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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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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 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

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 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)

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

Harley Davidson Handlebar Top Clamp Instruction Manual

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Filed Under (Harley Davidson) by admin on 13-04-2012

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Mounting of the Handlebar Top Clamp • Mount the motoscope mini to the handlebar top clamp by using the enclosed metric countersunk screws (M3). Do not exceed the maximum tightening torque which is 4 Nm. • Laying both cables of the motoscope mini and indicator lights through the clamp inner groove in rear direction (to the driver). • Mark the position of the handlebar to the lower handlebar retainer with a marker pen. Undo the 4 clamping bolts and remove the original top clamp. • Put the motogadget handle bar clamp onto the handle bar and align the handle bar according the pen marking. Make sure both cables are still located in the groove; otherwise the cable will be damaged. • Then put the enclosed inch screws into the 4 drillings and tighten them crosswise and evenly. Take care that the gap between the upper and lower handlebar clamp remains the same at each point. A maximum torque for the inch screws of 20 Nm must not be exceeded. Connection and cable colours Before starting the electrical connection remove the vehicle battery or interrupt its connection to the onboard power supply. Use the original vehicle wiring diagram. Then connect the warning lights as described in the table below. If you have two indicator control lights see the wiring diagram below for joining them to one control light. Make sure all connections are fused. If you don’t fuse it properly, a damage of the connection cable can cause a cable fire. Make sure you are capable to connect the instrument properly. If you are not sure, let the professional shop do the job

HARLEY DAVIDSON CHROME BELT SPROCKET COVER KIT INSTALLATION MANUAL

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

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Installation 1. Remove rear wheel. Refer to the applicable Service Manual for the proper removal procedure. 2. Remove bolts and washers from sprocket. •If you intend to install Acorn Nut and Stud Kit (Part No. 91734-85), refer to that Instruction Sheet at this time (please note that this Acorn Nut and Stud Kit does not fit Sportster (XL) models). •If you do not intend to install Acorn Nut and Stud Kit (Part No. 91734-85), retain bolts and washers for reassembly. Proceed to Step 3. 3. Position sprocket cover so that its mounting holes align with the holes in the sprocket. NOTE There is only one position which allows each hole in the cover to align with a hole in the sprocket. If replacement bolts, washers, or nuts are required, use only genuine Harley-Davidson parts specified for your particular model. Aftermarket fasteners can adversely affect performance, which could result in death or serious injury. NOTE • See Harley-Davidson service manual for proper torque val- ues; •Aftermarket fasteners may not have the specific property requirements to perform properly. 4. Install bolts with washers through holes in sprocket cover and sprocket, and into threaded holes in wheel hub. Depending on the tensile strength grade of the bolts in your particular application, tighten bolts in a crosswise pattern to one of the torque values listed in the following table: 5. Refer to the applicable Service Manual for the proper procedure and perform the following: •Install axle. •Align belt. •Adjust belt tension. •Tighten rear axle nut to 60 – 65 ft-lbs torque. 6. Check sprocket for radial runout (eccentricity). If runout is visible, mark outer edge of sprocket at the location of runout. Loosen sprocket bolts and tap the marked location with a rubber mallet. Tighten sprocket bolts in a crosswise pattern to the applicable torque specified in Step 4.

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HARLEY DAVIDSON CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT GENERAL Kit Number 56032-08 Models For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only). This kit does not fit models equipped with a hydraulic clutch, handlebar mounted gauges or the Road Tech® Radio. Additional Parts or Accessories Required Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on this model motorcycle. Please see the P&A retail catalog or the Parts and Accessories section of for a list of required parts or accessories for this model. For Australia, Brazil, England, Europe and Japan, two special screws (Part Number 2935A) will also be required. Tools and Supplies Required Loctite® 271 Threadlocker and Sealant – Red (H-D Part Number 99671-97) is required for the proper installation of this kit. Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed. Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) For models that retain the original brake line, the two brake- line gaskets found at each banjo fitting must be replaced . Refer to the appropriate parts catalog or see a Harley-Davidson dealer for the correct part numbers. Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the parts catalog for replacement stock hand grips. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available. 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 this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 6 and Table 1. INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills)

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HARLEY DAVIDSON FXD HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-12-2010

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Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Using a æ” socket loosen the two riser mounting bolts located on the bottom side of the upper steering head. Using a º” hex key wrench loosen the four handlebar top clamp bolts. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four bolts from the top clamp and then remove the clamp. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the bolt from the bottom of one of the risers and remove the riser while keeping the bolt in place. Place one of the supplied Ω” washers onto the protruding bolt, and then the new riser (Note; There are LEFT & RIGHT risers.) and mount the bolt finger tight. (Take care not to scratch the top surface of the upper steering head while installing the new risers.) 4. Place the handlebars back up onto the new risers. Install the top clamp using the supplied four black 5/16-18 X 1 º” bolts. Set the height of the handlebars to the desired position; tighten the clamp bolts evenly making sure the gap between the clamps & risers are the same. (15-18 ft. lbs.) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. Also check that the throttle returns freely on its own

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