2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

HARLEY DAVIDSON TOURING DETACHABLE SISSY BAR UPRIGHTS INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE The Detachable Sissy Bar Upright can be installed on either a two-point or four-point Docking Kit. 1. If not already in place, install the Detachable Docking Hardware Kit (either two-point or four-point) to the vehicle per the instructions in that kit. 2. See Figure 2. While standing behind the motorcycle, place the left-side and right-side front upright notches (with bushings in place) onto the docking points (A) inboard of the upper shock absorber mounts. Make sure the notch bushings (9) seat fully into the shock absorber docking points. 3. See Figure 2, arrows (D) and (E), and Figure 1. Position the rotary latches (4) over the rear docking points (3). Check to be sure the upright sides (1) and latches fit into the neck (7) of the rear docking points as shown. This may require some gentle squeezing or spreading of the sissy bar upright sides. NOTE After installing the sissy bar upright, check to be sure the sissy bar is secure. The front and rear docking points must be fully engaged. See Figure 1 for correct engagement. 4. Push the rear of the sissy bar downward and close the latches by pressing the latch lever as far forward as it will go. You will hear a “CLICK” when the latch is in place. If the latch does not easily close, do not force. Check the sissy bar alignment again, as described in steps 2 and 3. 5. To remove the sissy bar upright, press the release button (G) on each side and pull the latch levers back. Carefully lift the rear of the sissy bar up and pull the upright out of the front docking points

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