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HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON TOUR-PAK KIT INTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Remove the rubber mat from the bottom of the Tour-Pak. 2. See Figure 1 and Table 1 to determine the proper hole configuration to attach the Tour-Pak to your luggage rack. Holes will be drilled as explained in Step 3 in the hole location for your luggage rack. Table 1. Luggage Rack and Hole Configurations Hole Configura- tion Luggage Rack C (3 holes) Stock 1997 B (4 holes) Detachable luggage rack 53107-96 A (5 holes) Luggage rack 53118-97A and luggage rack 53118-98 A (5 holes) Stock 1998 and later racks A (5 holes) Detachable Tour-Pak rack 53276-04 B (4 holes) Solo detachable Tour-Pak rack 53655-04 B (4 holes) Detachable Tour-Pak rack 53066-00B B (4 holes) Solo detachable Tour-Pak rack 53559-04A A (5 holes) Solo detachable Tour-Pak rack 53260-02 -J03631 1 of 3 B 1 A C 2 2 2 is00163 1. Front of motorcycle 2. Bottom view of Tour-Pak interior (rubber mat removed) Figure 1. Hole configurations for Tour-Pak attachment NOTE Drilling holes in Tour-Pak without wood underneath each hole site may result in the leather becoming damaged during the drilling process. 3. Place blocks of wood underneath the Tour-Pak where the holes will be drilled to prevent damage to the leather while drilling. Use the pre-drilled holes in the metal base as a guide and carefully drill the holes through the leather in the proper location using a 11/32 inch drill bit. 4. See Figure 2. For detachable luggage racks (53107- 96, 53066-00B and 53276-04): Install black cover tube to the front bar (1) of the luggage rack, as shown. This tube is used to provide a cleaner look. The black cover tube is not for use with other luggage racks. 5. Attach Tour-Pak to rack using the mounting screws provided in the Luggage Rack kit. Put bolt through from inside of Tour-Pak. Tighten screws to specifications found in the Luggage Rack kit. 6. Place the black rubber mat on the bottom of the Tour-Pak. 7. If luggage rack was removed, reattach to motorcycle according to kit instructions or Service Manual instructions

HARLEY DAVIDSON SOFTAIL DETACHABLE TWO-UP TOUR-PAK LUGGAGE RACK INSTALLATION MANUAL

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

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TOUR-PAK LUGGAGE INSTALLATION TO RACK 1. Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage.  Remove the rubber mat from the luggage floor. 2. If holes ARE NOT pre-drilled in the floor of the luggage,       see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites.  Use the four inboard holes (3) in the metal base of the luggage (2) as a guide, and carefully drill four 11/32 inch (9 mm)  holes through the floor of the luggage. 1 2 3 is04249 1. Front of motorcycle 2. Tour-Pak 3. Drill four 11/32 inch (9 mm) diameter holes Figure 1.  Drill Attachment Hole Locations in Tour-Pak NOTE See Figure 3. When installing the luggage to the rack in the following steps, note that holes in the luggage rack (2) provide forward (A) and rearward (B) positions for mounting the lug- gage. 3. Place the luggage on the luggage rack.  Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. 4. ALL applications: Obtain the hex head cap screws (9), lock nuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw, and insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage.  If the screws are installed from the bottom, the screw ends can tear the rubber mat and scratch objects, such as helmets, stored inside the luggage. 5. From the underside of the rack, install a washer and lock nut onto the threads of each screw.  In a crosswise pattern, incrementally tighten each screw to 19 ft-lbs (25 Nm) . 6. Install the rubber mat into the luggage.  Close and latch the lid. 7. If not already in place, install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit

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PASSENGER FLOORBOARD RELOCATION ARMS FOR TRIUMPH AMERICA AND SPEEDMASTER

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Filed Under (Triumph) by admin on 25-12-2010

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1. If you are installing the relocation arms at the same time as floorboards install the floorboards first per their instructions. When installing the relocation arms with floorboards already installed proceed as follows. 2. Starting on the left side, fold the floorboard up. Remove the socket head bolt and nut which secures the floorboard to the motorcycles stock peg support and remove the floorboard taking notice of which holes the dowel pins are located in. 3. Install one of the 5/16″x1 Ω” hex bolts supplied thru the stock peg support from the backside (The threads of the bolt will face out towards you.) Place the two dowel pins into the holes at one o’clock and seven o’clock on the stock peg mount. Place the spacer blocks backside (stamped with an “L”) onto the bolt and align the hole with the pins. 4. Locate the relocation arm that has an “L” stamped on the backside of it. Place two of the supplied dowel pins into one of the two sets of the holes in the arm that are directly across from one another (180 degrees apart). Place the arm onto the spacer bock aligning the pins in the arm with the holes closest to six and twelve o’clock. Depending on which of the two sets of holes on the arm you chose the arm would, either be down at about seven o’clock or just below nine o’clock. These are the initial height settings and you may select which ever set is most comfortable for the passenger. Install one of the acorn nuts supplied onto the bolt and make finger tight. 5. Place the floorboard with its two dowel pins into the set of holes at the other end of the relocation arm that allows the floorboard to be horizontal or parallel to the ground. Use one of the 5/16″x3/4″ socket head bolts supplied to bolt the floorboard to the relocation arm and make finger tight. 6. Install the right side in the same manner, place the dowel pins in the holes at eleven o’clock and at five o’clock on the stock peg mount, then the spacer blocks backside (stamped “R”) onto the pins followed by the relocation arm with two dowel pins in one set of holes (180 degrees apart). Check to see that the right arm is at the same height or position as the left then install the acorn nut finger tight. Bolt the floorboard the other end of the arm using the remaining dowel pins and socket head bolt. Tighten the two bolts with the acorn nuts and the two socket head bolts securely

YAMAHA ROADLINER AND STRATOLINER PASSENGER FLOOBOARD RELOCATION ARMS

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Filed Under (Yamaha) by admin on 23-12-2010

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1. When installing floorboards at the same time first refer to their instructions and using the longer right side black floorboards mounting block supplied with this set of relocation arms. Leave the final floorboards mounting bolt installed loosely at this time. 2. If installing the relocation arms after installing the floorboards at an earlier date proceed as follows. 3. On the left side remove the Allen screw below the floorboards pivot and remove the floorboard from the black mounting block. Remove the dowel pins from their holes on the block. Locate the left relocation arm (stamped “L” and “R” on their backsides). On the end with the clearance hole (not threaded) Place the two dowel pins into one of the two sets of holes which are directly across from each other (180 degrees apart). Hold the arm with the dowel pins up to the mounting block. Align the dowel pins with each of the three sets of holes in the block one at a time noting the height of the opposite end of the arm where the floorboard will mount. Move the dowel pins to the other set of holes on the arm and again hold the arm with the dowel pins up to the blocks three sets of holes. Choose the set of holes in both the block and arm which will set the floorboard to the desired height and place the arm with the dowel pins onto the block. Using one of the button head Allen screws supplied bolt the arm to the block and tighten securely. 4. Locate two of the dowel pins supplied and one of the Allen screw removed earlier. Place the dowel pins into the holes of the arm which allow the floorboard to be level or parallel to the ground. Place a drop of loctite on the threads of the screw and tighten securely. Install the right floorboard in the same manner. 5. On the right side remove the floorboard from the mounting block. Remove the mounting block and replace it with the longer one supplied. Install the right arm in the same manner as the left using the set of dowel pin holes to match the height or angle of the left arm. Install the right floorboard and tighten securely. Recheck all fasteners for tightness.

HARLEY DAVIDSON CHROME SADDLEBAG LID TRIM KIT INSTALLATION INSTRUCTIONS

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

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

HARLEY DAVIDSON VRSCF LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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REMOVAL 1. See Figure 1. Remove four rear fender mounting bolts (1) and washers (2). If necessary, move the ECM to access the four fender mounting bolts. 2. Disconnect the tail lamp following the instructions in the appropriate service manual. 1 2 is05463 1. Bolt (4) 2. Washer (4) Figure 1. Fender Mounting Bolts INSTALLATION NOTE There are bosses molded into the inside of the fender to use as the hole drilling templates. 1. See Figure 2. Apply masking tape to the outside painted surface of the fender at the three hole locations (1 and 2). This will protect the painted surface during the drilling operation. 2. Put the fender on a work bench, painted surface down. Use clean, soft cloth between the fender and the work bench to protect the paint finish. NOTES Drilling each hole in the fender is a two-step procedure that requires a specific type of drill bit to avoid damaging the fender. 3. See Figure 2. Use a 1/2-inch spade bit or 1/2-inch unibit (do not use a spiral-type drill bit) to drill three holes from the inside of the fender through the three pilot hole bosses (1 and 2). Stop drilling when the tip of the bit just pierces the outside surface of the fender. 4. Turn the fender over so the painted surface is now facing up. Complete each hole by using the same 1/2-inch drill bit at each of the pierced holes. Clean excess material from the holes and clean the fender surface of any debris. 5. See Figure 5. Remove the masking tape from the holes and apply the protective tape (3) to the painted surface using the drilled holes for alignment. 6. See Figure 3. Put the luggage rack (1) upside down on the work bench and align the holes in the luggage rack with the holes in the fender (2).

HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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LED Motorcycle Power Box Installation Instructions

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Filed Under (Tips and Review) by admin on 29-01-2011

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This box requires the presence of a mounting plate secured to the motorcycle’s luggage rack. If the bike in question is not equipped with a mounting plate, one must be fabricated prior to installation of this box. Five mounting holes (.281″ dia.) are required to mount this box. If the motorcycle is already equipped with a mounting plate, it may be necessary to drill the 5 mounting holes required for this installation. Use the diagram shown to determine the precise location of these holes. 1. Position the box onto the mounting plate. Align the 5 vibration dampeners with the 5 mounting holes in the mounting plate. 2. Using the illustrations shown, secure the box to the mounting plate using the provided hardware. Note: Your luggage rack may already have the correct mounting holes drilled. Check the measurements below and if these holes already exist at the proper distance, remove any existing mounting hardware from the holes and secure the box with the supplied mounting hardware. 3. Place the box into its mounting position on the deck and secure it with the supplied mounting hardware as shown in the diagram. Wiring: Diagrams for optional equipment are found below. Refer to the diagram on the following page for general motorcycle box wiring information

1994 HARLEY DAVIDSON FXD (DYNA) PASSENGER FLOOR BOARDS AND RELOCATION ARMS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-04-2012

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1. Beginning on the RIGHT side, use a 9/16″ wrench to remove the bolt from the back of the passenger peg mount. Remove entire peg assembly. 2. Remove the new floorboards and mounts from their packaging. Notice the Left and Right markings on the backside of the floorboard mounting plates. 3. Install the supplied Right floorboard support (the longer one) with the round mounting face for the floorboard towards the upper-right using the supplied 7/16 x 1 º” long bolt. Apply blue Loctite to the threads. Insert the bolt from the backside where the original peg was mounted. Use a 5/8″ wrench & tighten securely. Note: If also installing with optional Relocation Arms (#FXD005-5) skip step 4 and go onto step 5. 4. Installation of Right Floorboard only. There are two sets of alignment holes on the floorboard support. Insert two of the four dowel-pins into the dowel pinholes at six and twelve o’clock. Place the right floorboard onto the mount and dowel pins so that it is parallel (horizontal) to the ground. Insert the supplied 5/16 X 1″ socket head cap screw through the floorboard mount & thread into the floorboard support. Use a º” hex key wrench & tighten securely. 5. Remove Right Floorboard – Installation of Right Floorboard with Relocation Arm. There are two sets of alignment holes on the floorboard support. Insert two of the four dowel pins into the dowel holes 180 degrees apart. Notice the L & R markings on the backside of the relocation arms. Install the Right relocation arm so marking (R) is facing inward and the threaded hole is facing toward the front of the motorcycle. There are two sets of alignment holes on the relocation arms. Place the arm onto the mount (Match dowel pin holes) in desired upper or lower position. Insert the supplied 5/16 X 1″ socket head cap screw through the relocation arm & thread into the floorboard support. Use a º” hex key wrench & tighten securely. 6. At the other end of the relocation arm there are two sets of alignment holes. Insert two of the supplied dowel pins into the set of dowel pin holes 180 degrees apart that will allow the floorboard to be horizontal or parallel to the ground. Insert the supplied 5/16 X 3/4″ socket head cap screw through the floorboard mount & thread into the link arm. Use a º” hex key wrench & tighten securely.

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