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HARLEY DAVIDSON CHROME SADDLEBAG LID TRIM KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION 1. Remove all articles from inside, then thoroughly wash and dry the saddlebag lid. 2. Close the saddlebag lid. Cut a piece of masking tape at least 10 inches (25 cm) long and lay it lengthwise down the center of the top outer surface of the lid starting at the front. Mark a line lengthwise down the tape, measuring an equal distance from each side so the line is centered on the lid. 3. Obtain the template (7) from the kit, and position it on the line, with the short leg held against the front surface of the lid. Carefully mark the tape at the two arrows, then remove the template and set it aside. 4. At each of the marks made in Step 3, carefully drill a 1/8 inch (3 mm) diameter pilot hole. 5. Using the pilot holes drilled in Step 4, use a 9/32 inch (7 mm) diameter bit to finish drilling the holes for the trim piece. NOTES Before installing the lid trim, test fit to ensure adequate clearance of both mounting pads through the drilled holes in the saddlebag lid. The trim pieces are side-specific; the front legs are angled to match the lid front. If the pads do not fit loosely in the holes, it may be necessary to slightly enlarge the holes to provide clearance and maintain proper alignment of the trim on the lid. Clean the saddlebag lid inside and out, and the inside of the saddlebag with a soft cloth, making sure to remove any shavings left from drilling. 6. Obtain the correct saddlebag lid trim (1 or 2) and a trim gasket (3) from the kit. Peel the liner from the adhesive backing of the gasket. 7. Position the gasket onto the bottom surface of the trim, making sure the gasket remains inside the outer edges of the trim, and smooth it into place. 8. Obtain a pan head screw (6) from the kit. 9. Using a T25 TORX® drive head, start the screw part way into one of the holes on the underside of the trim, to form a few threads in the hole, then back the screw out of the hole. Repeat for the second hole. 10. Install the trim piece onto the lid, fitting the mounting pads into the holes drilled in Step 5. 11. Place a flat washer (5) from the kit onto the threads of the screw (6), followed by a rubber washer (4). Place two drops of Loctite® 243 (blue) onto the screw threads. 12. While supporting the lid trim in place, open the saddlebag lid and install the washers and screw through the lid into one of the trim mounting pads, finger tight. Repeat for the remaining trim mounting pad, with another screw, flat washer and rubber washer. 13. Apply a small amount of pressure to the trim piece above each screw and continue to tighten both screws to 25-28 in-lbs (2.8-3.2 Nm) . 14. Repeat steps 1 through 13 for the opposite saddlebag lid

HARLEY DAVIDSON SADDLEBAG LID COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION NOTE To avoid failure, the fastening tab adhesive must be allowed to cure for 24 hours before installing these Lid Covers. NOTE Lid Cover installation may be easier with the saddlebags removed from the motorcycle. 1. See Figure 1. Open the saddlebag lid. Remove the two T-20 TORX® screws (5) attaching the check strap (3) to the lid. 2 4 2 3 1 6 7 4 4 6 5 is02962 1. Saddlebag lid cover 2. Hook and loop fastener, 1.5 inch 3. Check strap 4. Hook and loop fastener, 4.0 inch 5. Torx screws (2) 6. Hook and loop fastener, 6.0 inch 7. Anchor tab (install first) Figure 1. Saddlebag Lid Cover Installation 2. Wash the entire saddlebag lid, inside and out, with warm, soapy water. Rinse and dry thoroughly. 3. Use the alcohol prep pad provided in the kit to further clean the inside of the lid in the areas where the hook and loop strips will be attached. NOTE The Saddlebag Lid Covers are side-specific. A Bar-and-Shield logo is stitched into the rear face of each cover. NOTE DO NOT fasten the Saddlebag Lid Cover tabs to the hook and loop strips until the adhesive has cured for 24 hours. 4. Place the correct Saddlebag Lid Cover (1) over the saddlebag lid in its proper position. Bring the cover tabs over the edge of the lid to serve as a guide in positioning the hook and loop strips on the inside of the lid. Remove the protective backing from one hook and loop strip at a time. Use the corresponding tab on the cover only as a positioning guide, then fold it back out of the

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

Ducati Hypermotard Large Fuel Tank Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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REMOVING THE OEM FUEL TANK GO FOR A RIDE The best way to remove fuel from your original fuel tank is to RIDE your bike. You should already be familiar with how low you can go and the less fuel that’s in your tank before you start means the less mess you make when draining it. HM69 Fuel Tank Installation Instructions This manual is provided for marketing and informational purposes only and is a guide to assist experienced motorcycle technicians with the installation of the HM69 fuel tank. This installation involves gasoline. Improper installation, adjustment, alteration, service or maintenance regarding the HM69 fuel tank can cause property damage, personal injury or death. At-home Do-It-Yourself mechanics should not install the HM69 fuel tank if you are uncertain of your ability to properly install it and refer the installation to an authorized Ducati service department. ! REMOVE THE SEAT Remove the seat bolt at the rear of the seat with a 4mm hex key. To remove the seat, grasp both sides of the seat, lift the rear of the seat slightly, and pull the seat to the rear of the bike. The front of the seat engages onto bolts on either side of the fuel tank and can be stubborn. THIS KIT ALSO CONTAINS: © 2009 California Cycleworks, Inc. Questions? Email orders@ca-cycleworks.com 1
REMOVE THE BODYWORK The tank cover is fi rst. Remove the fuel fi ller cap and then the 4 screws you see: 2 near the front of the cover and the two aside the fi ller neck. Lift up on the forward portion of the cover and move the entire cover rearward so that the back of the cover is away from the retaining contour on the fuel tank. SIDE PANELS Remove the right side panel’s inner cover using a large coin. Both left and right side covers are retained by 3 screws with 4mm hex heads. Remove the 2 screws on the side of the tank (which were revealed with the removal of the seat). While holding the side covers to support them, remove the bottom screw. The left side cover pulls away naturally – take care not to drop the cover as the tool kit is housed inside of it, adding unexpected weight

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HARLEY DAVIDSON SADDLEBAG LID ORGANIZER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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installation NOTE Prior to installation, hold each organizer up to the lid (without removing the adhesive backing tape) to verify that the organizer fits properly within the recess of the saddlebag lid before moving on to the installation. 1. Use the isopropyl alcohol wipes included in the kit to thoroughly clean the interior surface of both saddlebag lids. Make sure any residue is removed, then allow the lids to dry completely. Make sure the lid surface is free of condensed moisture. NOTE The ideal temperature range for applying the tape is 70 to 100 degrees F (21 to 38 degrees C). Minimum application temperature is 50 degrees F (10 degrees C). If you attempt to apply the tape below these temperatures, the adhesive will become too firm to adhere properly. 2. Locate the double-sided tape on back of the left lid organizer and remove the backing material. NOTE When performing the next Step, be sure to apply pressure to entire length of tape to ensure proper activation of pressure- sensitive adhesive. 3. Carefully center the left lid organizer in the left saddlebag lid recess and press firmly into place. While applying opposing force from outside of lid (to minimize force on tether, hinges, etc.), apply moderate pressure around entire perimeter of organizer and in middle (making sure to include all areas of tape contact). 4. Repeat Steps 2 and 3 on the right saddlebag lid with the right saddlebag lid organizer. 5. Allow the tape to cure (“wet-out”) for a minimum of 48 hours at 70 degrees F (allow extra time if temp is below 70 degrees). Do not place items in the Lid Organizer while the adhesive is curing

KTM Superduke 990 MotoHooligan Airbox Installation

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Filed Under (KTM) by admin on 26-01-2012

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Undo the screws retaining the left and right front tank spoilers and remove. Fitment of Motohooligan airbox is possible without removing the tank but task is much easier if this is done. Access for removal of SAS system and installation of PC111 is also much improved and it’s worth the additional 5 minutes work. It would also be a good idea to do this with an empty tank so it’s lighter to handle. Unscrew front retaining bolt from front of tank and lift tank to access the spring damper on the left hand side. On standard Superdukes release the two circlips, carefully support tank and remove damper unit. (NB. SDR model not fitted with damper). Lower tank back into position and unscrew one of the pivot bolts at rear of tank Stage 1 – remove spoilers and tank Note : Fuel line has a connector half way between tank and airbox. but leave it in position to support the tank whilst you unscrew the other side. Once both bolts are unscrewed tank is free but still attached by fuel lines and electrics. Lift the rear of the tank to expose the two electrical plugs and disconnect both making sure that the retaining pins are pushed in first before you pull them apart. Reaching underneath the rear of the tank you’ll see the fuel line running into the base of the airbox. Half way down there is a connector with a metal button. Press this and pull the fuel line apart – you might want to have a rag handy to catch any fuel drips. Pull off the breather tube at the front, (on US models also pull off the breather that leads to the charcoal canister in the tail), and lift the tank away

2000-2002 Aprilia Mille INSTALLATION INSTRUCTIONS

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Filed Under (Aprilia) by admin on 26-10-2010

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1) It is a good idea to use Blue Loc-tite on all bolts you are about to remove and replace. 2) This kit has extremely close tolerances and in order for all the parts to clear the triple clamp and gas tank, you will probably have to loosen and align most of the associated bolts. We have tried very hard to make this as compact as possible but we know the factory tolerances vary from bike to bike. Be patient, the results are worth it. 3) Remove both front fuel-tank retaining bolts. You will use the longer bolts provided in our kit. 4) Install the frame bracket (part #22-6036-03) that mounts to your front (2) tank bolts holes. The frame bracket sits on top of the stock tank spacers. The frame bracket is offset. This means it fits correctly only one way, with the offset toward the triple clamp, part numbers facing forward, (see photo below). Due to the tight clearances on this model you’ll want to be sure the frame bracket does not make contact with the tank itself. It’s easier to start the tank bolts if you lift up on the tank slightly, while starting the new bolts into their threaded hole. Tighten the new tank bolts to 6 ft lbs. and use Loc-tite. 5) Remove the large 14mm Allen nut and washer that holds your triple clamp on. You will not re-use either one. 6) Install the new “Triple clamp damper mount” Part # 22-2925-00 into the recess area where the stock Allen head bolt was sitting. There is a machined recess or built-in-washer on the bottom of our mount to match the recess on your triple clamp. The 2 nubs that hang down, should match the rear contour of your triple clamp precisely. Use loc-tite and retighten the new 14mm Allen nut provided to your factory torque specs, usually a minimum of 35 ft lbs. and maximum of 85 ft. lbs. Do not use the stock washer that was under the original 14mm nut. 7) Grease the tower pin and drop it in the tower pin hole portion of the frame bracket. The tower pin is designed to “float” and requires no retaining devices. Keep the tower pin lightly greased! It should not touch the gas tank on the bottom side. 8) Install the stabilizer using the (2) 6×20 Allens with the slot in the link arm matching the tower pin. 9) Since the tank is rubber mounted at the rear, you want to be sure it won’t push forward and rub the frame bracket. After riding the first time, be sure the tank has not shoved forward by your body making contact with it. Remember, under heavy braking your entire body weight is pushing the tank forward. Until you have verified sufficient clearance between the tank and the tower pin, it might be smart to put something between the tank and tower pin to protect the tank. 10) Read your damper manual for initial settings on the controls. The damper is infinitely adjustable and totally up to the user to find their preference. Start with softer (counter clockwise) settings. Normally where we set the unit, at 8 clicks out on the base valve, is a good starting point.

HARELY DAVIDSON BOOM! AUDIO TANK POUCH OPERATION INSTRUCTIONS

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

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This kit will work on all Harley-Davidson® motorcycles with a metal fuel tank. Always clean fuel tank before using the Audio Tank Pouch, to prevent trapped dirt from scuffing or scratching paint. Scuffing and fine scratches can be removed using Harley-Davidson® Swirl & Scratch Treatment. •See Figure 1. Flip access flap (3) fully to the front as shown to put media player into the pouch (1). •Remove the cushion from the inside of the pouch. Place the media player face-up on top of the cushion and slide both back into the pouch. Make sure the cushion is under the media player for the best protection. •See Figure 2. Two access holes (2) are available for connecting headphone or speaker connectors (3). •Place the media player and pouch (1) on top of the fuel tank and verify that the magnets are holding the pouch firmly in place. 2 3 1 is06064 1. Audio tank pouch 2. Cushion 3. Access flap Figure 1. Audio Tank Pouch and Cushion 2 2 1 3 is06061 1. Audio tank pouch 2. Access hole (2) 3. Headphone connector Figure 2. Audio Tank Pouch on Fuel Tank

Harley- Davidson Bagger Audio factory service manual for removal

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Filed Under (Harley Davidson) by admin on 03-04-2012

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POWER & SPEAKER HARNESS INSTALLATION- (Read electrical connections prior to connecting center power and ground wires) 1. Disconnect battery (negative cable first!) 2. Remove outer faring cover 3. Route long speaker wires from fairing area through tank channel to seat area. 4. Route one pair of speaker wires under each fender strut support; purple and purple and black wires to the right and green and green and black wires to the left. AMPLIFIER INSTALLATION- 1. Factory installed electronics will determine suggested placement of amplifier. 2. Position and attach amplifier to outer fairing support bars with supplied wire ties. (Electra/Ultra/Street Glide) BAGGER AUDIO™ LIDS INSTALLATION- Detach factory lid by removing the 2 screws holding the factory strap to inner lid and 5 small torque screws holding lid to factory latch assembly. (Consult factory service manual for further instructions) Remove metal strap from behind factory seal (This is the metal strap that the previous 5 small torque screws were removed from) Position metal strap in same location on your new lid. (If you purchased your product unpainted, you must install the supplied seal to your finished lid) Reattach BAGGER AUDIO™ LIDS by installing the 5 small torque screws in the same location as on the factory lid. (We suggest that you have an assistant hold the lid in place while attaching your new lids) Replace factory nylon Hinge straps with new nylon straps supplied in kit. Use metal straps and machined screws to secure the nylon hinge straps. 
 Place a small bead of silicone on the inside rim of the speaker basket to create a watertight seal between the inside of the lid and the speaker. 
 Install speaker into the bottom of the lid (not through the top opening) with supplied stainless screws and washers (4 per lid). Be sure to center speaker in lid opening to ensure proper speaker grill placement. Install speaker with terminals facing toward the front of the lid. One 1/4″ hole must be drilled in each bag. Holes can be positioned at the ownerʼs discretion. Place rubber grommet in drilled hole before running wires