well labelled diagram of a disc plough and mould board plough

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HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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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. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

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motorcycle Turn Signal Conversion Kit Installation Instructions

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Filed Under (Tips and Review) by admin on 09-11-2010

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1. Place motorcycle on solid, level ground and on center stand if equipped. 2. Remove your turn signal lens. Place it upside down and clean the lens interior with the supplied alcohol wipe. Allow to completely air dry. Note: the LEDs are mounted to the inside of the turn signal lens with the LEDs making direct contact with the lens. The supplied silicone is used to secure the LED board to the lens. It remains flexible but can be removed. Test fit the board in your lens prior to using silicone. 3. Using a small screwdriver, poke a small hole in the end of the tube of silicone. Place a dab of silicone on each of the 12 LEDs on the circuit board. CAUTION : Note the position of the metal pins on the back of the LED board, They must be located 90 degrees from where the holes are that secure the lens to the housing. See attached diagram. 4. Position the round circuit board over the inside of your turn signal lens with the LEDs facing down. Get the board as centered as possible. Allow the silicone to make contact with the inside of the lens and then push down and slightly rotate the board back and forth to allow the LEDs to make contact with the lens surface. Repeat other side. NOTE : the silicone will require 30 minutes in 70 degree weather to tack up. Full cure will occur within 24 hours. We suggest not riding for several hours if possible to allow the best adhesion. 5. You will need to access the following wires; running light (license plate can be used), brake lights, right turn and left turn. Disassemble the bike as needed to gain access to the wiring. Shop Tip: we have found that on the Yamaha Star Series and the Kawasaki Cruisers that installation is much easier when you remove the turn signal bar from the fender. On the Yamahas, there are 3 bolts holding the moustache in position. The wires will unplug from behind the license plate. On the Kawasakis, unplug the signals under the seat and bend the tabs under the fender to be able to remove the wires. 6. We have provided some tubing to slide over the wires so that when you re-install the bulb socket, our wires for the LED boards will not be pinched. This tube should be slid all the way into the turn signal housing. You may have to shorten the tubing for your installation. 7. You will need to run wires through the stem of the turn signal. You can see samples of how the various manufacturers signal housings come apart on our web site. Click on “Other Lighting Products” and then “Turn Signal Conversion Kits” and follow the link. We suggest placing the removed turn signal assembly on a towel on your work area. 7. You will need to leave 2″ of slack in the wires at the turn signal housing to allow for wire connection. 8. Reinstall the turn signal housing back on the motorcycle if removed. NOTE: both of the run/brake circuits must be used. You may shorten the wires only on the run/brake circuits as needed. Do not change the circuits under the heat shrink. T-Tap instructions. Lay the “donor” wire in the slot in the burgandy connector. Close and snap together with pliars. Strip some insulation off of the wire which will be tapping into the factory wire. Crimp one of the pink connectors on the bare wire and plug it into the burgandy T-Tap 9. Connect the green wires from the run/brake circuits to the bikes running lights. The 2 greens can be connected together. 10. Connect the blue wires from the run/brake circuits to the bikes brake lights. The 2 blues can be connected together. 11. Take one of the red wires from a run/brake circuit and connect it to one of the black with white stripe wires coming from one of the LED boards using the supplied red butt connector. Connect the other run/brake circuit red wire to the remaining black with white stripe wire on the other LED board. 12. Connect the black wire from the LED board on the right side of the bike to the right turn signal positive (+) wire on the motorcycle. 13. Connect the black wire from the LED board on the left side of the bike to the left turn signal positive (+) wire on the motorcycle. 14. Plug the wires into the LED boards. If you hold the turn signal lens so that you are viewing the back of the LED board, position the connectors on the board at the 12 o’clock (top) position. The connector on the left is the positive (+) terminal. Connect the red wire to it. Connect the black wire to the remaining connector on the right side. 15. Check operation. LEDs should come on with running lights. LEDs will brighten when brake lights are applied. LEDs will shut off when the amber turn signal comes on. 16. Should you have any problems, please see the troubleshooting chart on our website.* * 17. Reassemble bike

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Toyota Camry L4 – 2.4L 2004 Brakes and Traction Control Disc Brake System Service and Repair

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Filed Under (Toyota Manuals) by admin on 24-05-2011

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REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH 10. Remove the cylinder slide bush from the cylinder slide pin.
a. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 11. Remove the 2 bush dust boots from the disc brake cylinder mounting. a. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 12. Remove the 2 bolts and disc brake cylinder mounting LH. a. REMOVE CYLINDER BOOT 13. Using a screwdriver, remove the set ring and cylinder boot.
a. REMOVE FRONT DISC BRAKE PISTON 14. Place a piece of cloth or similar, between the piston and the disc brake cylinder. a. Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place
your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid

2005 TRIUMPH SPEED TRIPLE AND SPRINT ST INTEGRATED TAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 30-10-2010

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1 ) PLACE THE TAIL LIGHT ASSEMBLY ON A SOFT SURFACE TO AVOID SCRATCHING OR DAMAGING THE LENS DURING THE CUTTING OPERATION. 2 ) POSITION YOUR CUTTING WHEEL AS SHOWN IN THE PICTURE TO THE LEFT WHERE THE CLEAR PART OF THE LENS MEETS THE BLACK PART. 3 ) PROCEED TO CUT INTO THE CLEAR LENS APPROXIMATELY HALF OF THE THICKNESS, ALL THE WAY AROUND THE PERIMETER OF THE LENS – BE SURE NOT TO CUT ALL THE WAY THROUGH BECAUSE IT WILL NOT GLUE BACK TOGETHER PROPERLY. SEE “TIPS FOR CUTTING YOUR LENS” BEFORE BEGINNING. TIPS FOR CUTTING YOUR LENS A) KEEP THE CUTTING WHEEL MOVING AND APPLY LIGHT PRESSURE. SITTING IN ONE SPOT WILL JUST MELT THE PLASTIC. WHEN YOU MAKE YOUR WAY AROUND THE ENTIRE PERIMETER, CLEAN ALL THE BURRED PLASTIC FROM AROUND THE EDGES AND FROM INSIDE THE GROOVE YOU’VE MADE. OPENING THE LENS 4 ) PLACE THE TIP OF A FLAT HEAD SCREWDRIVER IN THE GROOVE YOU HAVE CREATED. 5 ) GENTLY TWIST THE SCREWDRIVER TO CRACK THE GLUE ALONG THE GROOVE. NOTE: AS SOON AS YOU HEAR THE SOUND OF THE GLUE GIVING (A CRACK), MOVE THE SCREWDRIVER SLIGHTLY AND ADVANCE THE CRACK. SLOW AND STEADY IS THE NAME OF THE GAME HERE. IF YOU FIND A HARD SPOT, WEAKEN IT WITH THE CUTTING WHEEL AS NECESSARY. THE HARD PART IS OVER! YOU CAN RELAX NOW!
2 ©2005 Custom LED LLC. All Rights Reserved. 6 ) REMOVE THE SCREWS HOLDING THE STOCK LED BOARD TO THE HOUSING (YOU WILL BE REUSING THE SCREWS SO PUT THEM TO THE SIDE). 7 ) REMOVE THE STOCK LED ASSEMBLY FROM THE LENS HOUSING AND TURN IT FACE DOWN TO EXPOSE THE WIRING BEHIND. 8 ) SNIP OFF THE WIRES THAT CONNECT TO THE LED CIRCUIT BOARD AS CLOSE TO THE CIRCUIT BOARD AS POSSIBLE. 9 ) PLACE THE STOCK LED CIRCUIT BOARD OUT OF THE WAY. YOU WILL NO LONGER NEED THIS PART, DISPOSE OF IT AS YOU WISH. 10 ) DRILL A HOLE IN THE BACK SIDE OF THE ENCLOSURE IN THE LOCATION SHOWN IN FIGURE 10. THIS HOLE WILL BE USED TO ROUTE THE TWO BLINKER WIRES (RED AND WHITE) OUT OF THE ENCLOSURE. CHOOSE A BIT SIZE THAT IS ONLY AS LARGE AS NECESSARY TO FIT THE TWO WIRES THROUGH THE HOLE. WIRING UP YOUR CUSTOM LED BOARD PLACE YOUR CUSTOM LED INTEGRATED TAIL NEXT TO THE HOUSING, AND MATCH THE WIRE COLORS AS FOLLOWS: TRY TO HANDLE THE CIRCUIT BOARD AS LITTLE AS POSSIBLE AS FINGERPRINTS AND DIRT WILL HINDER THE PERFORMANCE. • • • • BLACK ON HARNESS TO 6″ BLACK ON CUSTOM LED BOARD • • • • GREEN ON HARNESS TO 6″ GREEN ON CUSTOM LED BOARD • • • • YELLOW ON HARNESS TO 6″ YELLOW ON CUSTOM LED BOARD USE THE THREE (3 OF 5) SUPPLIED ORANGE SPLICE CONNECTORS. PUSH THE TWO WIRES TO BE SPLICED TOGETHER INTO THE OPEN END. BE SURE TO PUSH THE WIRES ALL THE WAY IN (UNTIL YOU CAN SEE THEY HAVE REACHED THE OTHER SIDE). NOTE: THE SPLICE IS MORE RELIABLE IF THE WIRE IS NOT STRIPPED. BE SURE TO SNIP OFF THE BARE ENDS OF THE WIRES ON THE CUSTOM LED TAIL TO ENSURE THAT THERE IS INSULATION WHERE THE SPLICE WILL OCCUR. THE SUPPLIED SPLICE CONNECTORS AUTOMATICALLY DISPLACE THE INSULATION AS NECESSARY. ONCE YOU DOUBLE CHECK YOUR COLOR MATCHING AND ARE ABSOLUTELY SURE THAT THE WIRES ARE FULLY INSERTED INTO THE SPLICE CONNECTORS DO THE FOLLOWING: 11 ) SQUEEZE THE SPLICE CONNECTORS FIRMLY WITH PLIERS. VISUALLY INSPECT YOUR CONNECTIONS TO SEE THAT THEY HAVE BEEN SPLICED PROPERLY INSIDE. 12 ) RUN THE RED AND WHITE WIRES THROUGH THE HOLE YOU OPENED UP IN STEP 10. 13 ) POSITION YOUR CUSTOM LED BOARD IN PLACE AS SHOWN AND FASTEN THE BOARD USING THE SCREWS REMOVED FROM THE STOCK BOARD.

HARLEY DAVIDSON FRONT TYPHOON WHEELS INSTALLATION MANUAL

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

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If installing kit 44615-08, 40774-10, 44657-08 or 43300053 on a Dyna model with stock laced wheels, the separate purchase of stock brake disc (44553-06A) or polished brake disc (41500012) is required. 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) •Harley® Preserve™ Bare Aluminum Protectant (99845-07) Touch-up paint for painted wheels is available from a Harley- Davidson dealer: •Touch-Up pen, wheel, black (94482) 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. 1 2 is06470 1. Closed brake disc 2. Open brake disc or floating rotor Figure 1. Front Brake Disc Styles Table 1. Front Disc Hardware Fitment Hardware Brake Disc 5 Stock disc screws (3655A) Closed disc Chrome screw kit (46646-05) includes 5 screws 5 Stock disc screws (3762M) and 5 disc washers (6966M) Open disc NOTE: Models equipped with dual front brakes and models being equipped with a wheel with dual brake mounting surfaces require twice as many screws/washers (10 total screws or 2 chrome screw kits if available). INSTALLATION NOTE Use plastic protectors on tire mounting tools and rim clamps when mounting a tire to a painted wheel. For wide low profile tires a tire mounting machine with a second arm to press down on the sidewall while the wheel is rotating is recommended.

HARLEY DAVIDSON FRONT BRAKE DISC LOCK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION Do not operate vehicle with brake disc lock in place. Operation with lock on disc will restrict movement of the wheel, which could result in death or serious injury. (00457b) NOTE Insert key all the way to the bottom of the cylinder. Turn key clockwise 180 degrees to the open position. DO NOT FORCE KEY! Key should turn freely. If key does not freely rotate, try turning key slightly left and right while inserting to align disks inside cylinder. Failure to insert key all the way to the bottom of cylinder could cause key to jam. For Models with Hydraulic Fork Front Ends 1. See Figure 1. Insert reminder cord (3) into slot on disc lock (1). 2 1 3 is 01599 1. Lock 2. Caliper 3. Reminder cord Figure 1. Installing Disc Lock 2. Slide lock (1) over front brake disc as close to rearward edge of brake caliper (2) as possible. Push button completely down to lock. 3. Roll motorcycle forward slowly until lock gently contacts caliper. 4. See Figure 3. After installing disc lock, place loop end (1) of reminder cord (2) over handlebar grip. For Models with Springer Front Ends 1. See Figure 2. Insert reminder cord (5) into slot on disc lock

Vespa GTS Super Specification

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Filed Under (Vespa) by admin on 11-11-2010

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Gts super 300 ie Gts super 125 ie s 125cc s 50cc Gts 250 ie Gts 125cc LX 125cc LX 50cc 2 stroke Engine Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder LEADER 4 stroke with electronic injection Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder, catalised, LEADER 4 stroke, 4 valve Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Capacity 278cc 124cc 124cc 50cc 249cc 124cc 124cc 49cc Power 16.4 kW / 7500 rpm 10.5 Kw / 9500 rpm 7.65 Kw / 8250 rpm 3.2 Kw / 7500 rpm 15.7 Kw / 8500 rpm 7.65 Kw / 8250 rpm 7.65 Kw / 8250 rpm 2.5 Kw / 8500 rpm Max Torque 22Nm / 6500 rpm 12 Nm / 8000rpm 9.6 Nm / 7250 rpm 4.4 Nm / 6500 rpm 20.1 Nm / 6500 rpm 9.6 Nm / 7250 rpm 9.6 Nm / 7250 rpm 3.3 Nm / 6500 rpm Cooling Liquid Liquid Forced Air Forced Air Liquid Liquid Forced Air Forced Air Starter Electric Electric Electric and kick starter Electric and kick starter Electric Electric Electric and kick starter Electric and kick starter Transmission Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Front Suspension Single arm, dual chamber hydraulic shock absorber with coaxial spring Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Rear Suspension Two dual effect shock absorbers with adjustable preload Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Twin hydraulic shock absorbers with preload adjuster Twin hydraulic shock absorbers with preload adjuster Hydraulic shock absorbers with preload adjuster Hydraulic shock absorber Front Brake ø 220mm disc brake 220mm disc brake ø 200mm disc brake ø 200mm disc brake ø 220mm disc brake ø 220mm disc brake ø 200mm disc brake ø 200mm disc brake Rear Brake ø 220mm disc brake 220mm disc brake ø 110mm drum brake ø 110mm drum brake ø 220mm disc brake ø 220mm disc brake ø 110mm drum brake ø 110mm drum brake Front Tyre Tubeless 120/70-12″ Tubeless 120/70 – 12″ Tubeless 110/70 – 11″ Tubeless 110/70 – 11″ Tubeless 120/70-12″ Tubeless 120/70-12″ Tubeless 110/70 – 11″ Tubeless 110/70-11″ Rear Tyre Tubeless 130/70-12″ Tubeless 130/70 – 12″ Tubeless 120/70 – 10″ Tubeless 120/70 – 10″ Tubeless 130/70-12″ Tubeless 130/70-12″ Tubeless 120/70 – 10″ Tubeless 120/70-10″ Running weight 158kg 158kg 114kg 96kg 151kg 145kg 114kg 96kg Length/Width/Height 2230mm / 755mm / 1170mm 1930mm / 755mm / 1930mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm 1930mm / 755mm / 1170 mm 1940mm / 755mm / 1180 mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm Fuel Tank Capacity 9 litres 9 litres 8.5 litres 8.5 litres 9.2 litres 10 litres 8.5 litres 8.5 litres Emmissions Euro 3 Euro 3 Euro 3 Euro 2 Euro 3 Euro 3 Euro 3 Euro 2 Colours Rosso Dragon Nero Lucido Montebianco Rosso Dragon Nero Lucido Montebianco Taormina Nero Lucido Montebianco Taormina Nero Lucido Montebianco Marrone Terra Di Toscana Bronzo Perseo Nero Vulcano Blu Midnight

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2005-2010 TACOMA RUNNING BOARD REPAIR

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Filed Under (Toyota Manuals) by admin on 31-10-2011

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Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- — Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). — Safety (eye protection, rechecking torque procedure, etc.). — Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). — Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Remove Running Board from Packaging. (a) Remove running board assembly from package and place on a clean protected surface. The boards are sided (Fig. 1-1) (b) Verify kit contents and inspect the running board for damage. 2. Running Board Preparation for Installation (LH/RH Side). (a) Verify hardware bag content by referring to the cover page of this instruction sheet. (b) Loosen the 1/4 – 20 flange nuts at each of the three (3) bracket locations on each running board. (Fig. 2-1) (c) With a small slotted screwdriver, remove the plastic plugs covering M8 weld nuts in body of vehicle at 6 points/side.

CUSTOM LED 2004-2006 YAMAHA ROAD STAR INTEGRATED TAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 10-11-2010

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1 ) REMOVE THE SCREWS ON THE BACK SIDE OF THE TAIL LIGHT THAT HOLD THE CHROME TRIM TO THE TAIL LIGHT. 2 ) POSITION YOUR CUTTING WHEEL AS SHOWN IN THE PICTURE TO THE LEFT WHERE THE CLEAR PART OF THE LENS TURNS 90 DEGREES. THE CUTTING WHEEL SHALL REMAIN IN THE PLANE OF THE LENS. 3 ) PROCEED TO CUT INTO THE CLEAR LENS APPROXIMATELY HALF OF THE THICKNESS, ALL THE WAY AROUND THE PERIMETER OF THE LENS – BE SURE NOT TO CUT ALL THE WAY THROUGH BECAUSE IT WILL NOT GLUE BACK TOGETHER PROPERLY. SEE “TIPS FOR CUTTING YOUR LENS” BEFORE BEGINNING. TIPS FOR CUTTING YOUR LENS A) KEEP THE CUTTING WHEEL MOVING AND APPLY LIGHT PRESSURE. SITTING IN ONE SPOT WILL JUST MELT THE PLASTIC. WHEN YOU MAKE YOUR WAY AROUND THE ENTIRE PERIMETER, CLEAN ALL THE BURRED PLASTIC FROM AROUND THE EDGES AND FROM INSIDE THE GROOVE YOU’VE MADE. OPENING THE LENS 4 ) PLACE THE TIP OF A FLAT HEAD SCREWDRIVER IN THE GROOVE YOU HAVE CREATED. 5 ) GENTLY TWIST THE SCREWDRIVER TO CRACK THE GLUE ALONG THE GROOVE. NOTE: AS SOON AS YOU HEAR THE SOUND OF THE GLUE GIVING (A CRACK), MOVE THE SCREWDRIVER SLIGHTLY AND ADVANCE THE CRACK. SLOW AND STEADY IS THE NAME OF THE GAME HERE. IF YOU FIND A HARD SPOT, WEAKEN IT WITH THE CUTTING WHEEL AS NECESSARY. THE HARD PART IS OVER! YOU CAN RELAX NOW! 2 ©2005 Custom LED LLC. All Rights Reserved. 6 ) REMOVE THE SCREWS HOLDING THE STOCK LED BOARDS TO THE HOUSING (YOU WILL BE REUSING SOME OF THE SCREWS SO PUT THEM TO THE SIDE). 7 ) REMOVE THE STOCK LED ASSEMBLY FROM THE LENS HOUSING. YOU WILL NO LONGER NEED THE STOCK LED BOARD, DISPOSE OF IT AS YOU WISH. 8 ) GENTLY PRY OFF THE PLASTIC COVER TO EXPOSE THE DRIVER BOARD UNDERNEATH. 9 ) REMOVE THE SCREWS SUPPORTING THE DRIVER BOARD AND SNIP OFF THE THREE WIRES (BLUE, BLACK, YELLOW) AS SHOWN AS CLOSE TO THE CIRCUIT BOARD AS POSSIBLE! YOU WILL NEED TO CONNECT TO THESE WIRES LATER. 10 ) POP OUT THE LITTLE BLACK PLUG AS SHOWN IN THE PICTURE. YOU CAN POKE IT OUT FROM THE INSIDE OF THE HOUSING. WIRING UP YOUR CUSTOM LED BOARD PLACE YOUR CUSTOM LED INTEGRATED TAIL BOARD NEXT TO THE HOUSING AND MATCH THE WIRE COLORS AS FOLLOWS: TRY TO HANDLE THE CIRCUIT BOARD AS LITTLE AS POSSIBLE AS FINGERPRINTS AND DIRT WILL HINDER THE PERFORMANCE. • BLACK ON HARNESS TO 6″ BLACK ON CUSTOM LED BOARD • BLUE ON HARNESS TO 6″ BLUE ON CUSTOM LED BOARD • YELLOW ON HARNESS TO 6″ YELLOW ON CUSTOM LED BOARD USE THE THREE (3 OF 5) SUPPLIED ORANGE SPLICE CONNECTORS. PUSH THE TWO WIRES TO BE SPLICED TOGETHER INTO THE OPEN END. BE SURE TO PUSH THE WIRES ALL THE WAY IN (UNTIL YOU CAN SEE THEY HAVE REACHED THE OTHER SIDE). NOTE: YOU WILL NEED TO SEPARATE THE THREE WIRES FIRST BY CUTTING THE PLASTIC COLLAR THAT BINDS THEM. FOR THE WIRES TO FIT PROPERLY INTO THE CONNECTORS, YOU MUST ALSO REMOVE THE REMNANTS OF THE COLLAR FROM THE WIRES. NOTE: THE SPLICE IS MORE RELIABLE IF THE WIRE IS NOT STRIPPED. BE SURE TO SNIP OFF THE BARE ENDS OF THE WIRES ON THE CUSTOM LED TAIL TO ENSURE THAT THERE IS INSULATION WHERE THE SPLICE WILL OCCUR. THE SUPPLIED SPLICE CONNECTORS AUTOMATICALLY DISPLACE THE INSULATION AS NECESSARY. ONCE YOU DOUBLE CHECK YOUR COLOR MATCHING AND ARE ABSOLUTELY SURE THAT THE WIRES ARE FULLY INSERTED INTO THE SPLICE CONNECTORS DO THE FOLLOWING: 11 ) SQUEEZE THE SPLICE CONNECTORS FIRMLY WITH PLIERS. VISUALLY INSPECT YOUR CONNECTIONS TO SEE THAT THEY HAVE BEEN SPLICED PROPERLY INSIDE. 12 ) RUN THE GREEN AND BROWN WIRES THROUGH THE HOLE YOU OPENED UP IN STEP 9

HARLEY DAVIDSON DUAL DISC FRONT BRAKE KIT REMOVAL AND INSTALLATION MANUAL

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

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This kit is designed for installation on the following models which have original equipment 39mm front fork tubes (including chromed tubes) and 19-in. cast-aluminum front wheels: • 2000 – 2003 XLH 883, XLH 883 Hugger and XLH 1200 • 2000 – 2003 FXD (Super Glide) This kit can also be installed on the above XLH and FXD models which have original equipment 39mm front fork tubes and 19-in. laced front wheels only after one of the following procedures is performed: • The original single-flange hub of the 19-in laced front wheel is replaced with a new double-flange hub (H-D Part No. 43629-00), (sold separately) which will accept the second brake disc. OR • The original 19-in. laced front wheel assembly, which has a single-flange hub, is replaced with a new 19-in. laced front wheel assembly (H-D Part No. 43579-00), (sold separately) which has a double-flange hub designed to accept the second brake disc. See the Service Parts Illustration for a list of the contents included in this kit. This kit does not include the front brake line required for a dual disc system; the brake line must be purchased separately as follows: • For XLH 883 motorcycle equipped with low-rise (flat) handlebars, order dual disc brake line H-D Part No. 45148-96. • For XLH 883 Hugger, XLH 1200, and FXD Super Glide models with “buckhorn” (pull-back) handlebars, order dual disc brake line H-D Part No. 45111-96. 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) Brakes are a critical safety component. Contact a Harley- Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a) Removal and Disassembly – Front Brake System NOTE A Service Manual for your motorcycle is available at your Harley-Davidson Dealer. 1. Block motorcycle underneath frame so that front wheel is raised off the ground slightly. 2. Remove original front brake caliper from left side of front fork according to appropriate Service Manual procedures. Let caliper hang loose on brake line. Save all components and fasteners for reinstallation. NOTE Do not operate the front brake lever with the front caliper removed because the piston may be forced from the caliper. Reseating the piston requires disassembly of the caliper . 3. Remove socket head screw which secures a clamp (retains front brake line) to underside of front fork lower bracket (lower triple clamp). Discard clamp and screw. 4. Remove screw, lockwasher, and clamp which secure front brake line to right rear side of front fork upper bracket (upper triple clamp). Save all components for reinstallation. 5. Remove right mirror and, if applicable, right turn signal lamp assembly from original front brake master cylinder casting. Save all components and fasteners for reinstalla- tion.

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