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HARLEY DAVIDSON XL SEAT KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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

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1 2 is 00911 1. Tongue 2. Keyhole Figure 2. Underside of 2-up seat INSTALLATION NOTE If installing the seat with a sissybar/backrest pad present, remove the backrest pad prior to seat installation. This will prevent damage to the pad and/or seat. Reinstall backrest pad after the seat is installed. 1. Models equipped with solo seats: See Figure 1. a. Remove the plastic plug (1) from the rear hole location in the fender (2). Save the plastic plug for installation. b. Move the seat retention nut (4) and lockwasher (5) from the middle location to the rear location, where the plug was just removed. As shown in the inset, a cable strap (6) can be used as an installation aid. Place the retention nut (5) over the cable strap so that the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender, and through the fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. c. With the rib of the retention nut (4) seated into the notch in the fender hole, slide the retension washer (5) into place from the rear. This will lock the retention nut in place. d. Reinstall the plastic plug in the fender hole in the middle location. NOTE The foam cushioning of the seat needs to be compressed as the seat is slid forward to engage the post on the frame when the seat is dropped into place. When properly installed, the front tongue on the underside of the seat should fit snugly in the groove at the fuel tank rear mounting location and the keyhole on the underside of the seat will lock the seat to the post on the frame. 2. All models: See Figure 2. a. Angle the front of the new seat into place so the tongue (1) engages the slot at the rear fuel tank mounting location. b. Push the seat forward and rotate the rear of the seat downward until the seat contacts the frame. Flex the seat slightly in the middle and slide the seat towards the rear so that the keyhole slot (2) on the seat bottom engages with the center seat post on the frame. 3. See Figure 3. Pull up on the center of the seat to verify that it is locked into place. (There will be a small amount of play, but the seat should only come up about a half an inch and then will be held firmly in place by the post on the underside of the seat.) If the seat is not firmly in place, repeat Step 2 until the seat is firmly in place. Reference the Owners Manual for further instruction on seat placement if needed

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HARLEY DAVIDSON FXD SOLO SADDLE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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Removal of Stock Seat 1. Remove screw (6) to detach rear seat mounting bracket (9) from fender. 1996 models will have a nylon washer under the bracket that should also be saved for installation of new seat. 2. Slide seat rearward to unhook front of seat from frame, then pull seat forward out of passenger strap. 3. Remove two capscrews (10) that attach seat mounting bracket to bottom of stock seat. Install original seat mounting bracket to bottom of new solo saddle with original capscrews. Tighten capscrews securely. 4. Remove nut (7) and washer (8) that hold passenger strap (11) in place and remove strap. Installation of Kit Seat This seat is for solo driver use only. Do not attempt to carry a passenger with this solo seat installed. Use of a luggage rack, fender, or tail section as an additional seat may result in death or serious injury. NOTE When a solo seat is installed without a passenger seat, the passenger footpegs or footboards and the passenger grabstrap must be removed. For 1996 models: 1. Slide seat into position until front seat tab engages frame, then place original nylon washer under hole in rear seat mounting bracket and secure bracket to fender with screw (6). NOTE For 1997 models, a retention nut and washer must be installed into the fender hole, covered with a plastic cap, where the rear seat bracket will be attached. A cable strap is included to aid in this installation. For 1997 models: 1. Remove plastic cap from hole in fender where the rear seat bracket will be attached. 2. Place retention nut (3) over cable strap (2) so wide end of nut rests on eye of cable strap. Thread cable strap up under fender and through fender hole. Pull up on cable strap to hold nut snug against underside of fender. 3. With rib on retention nut seated into notch in fender hole, slide retention washer (4) into place from the rear. This will lock the retention nut in place. 4. Slide seat into position until front seat tab engages frame, then secure rear seat bracket to fender with screw (6). Install chrome cap (5) in rear retention nut

HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY DAVIDSON FXSTD PASSENGER BACKREST AND LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) INSTALLATION Passenger Upright 1. Unscrew the captive screw fastening the seat rear bracket to the fender. 2. Remove the rubber plugs from the three holes in the rear fender where the passenger upright installs. 3. See Figure 2. Fasten the studplate (2) to the fender (A) with the backing plate (3) and three flange locknuts (4). 4. See Figure 1. Fasten the passenger upright (3) to the studplate (1) with three flange locknuts (2). 5. Insert the seat front bracket into the frame, then fasten the seat rear bracket to the fender. NOTE The seat must be temporarily bowed up in the center to fit the seat rear bracket through the slot in the passenger upright. 6. Kit 51144-02 only. See Figure 2. Carefully clean the lower hole (B) on the passenger upright (1) with isopropyl alcohol to remove any grease or dirt. Remove backing from adhesive emblem (5) and press the emblem firmly in to place. 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) 1 4 3 2 is03890 1. Stud plate 2. Locknut, flange (3) 3. Passenger upright 4. Backrest pad Figure 1. Passenger Upright, Backrest Pad and Luggage Rack Installation NOTE When temporarily removing the passenger upright, the mounting and backing plates may be left in place to simplify passenger-upright re-installation. Thread the flange nuts back onto studs to store the nuts. 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) Backrest Pad See Figure 2. Fasten the backrest pad (7) to the passenger upright (1) using the button-head screw (6) as shown. Luggage Rack NOTE See Figure 2. Fasten the luggage rack (8) to the backrest with the backrest pad (7) removed from the studplate (2). -Fasten the luggage rack (8) to the passenger upr ight (1) using the luggage-rack mounting plate (11), button-head screw (12)

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HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

Yamaha XVS 650 SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 07-11-2010

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Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 1. Brake lever INSTRUMENT AND CONTROL FUNCTIONS 3 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. WARNING Make sure that the fuel tank cap is properly installed before riding. knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. INSTRUMENT AND CONTROL FUNCTIONS 3 ON With the fuel cock lever in this position, fuel flows to the carburetors. Turn the fuel cock lever to this position when starting the engine and riding. RES 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” Seats (XVS650) Passenger seat To remove the passenger seat Remove the nut, and then pull the passenger seat up. To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown, place the seat in the original position, and then install the nut. 1. Nut INSTRUMENT AND CONTROL FUNCTIONS 3 Seats (XVS650A/AT) Passenger seat To remove the passenger seat Remove the bolt, and then pull the passenger seat up. To install the passenger seat Insert the projections on the front of the passenger seat into the holders as shown, place the seat in the original position, and then install the bolt. 1. Bolt Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key

HARLEY DAVIDSON DYNA PASSENGER PILLION SEAT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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REMOVE SEAT NOTE When performing the following installation procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove screw to detach rear seat mounting bracket from fender. 2. Remove two capscrews that attach seat mounting bracket to bottom of stock seat. 3. Remove the existing seat from the motorcycle. Save the seat bracket and mounting screws for installation of the new seat. 4. If motorcycle has a grabstrap installed, remove nut and washer that holds passenger strap in place and remove strap. 5. See Figure 1. Remove the plastic cap from rearmost fender hole (3). 6. Remove the seat retention nut and washer from the solo seat mounting hole. 7. See Figure 2. A cable strap may be used as an installation aid to remove and reinstall the retention nut and washer. Place the retention nut (1) over the cable strap (3) so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the rearmost fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. 8. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear. This will lock the retention nut in place. Remove the cable strap. 2 5 1 2 1 3 6 7 4 is00363 1. Retention nut and washer (2-up seat positon) 2. Retention nut and washer (solo seat position) 3. Rear-most fender hole 4. Middle fender hole 5. Grabstrap mounting hole 6. Flange screw 7. Plastic retention nut

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

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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 SIGNATURE SERIES SOLO SEAT KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTE Refer to owner’s manual or service manual for seat removal instructions for your model. 1. Remove right and left saddlebags according to the instructions in the service manual. Save saddlebag mounting brackets and hardware. 2. Remove passenger seat strap. Discard passenger seat strap. 3. Remove existing seat from vehicle. 4. See Figure 1. Remove and discard stock nuts (2) from studs (1) on rear fender (3). INSTALLATION Install Rider Seat 1. Push front seat on frame with mounting bracket at rear. 2. Firmly push front of seat downward and rearward until frame tongue engages slot in seat. 3. Push seat forward until studs are centered in slots of mounting bracket. 4. See Figure 4. Install two nuts (4) on studs to secure rear seat mounting bracket to rear fender. Alternately tighten nuts to 60-96 in-lbs (6.8-10.9 Nm). 5. If installing a new passenger seat, refer to the instructions included with the kit. 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) 6. If installing passenger seat, install passenger seat strap following the instructions in the service manual. 7. Install right and left side saddlebags following the instructions in the service manual. 1 2 3 2 1 is04121 1. Stud (2) 2. Nut (2) 3. Rear fender Figure 1. Rear Fender Install Rider Backrest NOTE Flaps shown removed for clarity of illustration. 1. See Figure 2. Turn backrest assembly (1) at a 45 degree angle clockwise to the seat. Slide the backrest shaft (2) through the flaps and into the receptacle in the seat. 2. While pushing down on the backrest assembly, twist the backrest counterclockwise until the shaft hits the stop. 3. Verify that the backrest assembly is locked in place by pulling up in the backrest pad

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