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Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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Filed Under (Harley Davidson) by admin on 16-04-2012

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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HARLEY DAVIDSON MULTI-POCKET WINDSHIELD BAG INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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Installation 1. Remove the acorn nuts from the inside-center, left and right on the horizontal windshield bracket. 2. Apply protective tape strips to the horizontal windshield bracket to protect chrome finish. 2. Place windshield bag and bracket with eyelets over screws in the horizontal windshield bracket. Mark the location of the vertical supports for correct placement of the rubber bumpers to protect the bottom of the bag bracket. Place two bumpers each at the marked locations of the vertical windshield supports. 3. Align the metal brace with the eyelets, to fit snugly onto the windshield horizontal bracket screws. 4. Fasten the acorn nuts removed in step 1 onto the screws through the eyelets under the windshield bag. Torque the nut to 90-110 in-lbs (10.2-12.4 Nm). NOTE The brace under the bottom of the windshield bag conforms to the contour of the windshield bracket as the acorn nuts are torqued. To keep this surface in the best condition, lightly wipe with a Harley-Davidson Micro Fiber cloth, part number 94663-02, using clear water or a mild Harley-Davidson cleaner such as: • Sunwash (part number 94659-98), • Bug Remover (part number 94657-98) or • Harley Gloss (part number 94627-98).

Harley-Davidson Hard mount installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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1. It is recommended that you create a template from cardboard or heavy paper (not included) of the back of the bag to assist in proper placement on the motorcycle. The template can be used for both bags simply by flipping it over horizontally 180 degree for slant style bags. For all other saddlebags transfer template to other bag making sure that the hole pattern corresponds with the bolts pattern on the opposite fender strut. 2-Assemble the saddlebags support 2. Remove your existing fender strut mounting bolts. 3. (A*) Install replacement 8mm x 70mm or 10mm x 70mm bolts. (Most Harley-Davidson models will utilize the 8mm bolts. Please determine which bolts will fit your specific application prior to assembly. Your make and model of motorcycle may require additional hardware. (See your motorcycle owner’s manual). 4. Install 2 upright and secure tight enough to maintain position and secure with the lock nuts (Metric applications do not require lock nuts). Ensure that bracket angles are away from the bike. 5. Lightly apply a dab of engine oil and lightly coat the exposed bolts(C or D) and barrel bolt Hex- head (E) assemblies (Mark at 4 points for each saddlebag). You can also use a marker or pen to mark. Take the template or bag and place against the brackets. Hold and press firmly to transfer the oil to the bag or template. The oil will leave a mark on the bag or template. If you are not satisfied with the position of the bag wipe the oil off and repeat as many times as necessary. Note: Position according to your specific setup, ensure the bag will not contact hot engine or exhaust components. If planning on carrying a passenger, ensure that there is enough clearance for the passenger’s legs between the bags and the foot pegs. Make sure that the uprights DO NOT contact moving parts, including but not limited to suspension components. 6. Place the Saddlebag on a firm surface and drill 4 holes (make sure you drill holes according to the size of the bolt to be passed) into the back of the bag only, according to your oil drop pattern. Also be careful not to damage the large mesh pocket inside the saddlebag. If a template was utilized cut the corresponding holes into the template and place temple on the back of the bag and drill following above directions. The template can be utilized for both sides of the bag

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 T-PAK RACK BAG INSTALLATION INSTRUCTIONS

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

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INSTALLATION See the Accessory and Cargo section in your Owner’s Manual. Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00021a) •Secure the bag straps to the rack to prevent bag shifting during vehicle operation. •See the owner’s manual for recommended tire inflation pressure. 1. See Figure 1. Set the rack bag on top of the luggage rack with carrying handle (1) toward the rear of the vehicle. 2. Install the four corner clips to the connector straps. 3. See Figure 2. Wrap the connector straps around the bars of the luggage rack and install the ends into the strap keepers. Tighten the straps as necessary. Tuck in to tie down any excess strap material. 4. Give the rack bag a final pull to verify the pack is securely attached.

Harley-Davidson Road King Classic Tour Pack INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Close the bag completely. Support the outside of the bag with a covered piece of soft material to prevent marring or scratching. 2. Position the template on the outside of the bag, centered between the buckles. Align the template along the gap between the seams as shown at right. Tape the template in place. 3. Drill all of the small holes on the template using a 1/4″ drill bit for the assembly holes. Drill or punch the 3/4″ hole for the lock. 4. Sandwich the lock. item 4, between items 3 and 5 as shown above in FIG.1. Fasten it to the bag with the black slotted blind screws (items 7). Sandwich the leather between the lock cover plate (item 6) on the outside and the lock assembly. It may be necessary to remove a section of excess overlapped leather. 5. Use the phillips head screws (item 7) provided to attach the spring loaded ratched bar assembly. 6. Lock operation. *a. rotate the locking bar down as the bag is closed * * so that it is started into the lock aseembly. *b. check that the bag straps are outside of the bag. *c. Press the bag lid down as your help to align the * * bag lock assembly with the locking ratched bar. the ratchet bar whill operate smoothly into the * * lock when properly aligned.

HARLEY-DAVIDSON MOTORCYCLE WASH KIT MANUAL

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

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THE WASHING PROCESS Allow the motorcycle to cool to the touch. Cool water can damage a hot motorcycle. 1. Pre-Wash: a. Verify the motorcycle is cool to the touch. b. Rinse the motorcycle from the bottom up. c. Verify you have the proper cleaning supplies. d. Spray on Bug Remover and let the product activate while proceeding to the next step. 2. Wheels and Tires: a. Rinse wheel and tire surfaces. b. Apply Wheel and Tire Cleaner. c. Wait one minute after spraying product. d. Clean wheel with a Soft Detailing Pad or Wheel and Spoke Brush. e. Rinse well. 3. The Wash: a. Have two buckets; one for the cleaner and one for rinsing. b. Pour Sunwash into the Harley-Davidson Cleaning Bucket and fill with water. c. Fill the rinsing bucket with clean, plain water. d. Soak the Wash Mitt in the Sunwash solution. e. Wash all surfaces from the top working down. f. Rinse from the bottom up first. g. End with top down rinse. 4. Drying the Motorcycle: a. Use the Soft Drying Towel to dry surfaces of the motorcycle. b. Dampen the towel in clean water. c. Wring out the towel as often as needed and continue until the surface is completely dry. 5. The Polish and Seal : (not applicable for denim paint finishes) Polishing and sealing isn’t just about good looks . A well cared-for motorcycle repels dust, dirt, bugs and dirty water. a. Use Harley Glaze polish and sealant and follow the instructions on the bottle. b. Use Softcloth disposable towels for application. c. A Softcloth or Microfiber detailing cloth is an absolute must for finish buffing. d. In between Harley Glaze applications, use Harley Spray Cleaner and Polish and Harley Gloss to maintain shine and protection of painted and chrome fin- ishes.

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HARLEY DAVIDSON FLST REPLACEMENT WINDSHIELD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION 1. See Figure 1. Remove stock windshield. 2. Remove all hardware that secures mounting brackets to windshield. The nine screws must be removed with a T- 27 TORX® screwdriver. Save all hardware and brackets for installing new windshield. 3. Remove all old tape from brackets and apply new tape (1, 2) from kit onto brackets. Align holes in tape with holes in brackets. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets. Tighten all screws and acorn nuts to 48-60 in-lbs (5.4 to 6.8 Nm) . 5. Install windshield (3) on motorcycle CARE AND CLEANING Polycarbonate windscreens/windshields require proper attention and care to maintain. Failure to maintain polycarbonate properly can result in damage to the windscreen/windshield. (00483d) •Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windscreen/windshield. Doing so will damage the surface. •Do not clean Lexan® polycarbonate in hot sun or high temperature. •Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. •Never scrape the windshield with a razor blade or other sharp instruments, as permanent damage will result. •Sunlight reflections off of the inside curvature of a windscreen/windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windscreen/windshield to avoid reflections. •Do not use benzene, paint thinner, gasoline or any other cleaning agents on the rubber bushings. Doing so will damage the bushing surfaces. Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant (00231a) NOTES Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier. Harley-Davidson Windshield Water Repellent Treatment Part Number 99841-01 is approved for use on Harley-Davidson Lexan windshields

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HARLEY DAVIDSON LUGGAGE RACK BAG INSTALLATION INTSRUCTIONS

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

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INSTALLATION 1. Set the rack bag on top of the luggage rack with the main pocket opening facing the rear of the vehicle. 2. See Figure 2, Figure 3 and Figure 4. Determine which luggage rack is installed on the vehicle. 3. See Figure 1. Open the hook-and-loop closures in the appropriate locations for the installed luggage rack. 4. Fasten the closures around the bars of the luggage rack and pressing the hook-and-loop ends together. 5. Give the rack bag a final pull to verify the pack is securely attached. 1 2 3 4 7 5 6 is05516 1. Rear left closure 2. Rear center closure 3. Rear right closure 4. Front left closure 5. Front center closure 6. Front right closure 7. Rain cover storage Figure 1. ook-and-Loop Closure Locations 1 2 3 4 5 6 is05513 Figure 2. Premium Rack Closure Locations -J00861 1 of 2 1 3 4 6 is05514 Figure 3. Air Wing Rack Closure Locations 2 5 4 6 is05515 Figure 4. Contoured Rack Closure Locations USAGE Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) •Combined load of top rack and Tour-Pak® must not exceed 25 lbs (11.3 Kg). Overloading the motorcycle will cause unstable handling and reduced braking efficiency, which could result in death or serious injury. See Figure 1. Open the hook-and-loop flap on the rain cover storage pocket (7) and wrap the tethered rain cover around the bag.

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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