HARLEY DAVIDSON WINDSHIELD MOUNTING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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This kit contains the following items: ITEMDESCRIPTION/ QUANTITY PART NO. 1 Stud, double ended, 5/16-18 (4) 3265A 2 Bushing (4) 67621-94 3 Acorn nut, keps, 5/16-18 (Chrome) (4) 7992 Installation 1. Using a T-40 TORX drive head, remove the upper left- side chrome button-head fork screw and chrome flat washer and discard. 2. See Figure 1. Obtain a double-ended stud (1) and chrome acorn nut (3) from the kit. Thread the nut onto the NON lock patch side of the stud and hand tighten. NOTE Position the clamp so the clutch cable is to the rear of the stud. 3. Slide the clutch cable clamp (4), along with the cable, into position on the stud as shown. Assemble a bushing (2) from the kit onto the stud threads. 4. Insert the lock patch side of the stud through the headlamp nacelle and into the upper fork bracket. Tighten the acorn nut and stud to 15-20 ft – lbs (20-27 Nm). 5. Continue, one at a time, replacing the three remaining chrome button-head fork screws and flat washers with the studs, bushings and chrome acorn nuts from the kit. Tighten to 15-20 ft – lbs (20-27 Nm)

HARLEY DAVIDSON DYNA DOCKING HARDWARE FOR FXDX WITH WIDE TIRE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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Installation NOTE Perform the following procedures on one side of the motorcycle until instructed to go to the other side. To keep fender in alignment the front docking point will be mounted first. INSTALLING DOCKING POINTS NOTE Save the acorn nuts and washers removed from the fender support bracket for use when installating docking points. 1. Loosen and remove the acorn nuts, washers, and screws from the fender support (right-hand) bracket. Save the washers and acorn nuts for docking point installation. Discard screws. 2. Obtain 1 plastic bushing, labeled 01, from a bushing set. 3. Place the bushing (4) (beveled side out) into the front support hole as shown in Service Parts illustration. 4. Place the countersunk side of the front docking point (2) so that it engages bushing (4). 5. From underneath (inside) the fender, insert hex-head screw (1) through fender, support bracket and front docking point (2). 6. Install washer (7) split lockwasher (5) and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 7. Obtain another plastic bushing, labeled 01 , from the bushing set. 8. Place bushing (4) (beveled side out) into the the rear support hole as shown in Service Parts illustration. 9. Place the countersunk side of the rear docking point (3) so that it engages bushing (4). 10. From underneath (inside) the fender, insert hex-head screw through fender, support bracket and rear docking point (3). 11. Install washer (7) split lockwasher (5)and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 12. Repeat procedures 1 through 11 for opposite (left-hand) side of the motorcycle. NOTE In time docking points may wear, causing the sideplates to become loose. The fit may be tightened using the following procedure. 1. Loosen docking hardware. 2. Rotate docking points clockwise approximately 45°. 3. Tighten docking hardware to the appropriate torque values. Repeat as often as required, up to 3 times

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HARLEY DAVIDSON BOOM! AUDIO BASS BOOSTER TOUR-PAK PORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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PREPARATION NOTE For vehicles equipped with security siren: • Verify that the Hands-Free Fob is present. • Turn the ignition key switch to IGNITION. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the owner’s manual and follow the instructions to remove the main fuse. INSTALLATION NOTE The Tour-Pak does not need to be removed from the vehicle to perform this installation. 1. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 2. Models equipped with mat: Remove the mat. Models equipped with liner: Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. 3. Remove four screws from the left-side speaker grille on the Tour-Pak. Remove the speaker grille from the speaker pod. 4. Remove the speaker from the speaker pod. Carefully pull the two socket terminals from the speaker spade contacts. 5. Remove the grommet, and draw the rear speaker/passenger controls connector out of the speaker pod. Separate the connector halves. 6. Repeat Steps 3 through 5 for the right-side speaker. 7. See Figure 1. Get the drill template (3) from the kit. If NOT equipped with power port: a. Remove one speaker pod mounting screw and flat washer. b. Align the drill template on the inside of the Tour-Pak with the speaker pod holes, and hold in place with the mounting screw and washer. c. Repeat for the remaining template mounting holes. If equipped with power port: a. Remove the two screws and flat washers to free the power port from the Tour-Pak. b. Align the drill template on the inside of the Tour-Pak with the power port holes, and hold in place with the mounting screws and washers. c. Repeat with the top speaker pod mounting screw and flat washer. NOTE Tighten the screws enough to hold the speaker pod in place as the pilot hole is drilled. 8. Where indicated on the template, drill a 3/16 inch (5 mm) diameter pilot hole through the Tour-Pak wall and speaker pod. 9. Remove the screws and speaker pod, and set aside. Turn the template over, and repeat Steps 7 and 8 on the left side of the Tour-Pak. NOTE Hole size will affect the fitment of the ports. The hole saw needs to be sharp. 10. Carefully drill a two inch (51 mm) diameter hole with a sharp hole saw, at the pilot location, through each speaker pod and in both locations on the Tour-Pak wall. 11. Temporarily install the Tour-Pak liner (if equipped), and mark the location of the two inch (51 mm) diameter holes on the outside of the liner. Remove the liner, and carefully cut the two holes in the liner front wall

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HARLEY DAVIDSON SHORT CB ANTENNA MAST REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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Additional Parts Required 1998 through 2008 models require use of the original equipment (OE) load coil. 2009 and later models DO NOT require use of a load coil. Kit Contents There are no service parts available with this kit. INSTALLATION 1. 2008 and earlier models: Use a 2 mm hex key to loosen the bottom set screw of the antenna mast. ALL models: Unscrew the antenna mast from the antenna base. 2. Thread the new antenna mast onto the threads of the antenna base. IN SERVICE 2008 and earlier models: If a degradation of CB performance is detected: 1. Open the Tour-Pak. 2. Open the map pocket (if present), and remove the acorn nuts with flat washers. Remove the map pocket and molded liner from the Tour-Pak. 3. Check the routing of the load coil wiring (see Figure 2). Wire routing other than as shown can cause a degradation of the CB signal

HARLEY DAVIDSON V-LOGO TURN SIGNAL INDICATOR FORROAD KING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1. Disconnect battery cables, negative cable first. 2. Following instructions in applicable Service Manual, remove the windshield. 3. Remove the phillips screw at the bottom of the of the headlamp door (chrome ring). Remove the headlamp door. 4. Remove the seven Phillips screws to free the headlamp housing from the headlamp nacelle. 5. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside. 6. See Figure 1. Reaching inside the headlamp nacelle, remove the speed nut to release the chrome strip at the top of the nacelle. 7. Remove the wire form clip holding the halves of the nacelle together at the bottom. 8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate. 9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove). 10. Loosen the two acorn nuts from the left and right side fork studs. 11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle. 12. Carefully align the template over the handlebar shroud cover and tape into place. 13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means. 14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure. 15. Drill one 1/4″ hole and two 5/32″ holes as indicated on the Drill Template (attached)

HARLEY DAVIDSON ULTRA TOUR-PAK BRAKE LAMP CHROME ACCENT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation- Corner Brake Lamp Trim 1. Carefully cut out brake lamp trim template (1) attached to this instruction sheet. 2. Position template (1) on plastic brake housing (2) as shown in Figure 2. 3. Using a punch, score two points indicated on template to mark mounting hole locations (3) on plastic brake housing (2). 4. Using a 1/8 in. drill bit, drill a pilot hole in plastic housing. 5. Use a 7/32 in. drill bit to drill through housing and fiberglass Tour-Pak. 6. See Figure 3. Insert studs on chrome brake lamp trim piece through holes drilled in plastic housing and Tour- Pak. Using two flatwashers (1), two lockwashers (2) and two acorn nuts (3) from kit, secure trim piece to Tour- Pak. Tighten finger tight. 7. See Figure 3. Locate brake lamp retaining clip (4) on inside of Tour-Pak and remove. Save clip (4) for later reinstallation. 8. Form chrome trim around corner of Tour-Pak, so that it is positioned around plastic housing evenly. While holding chrome trim in position, mark forward mounting hole position on Tour-Pak using a punch

HARLEY DAVIDSON SPLIT VISION MIRROR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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These kits are designed to fit all 1982 and later Harley- Davidson motorcycles. Kit Contents See Figure 1 and Table 1. INSTALLATION 1. Remove and discard the existing mirror. Discard any lockwashers and acorn nuts used to mount the original mirror. 2. For motorcycles with turn signals mounted to the underside of the hand lever housings except 2004 and later XL models: See Figure 1. Secure the left side mirror using only the flat washer (3) and the acorn nut (5) from the kit. 3. Secure the right side mirror with the flat washer (3) and acorn nut (5) from the kit and the turn signal retainer only. Do not use washer (4) on either side. For 2004 and later XL models use only the lockwasher (4), and acorn nut (5) on each side. 4. For motorcycles with turn signals mounted away from the hand lever housings: Insert the mirror studs into the holes in the hand lever housings, and secure the mirrors with the flat washers (3), lockwashers (4) and acorn nuts (5) from the kit. 5. Adjust the mirrors for proper field of vision and tighten the acorn nut to 12 ft-lbs (16 Nm). Check mirror adjustment and reposition if necessary

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 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 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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