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HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

Yamaha Road Star Engine Guard Installation Manual

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Filed Under (Yamaha) by admin on 07-11-2010

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1. Protect the rear portion of the front fender with a towel or other thick, soft cloth. 2. Remove the OEM engine guards if they have been installed on the motorcycle. Or, if OEM engine guards are not present, Remove the two lower engine mount bolts. These bolts are located on the inside of the right and left frame rails, and will be replaced with the longer 10mm bolts included with your new engine guard. 3. Position the engine guard so that the lower brackets point towards the rear of the motorcycle, and slide the engine guard into the space between the front wheel and the frame. 4. Raise the guard until the upper V” mount is located between the frame rails. Note: Your new Barons engine guard is equipped with a unique upper V” mount clamp. This clamp becomes a cradle for the upper frame supports when it is inserted between the frame rails. 5. Rotate the engine guard until the lower mounting brackets are aligned with the lower engine mount holes. Due to production line tolerances in both the motorcycle and the engine guard, the mounting brackets may be too wide or too narrow for the frame. If this is the case, remove the guard from the motorcycle. Place the guard on a flat, firm surface. Insert a towel or other protective material between the guard and the surface. Using a rubber mallet or a block of wood and a hammer, tap the lower brackets until they are correctly spaced. 6. Insert the new 10mm bolts and washers, and finger tighten only. 7. Tighten each 3/8″ bolt in the upper clamp evenly by using a 9/16″ socket or a wrench. Snug down each bolt until it draws the front of the upper clamp into contact with the upper frame supports, then adjust these bolts accordingly to achieve equal spacing between each floorboard and the lower engine guard rail. 8. Tighten the jam nuts against the washers to lock each bolt in place. CAUTION! It is critical that you do not over-tighten these bolts. Tighten all remaining nuts and bolts securely. If necessary, slightly loosen rear brake line banjo bolt and rotate banjo fitting for clearance with engine guard. Tighten banjo bolt and check brake for proper operation. You must re-tighten all four of the engine guard mounting bolts after 100 miles of riding! Care & Cleaning: Engine guards take the full brunt of the worst of what the weather in your area has to offer, making it critical that proper and complete cleaning take place on a weekly basis, or corrosion will occur which is not covered by warranty! Proper cleaning procedure would be to use a product like Simple Green, LOC, Salt-Away or similar. Mix a strong batch and apply it liberally with a soft towel or soft nylon brush to the entire

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HARLEY DAVIDSON NOSTALGIC SADDLEBAG GUARD RAILS REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. If desired, remove the saddlebags. 2. Remove screws (C) and locknuts (D). Save for installation. 3. Remove reflectors with fishing line or dental floss. Use a sawing motion to remove the adhesive. Clean the surface thoroughly with an equal mixture of isopropyl alcohol and distilled water. Allow the surface to dry thoroughly. INSTALLATION 1. See Figure 1. Position the correct saddlebag guard rail (1 or 2) over the saddlebag guard and support assembly (A). Loosely install the screw (C) through the saddlebag-to- fender support bracket (B), through the saddlebag support (A) and through the inner hole of the saddlebag guard rail bracket. Install nut (D). Tighten finger-tight. NOTE Position the saddlebag guard rail as low as possible on the stock saddlebag guard and support assembly. 2. Install screws (6) and washers (5) through the clamp end of the saddlebag guard rail. Position clamp end around the upright of the saddlebag guard and install the clamp (3 or 4). Tighten screws finger-tight. 3. Align the saddlebag guard rail (1 or 2) parallel to the bottom of the saddlebag and muffler. Tighten the cap screw (C) and locknut (D) to 15-20 ft-lb (20-27 Nm) . 4. Tighten the clamp screws (6) to 22 in-lb (2.5 Nm) . NOTE The reflectors are location-specific. There are markings on the back of the reflector – “L BOTTOM” or “R BOTTOM”. 5. Peel the backing from the base of the new reflector (7 or 8). Without touching the reflector to the saddlebag guard, position the reflector and press the reflector to the saddlebag guard above the clamp (3 or 4) and press for 30 seconds. After releasing pressure, avoid direct contact with the reflector for at least 20 minutes. 6. Repeat all steps for the other side of the motorcycle. NOTE For ease of use, move the saddlebag buckles to the highest hole on the strap. 7. Install the saddlebags, if removed

Yamaha V-Star 650 Engine Guard REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 03-01-2012

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Protect the rear portion of the front fender with a towel or other thick, soft cloth. Remove the OEM engine guards if they have been installed on the motorcycle. Your new Barons engine guard will fasten to the frame at the same points as the OEM guard and will use the same hardware. 2. Or, if OEM engine guards are not present, remove the 14mm bolts from the underside of the drivers footpeg mounts. 3. Remove the 12mm upper engine mount bolts located on both sides of the frame. Replacement bolts are included with your new engine guard. 4. Position the engine guard so that the lower brackets point towards the rear of the motorcycle, and slide the engine guard into the space between the front wheel and the frame. 5. Raise the guard until the holes in the lower mounting brackets align with the vacated bolt holes beneath the drivers footpegs. Due to production line tolerances in both the motorcycle and the engine guard, the mounting brackets may be too wide or too narrow for the frame. If this is the case, remove the guard from the motorcycle. Place the guard on a flat, firm surface. Insert a towel or other protective material between the guard and the surface. Using a rubber mallet or a block of wood and a hammer, tap the lower brackets until they are correctly spaced. 6. Insert the large washers (supplied with the guard) between the rear face of the lower bracket and the frame. The washer fills the space between the lower mounting bracket and the footpeg mount. Reinsert the 14mm bolts and finger tighten. 7. Rotate the guard until the holes in the upper mounting brackets align with the empty holes on each side of the frame. 8. Insert the replacement 13mm bolts, along with their washers, and tighten securely. Tighten all other nuts and bolts securely. 9. Remove the protection on the front fender and you’re ready to ride. CAUTION!!! You must re-tighten all four of the engine guard mounting bolts after 100 miles of riding! Care & Cleaning: Engine guards take the full brunt of the worst of what the weather in your area has to offer, making it critical that proper and complete cleaning take place on a weekly basis, or corrosion will occur which is not covered by warranty! Proper cleaning procedure would be to use a product like Simple Green, LOC, Salt-Away or similar. Mix a strong batch and apply it liberally with a soft towel or soft nylon brush to the entire

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Yamaha V-Star 650 Engine Guard Installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Protect the rear portion of the front fender with a towel or other thick, soft cloth. Remove the OEM engine guards if they have been installed on the motorcycle. Your new Barons engine guard will fasten to the frame at the same points as the OEM guard and will use the same hardware. 2. Or, if OEM engine guards are not present, remove the 14mm bolts from the underside of the drivers footpeg mounts. 3. Remove the 12mm upper engine mount bolts located on both sides of the frame. Replacement bolts are included with your new engine guard. 4. Position the engine guard so that the lower brackets point towards the rear of the motorcycle, and slide the engine guard into the space between the front wheel and the frame. 5. Raise the guard until the holes in the lower mounting brackets align with the vacated bolt holes beneath the drivers footpegs. Due to production line tolerances in both the motorcycle and the engine guard, the mounting brackets may be too wide or too narrow for the frame. If this is the case, remove the guard from the motorcycle. Place the guard on a flat, firm surface. Insert a towel or other protective material between the guard and the surface. Using a rubber mallet or a block of wood and a hammer, tap the lower brackets until they are correctly spaced. 6. Insert the large washers (supplied with the guard) between the rear face of the lower bracket and the frame. The washer fills the space between the lower mounting bracket and the footpeg mount. Reinsert the 14mm bolts and finger tighten. 7. Rotate the guard until the holes in the upper mounting brackets align with the empty holes on each side of the frame. 8. Insert the replacement 13mm bolts, along with their washers, and tighten securely. Tighten all other nuts and bolts securely. 9. Remove the protection on the front fender and you’re ready to ride. CAUTION!!! You must re-tighten all four of the engine guard mounting bolts after 100 miles of riding! Care & Cleaning: Engine guards take the full brunt of the worst of what the weather in your area has to offer, making it critical that proper and complete cleaning take place on a weekly basis, or corrosion will occur which is not covered by warranty! Proper cleaning procedure would be to use a product like Simple Green, LOC, Salt-Away or similar. Mix a strong batch and apply it liberally with a soft towel or soft nylon brush to the entire

HARLEY DAVIDSON FLSTN SADDLEBAG GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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REMOVAL All Models 1. If equipped with saddlebags, removal may ease installation. Follow the instructions in the appropriate Service Manual or Instruction Sheet. 2. See Figure 1. Remove and discard the forwardmost fender support bolt (1). Repeat for the other side. 3. See Figure 2. On the left side, remove the footrest support mounting bolt (1) and footrest support bracket assembly (2). Discard the mounting bolt. 2005 – 2006 Models 1. Loosen the exhaust shields as necessary following the instructions in the appropriate Service Manual. Move as necessary for access. 2. Loosen the exhaust header nuts following the instructions in the appropriate Service Manual. 3. See Figure 3. Remove bolt (1) connecting the exhaust system (2) to the support bracket (3). 4. See Figure 4. Remove the two rear muffler bracket bolts (1). 5. See Figure 5. Move mufflers enough to access the rear bolt attaching the exhaust mounting bracket to the frame. Remove bolt (1) and discard. 2007 – Later Models NOTE On 2007 – later models, the frame tab (4) has a plug instead of a bolt (see Figure 6, item 1). 1. Remove plug and discard. 1 is05313 1. Fender support bolt (discard) Figure 1. Remove Docking Hardware 1 2 is05320 1. Footrest support mounting bolt 2. Footrest support bracket assembly Figure 2. Footrest Support Bracket Assembl NSTALLATION Right Side See Figure 5 or Figure 6. 1. See Figure 7. Install upper screw (7) in the fender support. Tighten screw finger-tight. 2. Install the lower screw (4 or 5) with the saddlebag guard, washer (9) and locknut (6) inside the frame. Tighten screw finger-tight. 3. Tighten the upper screw to 30 ft-lbs (41 Nm) . 4. Tighten the lower screw to 40 ft-lbs (54 Nm) . Tighten nut to 30 ft-lbs (41 Nm) . 5. 2005 – 2006 Models: a. Loosely install the exhaust header bolts. b. See Figure 4. Loosely install two rear muffler bracket bolts (1). c. See Figure 3. Loosely install bolt securing exhaust system (2) to support bracket (3). d. Tighten exhaust header bolts following the instructions in the appropriate Service Manual. e. Tighten support bracket bolt and rear muffler bracket bolts following the instructions in the appropriate Service Manual. f. Tighten exhaust shields following the instructions in the appropriate Service Manual. 6. Install saddlebag (if removed) following the instructions in the appropriate Service Manual or Instruction Sheet. 1 2 3 4 is05333 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Exhaust support bracket Figure 5. Install Saddlebag Guard – Right Side Shown (2005 Models) -J04645 2 of 4
2 1 3 4 is05332 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Frame tab Figure 6. Install Saddlebag Guard – Right Side Shown (2007-Later Models) Left Side 1. Loosely install upper screw (7) through the saddlebag guard and the fender support. NOTE Spacer (8) must be installed with the chamfer facing out. 2. See Figure 7. For 2005-2006 Models: Install lower screw (3) through the saddlebag guard, saddlebag guard spacer (8), footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . For 2007 and later Models: Install lower screw (10) through the saddlebag guard, footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . 3. Tighten upper screw to 30 ft-lbs (41 Nm)

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HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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HARLEY DAVIDSON CHROME UPPER BELT GUARD KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE When performing the following step, it is not necessary to completely remove the shock mount bolt, back the bolt out only until it is flush with the swingarm. 1. See Figure 1. Loosen the left rear shock mount bolt (1) and back it out until the threaded portion of the bolt is flush with the swingarm. 1 2 is03762 1. Shock mounting bolt (left side) 2. Belt guard Figure 1. Loosen Shock Mounting Bolt 2. Pull the belt guard (2) straight back toward the rear of the bike to remove the guard from upper and lower grommets. See Figure 2. It may be necessary to work the guard up and down slightly to dislodge it from the upper (1) and lower (2) grommets. Remove the belt guard and discard. 2 1 3 is03763 1. Upper grommet mount 2. Lower grommet mount 3. Front belt cover Figure 2. Rubber Grommet Mount Locations 3. Obtain the chrome belt guard from kit. While making sure belt guard is over the belt, slide the guard straight in between the shock and sprocket and align cover just below front belt cover (3). The cutouts in the bracket should be lined up to engage with upper and lower grommets. NOTE When performing the following step, gently pull the guard in and out at the center; it should feel fairly tight even though the rear mounting bracket has not been secured. 4. See Figure 3. Firmly push the guard toward the front of the bike until the cutouts are secured by the grommets and the belt guard mounting bracket (1) hole lines up with the shock bolt

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HARLEY DAVIDSON FLSTC, FLSTF, FLSTS BLACK ENGINE GUARD INSTALLATION MANUAL

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

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The front and/or rear guard(s) can provide limited leg and cosmetic vehicle protection under unique circumstances. (Fall over while stopped, very slow speed slide.) It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022a) Kit Contents See Figure 4 and Table 1. INSTALLATION 1. See Figure 1. Note mounting locations for engine guard. 2. See Figure 2. Hold Engine Guard (1) in place. Attach top center mounting flange of engine guard to cross brace located between front downtubes just below the steering head with panhead screw (4), 5/16 inch washer (3) and 5/16 inch hex nut (2) as shown. Tighten finger tight. is04094 Figure 1. Installed Engine Guard 3. See Figure 3. On left side of the bike, attach the engine mounting guard (1) in the indicated location with a button- head screw (4), 3/8 inch washer (3) and 3/8-16 nylon locknut (2). Tighten finger tight. 4. Repeat installation on right side of the bike, attach the mounting guard in the indicated location. Tighten to 33 ft- lbs (44 N-m). 5. Tighten engine guard left side mounting hardware to 33 ft-lbs (44 N-m). Tighten engine guard top mounting hardware to 19 ft-lbs (25 N-m).