender rail (3) from kit into position, aligning the front bracket hole of rail with hole in front of fender (4). Fender rail supports will fit snugly inside fender. NOTE Be careful not to damage the fender lamp wire when securing front fender rail into place. 4. Use a magnet to place a 10-32 x 1/2 inch phillips screw through the hole in front fender and through front bracket hole of fender rail (3). 5. Loosely secure fender rail (3) to fender (4) with 1/2 inch flat washer and hex locknut. 6. On right side only, remove two hex socket head screws and nuts. Retain nuts for installation. 7. Replace original two socket head screws with 5/16-18 x 2 inch screws from kit. 8. For vehicles without caliper/rotor covers: On left side of fender (4) only, install a washer between rail (3) and fender for both screws. Replace original two hex socket head screws with 5/16-18 x 2 inch screws from kit. For vehicle with caliper/rotor covers: Do not replace hex socket head screw that supports caliper/rotor cover. On left side of fender (4), install a washer between fender (4) and rail (3) on screw that does not support the caliper/rotor cover (towards the front of the vehicle). Replace remaining hex socket head screw with 5/16-18 x 2 inch screw from kit. 9. Install four original nuts. 10. Tighten front bracket Phillips screw securely. Tighten four hex socket head screws to 14-18 ft-lbs (19-24 Nm). 11. Install gasket and fender lamp lens removed earlier

HARLEY DAVIDSON HERITAGE REAR FENDER RAIL DISASSEMBLY AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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DISASSEMBLY NOTE See Figure 1. Saddlebags must be removed to insert spacer (1). 1. Using a small flat head screw driver, remove rear fender tip light lens cover (A) by gently prying cover away from assembly. (There is a notch at top of cover to ease removal.) Remove and retain cover (A) and gasket (C). 2. Remove fender tip light assembly (B) by removing two screws, four star washers, and two nuts (not shown) using a #2 Phillips screw driver and a 3/8 inch wrench. Retain all hardware for reassembly. 3. Remove hole plugs from rearmost fender strut holes on both sides of fender. 4. Mark fender on both sides of bike using rear most fender strut hole as a template. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) 5. Carefully remove fender strut and drill a 11/32 inch hole through each side of fender in locations marked in Step 4. 6. Loosely reinstall fender strut (D), allowing enough room to slip spacer (1) between fender (E) and strut. INSTALLATION 1. Align rear fender rail (2) from kit with rearmost fender strut (D) mounting holes, making sure lower mounting tab (3) is inside fender (E). Place large chrome washer (4) from kit next to head of button head socket bolts (5) from kit. Insert bolt through fender rail (2), fender strut (D), spacer (1) and fender (E), in that order. Install large unfinished washer (6) from kit onto end of bolt (5). Secure assembly into place by threading locknuts (7) from kit onto ends of bolts (5) from inside of fender (E). Tighten loosely at this time. 2. Install truss head screw (8) from kit through fender (E) and rear fender rail mounting tab (3). Secure into place using small washer (9) and locknut (10) from kit. Use #2 Phillips screwdriver and a 3/8 inch wrench to tighten rear mounting assembly securely. 3. Tighten fender strut bolts (5) to 21-27 ft-lbs.(28-37 Nm) 4. Reinstall fender tip light assembly (B), gasket (C) and lens (A) using original hardware (not shown)

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YAMAHA ROADLINER AND STRATOLINER LAY DOWN LICENSEPLATE/ TAIL LIGHT INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 29-01-2011

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1. Remove the license plate. Remove the license plate holder assembly from the rear fender (three 8mm Allen bolts 5mm wrench). Remove the five 4mm Allen screws underneath the rear fender which secure the taillight/turn signal assembly to the rear fender (3mm wrench). As shown in photo #2, pull the taillight assembly out away from the fender, turn it over, place a towel or rag between the light and fender and allow it to rest on the fender. 2. Locate the supplied triangular license plate mounting block, two 8 x 20mm Allen screws with holes driiled thru and three rubber washers. Place the two Allen screws thru the upper holes in the block and the rubber washers over the screws on the backside of the block. Start the screws into the upper holes on the fender. Use one of the three screws removed earlier from the original mount in the remaining lower hole of the new block sliding the remaining rubber washer between the block and fender. Tighten all three Allen screws secure enough to compress the rubber washers (4-6 ft lbs.). 3. Locate the supplied license plate mounting plate and LED lights. Cut off the excess red and black wires at the end of the black loom or tube. Referring to photo (1) thread the wires of the LED lights thru the small holes in the mounting plate, peel the cover from the adhesive backing on the lights and press them firmly into place as shown. 4. Locate the three supplied ¼” x ½” flat head Allen screws. Hold the plate up to the mounting block installed earlier with the wires at the bottom of the plate. Thread the wires from the LED lights thru the holes in the upper bolts of the block. Install the plate onto the block using the three flat head screws being sure to keep the exposed wire behind he plate as short as possible and fitting into the slot or cut out at the edge of the block. Snug the screws and again check to see tat the wires are in the slot or cut out in the block and do not become pinched as the screws are tightened. Tighten the screws securely. 5. Where the wires from the taillight go thru the fender there is a grommet, pull this grommet out from the fender. Thread the wires from the LED lights thru the grommet with the other wires. Replace the grommet into the fender and remove any slack from the wires under the fender. Cut the LED wires off at 6″ past the grommet. 6. Referring to photo (2) remove 2″ of the black tubing exposing the red and black wires on the LEDs. Locate the supplied brake/tail light dual function element (a red wire at one end with a red and orange wire at the other) and wire connectors. Cut all three wires on the dual element to 3″ long. Strip the end of the single red wire on the element and both of the red wires from the LEDs then connect them using one of the blue butt connectors. Connect the two black wires from the LEDs to any one of the black wires on the tail light or signals using one of the supplied splice connectors (place both black wires into one of the holes on the connector). Using the remaining splice connectors attach the red wire from the dual element to the yellow wire on the tail light and the orange wire to the blue wire on the tail light. Turn on the ignition and check that the LEDs are working both as tail and brake lights when the brakes are applied.

HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON FRONT FENDER RAILS AND STANCHIONS INSTALLATION MANUAL

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

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INSTALLATION 1. Carefully cut out appropriate template from sheet included in kit. One side is for FLSTS style fenders (with elliptical hole for front fender lamp), and the other side is for FLT style fenders (with rectangular front fender lamp). 2. Lay template on front fender (align around front fender lamp). 3. Underneath four holes marked on template, place high quality masking tape on fender. 4. Using a tape measure, measure from the top of the striping on the sides of each side of the fender, to the centerline of the each of the holes on the template (on some FLT models, with chrome fender trim, measure from the chrome fender trim at the bottom edge of the fender). Make sure that the distances are equal so that the template is centered on the fender. 5. Tape the template to the fender using high quality masking tape. NOTE Before proceeding, stand directly in front of the fender and carefully check to make sure the template is centered on the fender. 6. Center punch the center point of each of the four holes. 7. Remove the template from the fender. 8. Block motorcycle under frame so the front wheel is raised off the ground. 9. Follow appropriate Service Manual procedures and remove the front axle. 10. Place a rag on the top of the front brake caliper, then lower the front wheel so that it is resting on top of the brake caliper. NOTE When drilling fender holes, use care not to hit tire with drill bit. 11. While holding the fender firmly, and using caution to make sure that your drill bit does not hit the tire, drill the four holes at the points marked by the center punch. Begin with a 1/8 inch drill bit, followed by a 9/32 inch, and finally a 3/8 inch drill bit. 12. Remove the masking tape and any burrs that may have formed. 13. Remove the adhesive backing from each of the foam pads on the bottom of each of the stanchions. 14. Place the studs from each of the end stanchions into the holes (you may need to rotate the rails 180 degrees if they appear to be bowed out). 15. Reaching from the front of the fender, place kit washer, and then a locknut, over each of the studs on the underside of the fender. 16. Securely tighten each locknut so that the stanchion is firmly clamped to the fender. 17. Follow appropriate Service Manual procedures and replace the front wheel and axle

Victory Kingpin Rear LED Turn Signal Kit Installation Manual

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Filed Under (Victory) by admin on 31-10-2010

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Step 1 •Remove rider’s seat, strut covers, and passenger seat (if applicable) •Separate wiring harness connector for rear lights •Remove screws from each side of fender and plastic connectors from plastic inner fender •Carefully remove the fender by gentle prying outward and upward on one side to clear the mounting points, then the other side •Set aside on a flat and smooth surface to protect the fender’s finish Step 2 •Turn the rear fender assembly upside down on a stable and covered/protected surface to prevent damaging the fender/paint •Remove the metal piece that covers the rear wiring harness area (10mm socket) and unscrew the wire junction box (5mm Allen wrench) •Disconnect the turn signals from the stock wiring harness and unscrew the Allen bolts holding them in place (5mm Allen) •Enlarge the center mounting hole in the inner fender of the turn signal mounting location with a 3/8ths metal drill bit (see picture below). Victory Kingpin Rear LED Turn Signal Kit Installation Guide
Be extremely careful to drill slowly and make sure to avoid contact with the sides of the fender! Ensure that the surface area where the holes have been made are smooth. This will allow for a flush fit with the turn signal mounting blocks. If not, use a small file or other suitable tool to fix it. Don’t be concerned if your new hole extends into the other holes. Step 3 •Prior to installing the silver bullets, choose which style bezel you prefer, visor or visor-less. Both styles are included with amber LEDs only. Red LED silver bullets come standard with visor-less bezels, however visored bezels can be purchased separately. •Place the fender upright on a protected and secure surface. Insert the mounting blocks into place flush with the surface of the fender. They will only fit one way and are not interchangeable. Place a small amount of loc-tite on the threads of the hollow bolt. Hold the silver bullet LED light in place on the mounting block and thread the wire through the holes, and hand tighten the hollow bolt from the inside of the fender. Once a proper alignment of the lights has been achieved, tighten them securely with a 9/16ths box end wrench. Step 4 •Run the wiring of the turn signals in an appropriate/desireable path to the stock wiring harness. Once the wires are run, cut any excess wire and install the bullet connectors (included) to the end of the wires as noted in the wiring advisory and continue with wiring as follows: 1. Silver bullet right rear PURPLE to stock wire BLUE with RED stripe 2. Silver bullet right rear BLACK to stock wire BLACK 3. Silver bullet left rear PURPLE to stock wire BLUE 4. Silver bullet left rear BLACK to stock wire BLACK Make sure that the connectors are firmly snapped in place and are covered with the stock rubber connector. Ensure that the preexisting dielectric grease isn’t completely wiped off/removed, it will ensure conductivity and corrosion resistance. Please note that the amber LED silver bullets are dual intensity, while the stock system is single intensity (turn signal only). If you wish to wire your silver bullets to also function as running lights, the blue wire from each silver bullet must be wired to a “constant-on”/power wire, such as the stock purple wire that connects to the license plate assembly. If you do not wish to wire your turn signals for dual intensity then the blue wires should be tied off

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HARLEY DAVIDSON SISSY BAR SIDE PLATE KIT INSTALLATION MANUAL

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

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INSTALLATION NOTE When removing rear fender reflectors, be careful not to damage fender paint. 1. Carefully remove the rear reflector. Remove any remaining adhesive from the back side of the reflector and any adhesive from the side of the fender. 2. See Service Parts Illustration. Remove the screws, washers, locknuts and clipnuts that attach the fender support cover and fender support to fender. Discard the button head screws but retain the washers (A), locknuts (B,C) and clipnuts (D) for installation. NOTE Prior to performing the following step, obtain a little slack for the turn signal assembly by reaching under the fender and bending open the aluminum tab on the clip securing wiring to fender. 3. Remove the locknut (B) from the turn signal stud (E) and gently remove the turn signal assembly from fender support cover, fender support and fender. Save locknut for installation. The turn signal will remain loosely attached to motorcycle by rear directional wire. 4. Carefully position the side plate between fender support and fender. While holding sideplate in position, line up the screw mounting holes and make sure the turn signal wiring passes through the cutout (slot) in the side plate. Coat threads of screws (1 and 2) from kit with Loctite 243 (blue) (Harley-Davidson part number 99642-97) and install locknut and clipnut, however do not tighten completely. 5. Add Loctite 243 (blue) (Harley-Davidson part number 99642-97) to turn signal stud and install through fender support cover, fender support, side plate and fender. Install locknut and tighten to 8-13 ft-lbs (11-18 Nm). Making sure sideplate remains aligned, return to fender support screws and tighten to 8-13 ft-lbs (11-18 Nm). 6. Reach under fender and position turn signal wiring into tab on clipnut. 7. Obtain reflector (3) from kit. Peel off protective strip backing and firmly press reflector (3) to side plate (4), centering reflector horizontally and vertically. 8. Repeat steps 1 through 7 on opposite side of fender

SR-C400 Motorcycle Security System INSTALLATION MANUAL AND USER'S GUIDE

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Filed Under (Tips and Review) by admin on 29-01-2011

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Routing the Antenna Wire The MCM includes an 18″ antenna wire. The first 12″ is a coaxial wire; the remaining 6″ is the reception antenna wire. When routing, try to avoid running the antenna along or near metal. For best performance, have the antenna wire as vertical as possible and exposed. Wire Connections The system includes one harness (HAR-1a) that connects directly into the MCM. The harness is split into three plugs: one for the GEN-1a connector, one for the optional SN-5 connector and one for the data output for future expansion. Note: Each plug is unique and will only fit the appropriate component one way. Main Harness Note: If the optional factory connector kit is being used, please disregard this section of the instructions and refer to the instructions supplied with the factory connector kit. The main harness consists of two harnesses. One is labeled (HAR-1a) and the second is labeled (GEN-1a). Plug in the white 4 pin connector from the (HAR-1a) into the matching 4 pin connector from the (GEN-1a). The (HAR-1a) also has a waterproof connector that plugs into the MCM. The wires should be connected as follows: HAR-1a Black wire with fuse and ring terminal – To battery Positive (+). GEN-1a Black wire – To ground (-). Orange wire – To tail light wire or any other wire that is hot (+) when ignition is ON (NOTE: this is an input to the alarm this connection is not designed to flash the tail light). Color Codes: Ground (-) Tail Light Honda Green wire Brown wire Kawasaki Black wire Red wire Suzuki Black/White Brown wire Yamaha Black wire Blue wire Harley Davidson Black wire Blue wire

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HARLEY DAVIDSON FRONT FENDER SKIRT INSTALLATION MANUAL

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

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1980 and later Touring •1986 and later FLSTC •1993-1996 FLSTN •2006 and later FLST This kit is not designed for FLSTF model vehicles. Kit Contents Table 1. Kit Contents Quantity Description 1 Fender skirt 6 Screw, pan head 6 Locknut, hex 6 Washer, flat 1 Adhesive foam strip (Heritage models only) INSTALLATION 1. See Figure 1. Remove fasteners (2) from stock fender skirt. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) NOTE Some early models have rivets for fasteners. These rivets will need to be drilled out. Drill the rivet heads to a sufficient depth to remove the head from the rivet shaft. Do not attempt to drill the rivet all the way through. This may scratch the fender?s painted surface. 1 5 3 2 4 is 01097 1. Fender skirt 2. Screw, panhead 3. Locknut, hex 4. Flatwasher 5. Adhesive foam strip (Heritage models only) Figure 1. Front Fender Skirt and Assembling Hardware 2. Remove stock fender skirt (1). 3. Thoroughly clean the fender under the skirt. At this point it may be a good idea to wax this portion of the fender to prevent rust in the future. 4. For Concho style and Bar and Shield style fender skirts, cut the adhesive foam strip (5) into three equal parts. Remove the backing from the adhesive strips and apply adhesive on middle and two sides at the inside/bottom of the skirt. The foam strips will prevent rattling and unwanted noise. For V-Logo style skirts, cut foam strip into three pieces; however make two slightly larger to cover the heads of the screws that hold the V-Logos in place. Use the remaining smaller piece on the middle, inside/bottom of the skirt. NOTE On some FLT models, there may not be enough fender skirt support to allow the application of adhesive strips. If this is true for your motorcycle, you may install this kit without the adhesive strips. 5. Place the fender skirt in position, aligning fastener holes. 6. Install the screws (2) from the outside of the fender. Install the washers (4) and nuts (3) inside the fender

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