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HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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HARLEY DAVIDSON HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. 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 A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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DYNA IGNITION COIL INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 08-11-2011

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Remove the gas tank. Locate the two ignition coils. 2) Unplug the primary wires coming from the coils and disconnect the high voltage wires from the spark plugs. Remove the coil mounting bolts, and remove the coils. 3) Cut or unsolder primary wires from coils. Crimp or solder ring terminals supplied with kit to primary wires.4) Attach the primary wires to the DYNA COILS using the 10-32 x 5/16 pan head screws provided. Either wire can be mounted on either terminal of the dual output coils as they have no polarity. On the single output coils, the primary terminal opposite the side with the output tower has a + marking. Plus 12 volts from the ignition switch is applied to that terminal, and the points or ignition system output is connected to the other terminal. On a Kawasaki, make sure there is clearance between the screw head and the mounting screw spacer. Do not over- tighten screws as damage to the coil could result. 5) Using the stock hardware, mount the coils to the frame in the original location. NOTE: The DYNA COIL mounting hole spacing is designed to accommodate early model Honda, Kawasaki, and Suzuki motorcycles. There are a wide variety of physical sizes and mounting configurations on the late model motorcycles and it may e necessary to modify existing mounting brackets, or fabricate a bracket to adapt the DYNA COILS to your particular motorcycle

HARLEY DAVIDSON DYNA AND SPORTSTER Chrome Front Wheel Spacers INSTALLATION ISNTRUCTIONS

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

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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HARLEY-DAVIDSON SPORTSTER MID-LENGTH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-04-2012

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1. Find and unplug the O² sensor wires from the wiring harness and remove the ZIPSTRIP holding front O² sensor wires to the frame. Feed the end of the wire through the frame so they are free from the motorcycle. Note: pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear head pipe to gain easier access to the mounting nuts. 3. Remove the two head pipe mounting nuts from the flange at the heads. 4. Remove the clamp bolts that mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffler body where they attach to the stock mounting bracket. Carefully remove the exhaust system from the motorcycle and set aside. 6. Using a 7/8″ wrench, carefully remove the O² sensors from the stock head pipes and save for re-use on your RUSH system. 7. Remove the drive belt cover and remove the bracket off the rear cover bolt, bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T-30 torx socket. 9. Remove the three mounting bolts and washers attaching the exhaust mounting bracket. 10. If equipped with mid-controls, remove right side foot peg before installing your new RUSH system.

DYNA III ELECTRONIC IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 27-10-2010

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1)Fasten the clamp to the electronic module using the 4-4O x 5/16 screws and lockouts provided. The damp and nuts go on the inside of the case. 2)Remove the fuel tank. Attach the module to the frame in the location selected. Cut off excess clamp material. 3)Remove an engine case or valve cover bolt and fasten the ground lug (black wire) securely to the engine. DO NOT ATTACH TO FRAME. 4])Locate the two ignition coils (they are positioned behind the left side cover on some models). There is a white wire going to the positive side of one coil that carries the switched 12 volts. A short blue/black wire then connects that point to the positive side of the other coil. Connect the separate red wire included with the kit to the spare spade terminal that is available on the positive terminal of the second coil. 5)Plug the red wire coming from the electronic module into the red wire installed in Step 4. 6)Remove the cap from the contact breaker housing. Remove the alternator cover, timing mark inspection plug, and spark plugs. 7)Remove the two screws and clips holding the points plate to the housing. Remove the screws holding the condensers to the housing. Disconnect the red and green wires where they plug into the wire harness (or coils), and remove the entire points/plate/condenser assembly. 8)Make sure the top of the housing is clean. Place the DYNA III sensor plate on the housing and orient it so that the wires exit to the rear. Place one of the original wire grommets on the front end of the plate and secure it with the screw and clip previously removed. Route the sensor cable wires through the other grommet (2 wires in the largest hole) and secure with the other screw and clip. Before tightening the plate screws, make sure the plate does not obstruct the cap screw holes. 9)Using a hex wrench in the alternator bolt, rotate the engine forward until the right hand cylinder is at top dead center on the compression stroke (D mark aligned with index mark on engine case). 10) Make sure the points cam is free of dirt and grease, and slip the DYNA III rotor over the cam Push the rotor down until it’s flange is in contact with the top of the cam. Orient the rotor so that the mark on top aligns with the line on the left (right cylinder) sensor. While pushing down on the rotor, tighten the set screws using the alien wrench supplied with the kit. 11)Rotate the engine by hand and check run-out (wobble) of rotor by watching the rotor/sensor gap. If the rotor is installed correctly, there should be no more than . 005 run-out, and it should not come in contact with either sensor. As a final check, turn the engine with the electric starter and observe the run-out. 12)Connect the three sensor cable plugs to the module receptacles, matching the red, white, and black wires. 13)Plug the remaining red and green wires onto the spade terminals where the original points connected, matching the colors

HARLEY DAVIDSON DYNA REAR AXLE COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-03-2011

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Models This kit fits 2006 Dyna models. This kit does not fit on motorcycles equipped with saddlebags. Kit Contents See Figure 1 and Table 1. INSTALLATION 1. Place axle covers in position over ends of swingarm with the deeper cover on the left side (covering the axle nut). 2. Fasten the clamping bars (3) to the backs of the covers using hex-head screws (5) and Belleville washers (4), securing the covers to the swingarm. Tighten the hex-head screws to 21-27 in-lbs (2.4-3.0 Nm) . Do not overtighten SERVICE PARTS 4 1 3 4 5 2 3 5 is00709 Figure 1. Service Parts: Dyna Swingarm Axle Cover Table 1. Service Parts Table Part Number Description (Quantity) Item Part Number Description (Quantity) Item 45159-97 Washer, Bellville (4) 4 Not Sold Separately Axle cover, left side 1 3644 Screw, #10-24 x 1/2 inch (4) 5 Not Sold Separately Axle cover, right side 2 Not Sold Separately Clamping bar (2) 3

HARLEY DAVIDSON DYNA GLIDE CUSTOM SEAT KIT Installation Instructions

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

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

HARLEY DAVIDSON SOFTAIL EXTENDED REACH CONTROLS KITS INSTALLATION MANUAL

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

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PREPARE THE MOTORCYCLE 1. For models equipped with saddlebags: Remove the saddlebags following the instructions in the appropriate Service Manual. 2. Remove the seat following the directions in the Owner’s Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect the negative battery cable. 4. Secure motorcycle in upright position. NOTE This kit is not compatible with engine guards. 5. If the engine guard is present, remove and discard it. LEFT SIDE Component Removal 1 3 4 2 7 5 6 8 2 is05048 1. Pretzel clip 2. Bushing (2) 3. Screw (6) 4. Jiffy stand bracket 5. Bumper 6. Jiffy stand leg 7. Clevis pin 8. Spring Figure 1. Jiffy Stand 1 2 3 5 4 is05053 1. Jam nut 2. Shifter rod end 3. Acorn nut 4. Shifter rod 5. Shifter arm Figure 2. Shifter Linkage 1. For HDI Vehicles: Remove the left side foot control support, and jiffy stand sensor, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. For all other models: Remove the left side foot control support, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. NOTE Two bearing sleeves will remain inside the footrest bracket. The extended controls bracket from the kit will include two sleeves pressed into the bore of the shift lever arm support. 2. Remove rod ends and jam nuts from the shifter rod. Save the rod ends and jam nuts for installation. Component Installation 1. See Figure 9. Select shifter mounting assembly (6), O- rings (5), nylon washer (4) and the shift rod (1) from the kit. 2. Install the shift arm and new O-rings in the bracket. 3. Apply LOCTITE 243 Threadlocker and Sealant to the three mounting screws and mount the shifter bracket with shift arm to the frame. Tighten the mounting screws to 25-30 ft-lbs (33.9-40.7 Nm)

2007-2010 Harley Davidson Dyna EFI Tuner INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2012

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Remove the seat 2 Remove the left hand side cover (Fig. A). 3 Unplug the stock wiring harness connector from the ECM (Fig. B). 4 Move the data plug (Fig. B) out of the way to access bolt. 5 Remove the 3 bolts that hold the electrical box in place (Fig. B). 6 Slide the plastic box out from the frame. 7 Route the stock connector through to the back side of the electrical box (Fig. C). Fig. A Fig. B Fig. C Remove side cover Stock connector Stock connector Dat a plug Remove bolt Remove bolt s FM814 www .fuelmotousa .com 2007-20 1 0 Harley Davidson Dyna – FM EFI Tuner – 2 8 Lay the PCIII behind the electrical box temporarily. 9 Route the GREYconnector from the PCIII through the back of the electrical box and plug it into the ECM (Fig. D). 10 Connect the stock wiring harness to the BLACK connector of the PCIII. 11 Zip tie these connectors to the front side of the electrical box (Fig E). Make sure they are situated away from the rear exhaust pipe. Fig. D Fig. E PCIII connector Stock connector PCIII connector 12 Mount the PCIII to the underside of the stock ECM (Fig. F) using the supplied velcro. Make sure to clean both surfaces with the alcohol swab before attaching. Situate the PCIII so the USB and expansion ports point to the rear of the bike. This will allow you easier access to adjust the maps if necessary

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