what is the size of the passenger foot peg bolt harley softail

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1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

Harley Davidson Softail Sideshots Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. On FLSTN, FLSTF, FLSTH and FLSTC loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heat shield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (Not necessary on 2000- up models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head 5. Remove the bolts attaching the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. On pre 2000 models go to step #9, on 2000-up models go to step #10. 9. Remove the right passenger foot peg bolt. Position the motorcycle on the side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt, remove the bolt and stock mounting bar. Reinstall the pivot bolt and torque to 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″ x 3″ Allen bolt and 1-5/8″ length spacer (supplied). 10. Using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″ x 2 1/2″ Allen bolt and 3/4″ length spacer (supplied). 11. The bolts and spacers used in the above steps may also be used on all Softail models to space the right rear foot peg away from the exhaust. 12. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers (save for reuse). NOTE: If circlips look bent or twisted replace them with new circlips.

HARLEY DAVIDSON SOFTAIL Shortshot Exhaust System REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 17-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. On FLSTC, FLSTF, FLSTN and FXSTS loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heatshield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (This step is not necessary on 2000 models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. 9. Park the motorcycle on its side stand. Remove the right side 1/4″-20 bolt which holds the lower fender in place. The fender will flex out of the way allowing the removal of the right passenger foot peg bolt. Position a floor jack under the right hand frame tube of the motorcycle below the swing arm pivot bolt. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Set the mounting bar aside. Replace the pivot bolt and torque it between 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″-20 x 3″ bolt and an 1 5/8″ long spacer (supplied). 10. On 2000 year models, using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″-16 x 2 1/2″ bolt and 3/4″ length spacer (supplied). 11. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted replace them with new circlips. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Vance and Hines recommends you replace your exhaust gaskets with Sceamin’ Eagle gaskets part number 17048-98. 2. Install the mounting bracket to the frame, by aligning the two 3/8″ holes in the bracket with the two holes in the frame below the right rear footrest, using the two 3/8″-16 x 3/4″ flange head bolts (supplied), do not tighten at this time. When the bracket is mounting correctly, it should bend out and away from the motorcycle, with the four holes of the bracket toward the front of the motorcycle. 3. Install the circlips and flanges from the stock system on to both of the new head pipes

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HARLEY DAVIDSON SOFTAIL 2 into 1 Pro Pipe Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Loosen the crossover pipe clamp, located between the front and rear head pipes. 3. Remove the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the two nuts from the back side of each muffler. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them. 7. Remove the two bolts that hold the front muffler mounting bar to the frame. Note: FLSTN, FLSTF models require the removal of the stock exhaust system mounting bar. For removal: Remove the right passenger foot peg bolt. Position the motorcycle on it’s side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Replace the pivot bolt and torque it between 120 -150 ft. lbs. 8. Reinstall the foot peg bolt using the 1/2″ x 3″ bolt and spacer tube (both supplied). Tighten the bolt making sure the foot peg folds in the proper direction. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM Note: For easier installation on models with floorboards, it will be necessary to loosen the right side floorboard. 1. Check the stock exhaust gaskets to be sure they’re in good shape. If you have any doubts as to their condition, replace them. 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of each heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the motorcycle. 3. Install the circlips and flanges from the stock system onto both new head pipes. 4. Install the header using the stock nuts, but leave them loose at this time. 5. Install the new mounting bracket to the frame below the right rear foot peg, using the two 3/8″x 3/4″ flange bolts (supplied), and tighten. 6. Slide the dog bone shaped nut plate under the bracket that is welded to the backside of the muffler.

HARLEY DAVIDSON SOFTAIL REAR SADDLEBAG GUARDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION 1. Remove saddlebag, if equipped, from motorcycle. 2. Remove passenger footpeg or passenger footboard assembly (including footboard mount) from vehicle. 3. See Figure 1. Remove nut (1), seat strap bracket (if equipped) and 3/8 inch diameter bolt (2) from indicated position on rear fender support (immediately to the rear of the front seat) Discard the bolt, but save the nut for reinstallation. This location is where the upper part of the saddlebag guard will mount. 2 1 is03883 1. Rear fender support nut 2. Rear fender support screw Figure 1. Hardware Removal 4. See Figure 2. Install saddlebag guard (4) top flange (5) against fender support (3). Install 3/8-16 x 1-3/4 inch button head bolt with the seat strap bracket (if equipped) and hardware removed in Step 3 (if equipped) and nut in same direction as bolt removed in Step 3. Finger tighten only. 5. Position bottom flange (6) of saddlebag guard (4) against inboard surface of motorcycle frame (7) at location where passenger footpeg (2) (or passenger footboard bolt) attaches. If Heritage-Style Saddlebag relocation kit, Part Number 90238-00 is to be installed, the bracket should be positioned between the saddlebag guard flange and the motorcycle frame member. Follow installation instructions included with that kit. 6. See Figure 3. Determine your model application and follow the applicable installation procedure below: On models with passenger footpeg, but without saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support (B). Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Install lower saddlebag guard flange over bolt protruding from inboard surface of frame member. Install 3/8-16 lock nut to end of bolt. Tighten to 35-45 ft-lbs (47-61 Nm). Install footpeg (C) according to Service Manual instructions. On models with passenger footpeg and saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support. Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Position saddlebag relocation

V-Star 1100 Floorboard/ Foot peg Extension Kit Installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Take notice of the position of the shift peg positions relative to the floorboard or foot-peg. You will be adjusting it back to these locations upon installation of the extended linkage. 2. Loosen the shifter rod jam nuts and remove the OEM shift linkage. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Remove the jam nuts from the OEM shift linkage and thread them gently on to the new shift linkage. 7. Install the new shift linkage by aligning the control swivel and the shifter swivel and turning the linkage. Be careful not to cross thread the linkage. The linkage will thread into both swivels simultaneously. Adjust to the desired position and tighten the jam nuts that you removed from the OEM linkage. Do not over-tighten or damage will occur to the threads. Right Side Installation: 1. Take notice of the Brake pedal position relative to the floorboard/foot-peg before removal, as it will need to be readjusted upon installation of the kit. 2. Remove the cotter pin from the brake linkage and remove the clevis pin. The brake linkage will now be separate from the brake pedal assembly. Do not discard anything. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Loosen the jam nut from the brake linkage and remove the linkage bracket. 7. Assemble the threaded brake linkage extension to the coupling nut and tighten using one of the provided jam nuts. Don’t forget the thread locking compound if your using it. 8. Thread the coupling onto the brake cylinder linkage and install the other end of the assembly into the brake pedal end. Tighten the jam nuts. You should be able to adjust the linkage for proper brake pedal location before tightening the jam nuts. 9. Readjust the brake light switch and your ready to roll

Harley davidson Softail Drag Pipe Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 24-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. On FLSTN, FLSTF, FLSTH and FLSTC use a #45 Torx driver to loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heat shield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (Not necessary on 2000-up models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head. 5. Remove the bolts attaching the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models, remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. On pre 2000 models go to step #9, on 2000-up models go to step #10. 9. Remove the right passenger foot peg bolt. Position the motorcycle on the side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt, remove the bolt and stock mounting bar. Reinstall the pivot bolt and torque to 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″ x 3″ Allen bolt and 1-5/8″ length spacer (supplied).

HARLEY DAVIDSON PIVOT BOLT COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-02-2011

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This kit fits all 2004 and later XL (Sportster®) model motorcycles INSTALLATION Right-Side Pivot Bolt Cover Installation Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. See Figure 1. Start a set screw (2) from the kit into one of the pivot bolt covers (1) about two or three turns. 2. Note the position of the bottom-most flat on the rear-fork pivot hex-head bolt (3). Line up the pivot bolt cover over the bolt head so the set screw is centered on the hex flat. Use the 3/32 inch hex key from the kit to tighten the set screw securely to the head of the rear-fork pivot bolt. 3. Make sure the pivot bolt cover is clean and free of any oil or grease. Remove the protective backing from the adhesive disk on the back of the decorative insert (9). Install the decorative insert onto the end of the pivot bolt cover with the image or text upright and parallel to the ground. Press the insert firmly against the end of the pivot bolt cover and hold pressure for 30 seconds. After releasing pressure, avoid direct contact with the insert for about 20 minutes. Left-Side Pivot Bolt Cover Installation 4. Models without passenger footrests: Use an 8 mm hex key to remove the bolt (5) retaining the double-tube clamp (4). Models with passenger footrests: Use an 8 mm hex key to remove the two bolts (5) and the left-side passenger footrest and bracket assembly (6). 5. Start a set screw (2) from the kit into one of the pivot bolt covers (1) about two or three turns

2" PEG EXTENSIONS INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 23-12-2010

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* Remove the foot peg from the folding clevis base by loosening the allen bolt at the end of the foot peg, then remove the allen bolt from the peg. * Place the new longer allen bolt thru the peg and slide the smaller, male end of the peg extension onto the bolt. * Screw this assembly back into the clevis or folding part of the peg base. * Rotate the peg to the desired angle and tighten the allen bolt.

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