HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

Harley Davidson Softail Motorcycles EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Softail EZ-Steer Instruction Supplement Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Harley Davidson Softail Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Installation Notes • Note the torque specifications for the items listed below. Item # Description (Qty) Torque Spec. (Lb.Ft.) N/A OEM Steering Stem Bolt (1) 35 7 7/16-20 x 1.5 Socket Head Cap Screw (2) 45 • The supplied fork tube extensions (Item #2) must be used with the Champion EZ-Steer system. • Do not torque the steering stem bolt until fork tubes have been installed to the assembly. • Remove O-rings from OEM fork tube ends and install to Champion fork tube extensions (Item #2) prior to installation onto fork tubes. • The supplied fork tube covers (Item #9) must be installed to lower triple clamp prior to installation of fork tubes. WARNING: If the Champion EZ-Steer system is installed on a motorcycle / sidecar combination and the sidecar is removed, the motorcycle is not safe to ride, and OEM triple clamps should be replaced.

Honda VTX1800F Left/ Right Floor Board Assembly Installation Manual

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Filed Under (Honda) by admin on 14-11-2010

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1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

Victory Vegas Rear LED Turn Signal Assembly Installation Manual

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Filed Under (Victory) by admin on 31-10-2010

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Step 1 •Prior to installation it is recommended that you perform a Pre-Function check. To do so, remove the left side battery cover from the bike and expose the post terminals. Hold the positive red lead from the turn signal to the positive red lead of the battery and then place the negative black lead from the turn signal to the negative black lead of the battery. Do one side at a time and ensure that both sides light prior to installation. Step 2 •Remove seat (passenger too if installed) •Remove fender “eyelashes” (required first if passenger seat is installed) •Remove the fender mounting bolts •Disconnect the rear turn signal and taillight harness connector located in the battery box compartment •Remove the fender by gentle prying outward and upward on one side to clear the mounting points, then the other side •Set aside on a flat and smooth surface to protect the fender’s finish (you may want to wrap it in a large towel) Step 3 •Turn the rear fender assembly upside down on a stable and covered/protected surface to prevent damaging the fender/paint •Remove the rear tail assembly and disconnect the wiring harness and license plate light. THIS PART IS NO LONGER NEEDED! Victory Vegas Rear LED Turn Signal Assembly Installation Guide •Remove the stock metal spacers shown below and replace them with the ¼” rubber spacers included in your accessory/installation kit. Step 4 •Place the turn signal assembly mounting arms over the rubber spacers. Align the turn signal in place so the space between the fender and the turn signal tube is consistent. After completing this step, place a small amount of Loc-Tite to the bolt and slowly tighten the stock nuts snugly in place, (extreme over-tightening may damage turn signal or fender lip). You should not need to loosen the mounting arms which are attached to the turn signal bracket to obtain the ideal fit; they are pre-assembled to be aligned. Please also note that due to manufacturing tolerances in the production of the fender, the rolled inner lip of it may interfere with the turn signal assembly seating properly. If this is the case, the lip can be tapped down flush with a rubber mallet or other appropriate tool. Take the necessary precautions to maintain your fender’s finish should this step be necessary. Step 5 •Run the wiring of the turn signal assembly in an appropriate/desireable path to the stock wiring harness. See picture below as an example. Once the wires are run, cut any excess wire and install the bullet connectors (included in the installation/accessory package) to the end of the wires. Due to the small gauge of the wire it’s suggested that you double it over before placing it into the bullet connector and solder it in place. Wire as follows:

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