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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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HARLEY DAVIDSON FRONT AGITATOR WHEELS INSTALLATION MANUAL

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

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Recommended Additional Parts The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning: •Harley® Bright™ Chrome Cleaner (94683-99) •Harley® Glaze™ Polish and Sealant (99701-84) •Harley®Wheel and Spoke Brush (43078-99) •Harley-Davidson®Wheel and Tire Cleaner (94658-98) Kit Contents See Figure 1 and the Service Parts Tables. INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. See the service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) 2. See Figure 1. Install valve stem assembly (D) on wheel. See the service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. See the service manual. 4. Install primary bearing with a Wheel Bearing Remover and Installer. See the service manual. The left side of the wheel has DOT cast in the wheel to indicate the primary side of the wheel. 5. Install wheel spacers (previously removed). 6. Install front wheel (1) and stock axle. See the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 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) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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

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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. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 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) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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Harley Davidson engine modification

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Filed Under (Harley Davidson) by admin on 02-11-2010

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Looking for high performance engine specifications for your Harley- Davidson motorcycle? Need to know what high performance equipment provides the best performance at the lowest costs for your H-D. Here you can look at performance modifications with the dyno runs of many different engine combinations, so you can pick your own equipment, horsepower rating and dollars to spend. An incremental approach to engine development has provided some good results on many engines. Find out what combination of carburetor, camshaft, exhaust systems, ignition systems, head work, pistons and the other high performance components work well. There are tests of some equipment that did not work well. Know what works and what does not. Compare the results of your current bike to those seen here. Are you getting the performance you paid for? If you have had success in your engine development program, send a picture of the bike and your performance results (dyno sheets or time slips) to the V -Twin Café for publication. The V -Twin Café is always looking for good articles on motorcycle performance work. If you write performance oriented articles, contact us. Twin Cam 88 and 95 cubic inches Twin Cam Engines from Harley-Davidson have a good design and some nice upgrades available from the local Dealer including a 95 cubic inch big bore kit. What can you expect from this engine? Here are some engine configurations that have been tested. 45 to 50 HP Stock Evolution Engines are the starting point for all the modifications. The only way to validate what the performance gain was for any change is to have dyno runs before and after. These are the before runs of several bikes. 55 to 65 HP Up to $750 Stage One Evolution Harley-Davidson engines involve no internal changes made to the engine. All modifications are made by changing or modifications to external components on the engine. These components include air cleaners, carburetors, exhaust systems and ignition systems. No special tools or training is required to perform stage one modifications.

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HARLEY DAVIDSON SLOTTED 6-SPOKE FRONT WHEEL KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to FRONT WHEEL in Service Manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. For FXSTD Models: Discard tapered spacer. 2. See Figure 1. Install valve stem assembly (D) on wheel. Refer to TIRES in Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43918-07 and 43919-07: • The side of the wheel with the valve stem and directional arrow is the right side of the wheel. • The left side of the wheel is the primary bearing side. For Kits 43920-08 and 43921-08: • The left side of the wheel has a machined groove in the hub face to identify it as the primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44055-07, 44056-07, 44057-07, 44058-07, 43538-09, 43549-09 and 43577-09: • The wheel should be installed so that the hub markings are on the left side of the motorcycle. An arrow cast into the rim of Kits 44055-07, and 44056-07 indicates the direction of rotation. A groove is machined in the left-side hub face to indicate the primary bearing side. • For dual brake disc models, install the brake disc according to the Service Manual. The chrome hub cap (2) is not used. • For single brake disc models, install the brake disc according to the Service Manual. The chrome hub cap MAINTENANCE AND CLEANING Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner applied with the Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant.

HARLEY DAVIDSON REAR DEUCE WHEELS INSTALLATION MANUAL

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

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to REAR WHEEL in Service Manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 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) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to TIRES in Service Manual. 3. Assemble wheel installation kit components, stock brake disc and sprocket to wheel using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. The valve stem side of the wheel is the primary bearing side. NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. The valve stem side of the wheel is the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to REAR WHEEL in Service Manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON CHROME REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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Kits 41017-00, 41026-00 and 41262-03 are designed for installation on 2000 and later XL, FXD and 2000-2002 Softail Model Motorcycles (except FXSTD and FLSTS). Kits 41260-03, 41261-03 and 41265-03 are designed for installation on 2003 and later Softail Model Motorcycles (except FXSTD and FLSTS). Kit Numbers 41017-00 and 41261-03 contain a16 inch chrome slotted rear wheel. Kit Numbers 41026-00 and 41260-03 contain a 16 inch chrome fatboy rear wheel. Kit Numbers 41262-03 and 41265-03 contain a 16 inch mirror chrome disc rear wheel. See Service Parts Illustration for kit contents. nstallation Do not re-use brake disc screws. New screws are provided for disc installation. Re-using original disc screws can result in torque loss and damage to rotor and/ or brake assembly. (00319a) Refer to the appropriate Service Manual for wheel removal and installation procedures. See Service Parts Illustration. This kit contains the necessary parts for wheel installation, however you will need to save the Axle, Axle Nut, Brake Disc, and the Drive Pulley with related hardware for reinstallation. NOTE The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Apply two drops of LOCTITE THREADLOCKER 262 (red) to each of the five sprocket mounting screws. Follow the bolt torque procedure in your service manual or, if installing an accessory hardware kit, in the I-sheet included with the hardware kit. Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel & Tire Cleaner Part Number 94658-98 applied with Harley Wheel & Spoke Brush Part Number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner Part Number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, Part Number 99701-84

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HARLEY DAVIDSON FRONT DISC WHEELS INSTALLATION MANUAL

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

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in Service Manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. 2. See Figure 1. Install valve stem assembly (D) on wheel. Refer to TIRES in Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. The side opposite the valve stem is the primary bearing side. The front wheel should be installed so that the valve stem is on the right side of the motorcycle. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate the service parts table. Refer to FRONT WHEEL in Service Manual. 4. FLSTC and FLSTN models: Install wheel kit and right hand wheel spacer provided in kit installation. All other models: Install wheel spacers previously removed. 5. Install front wheel (1), stock axle, and stock axle nut. Refer to FRONT WHEEL in Service Manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON REAR SLOTTED SIX-SPOKE WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to REAR WHEEL in Service Manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Install long valve stem (43206-01) included in the installation kit. Discard all other valve stems. 2. See Figure 1. Install valve stem assembly (I) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) 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) NOTE For Kits 43928-08 and 43929-08: When installing wheel on 2008 and later XL models, install bearing shim from installation kit under the primary bearing. For Kits 43934-07, 43942-07 and 43972-07: When installing wheel on 2008 and later Dyna models, install bearing shim from installation kit under the primary bearing. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. NOTES The valve stem side of the wheel and machined grooves in the hub face indicate the primary bearing side. Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to REAR WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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