HARLEY DAVIDSON SPORTSTER CHOPPED FENDER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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INSTALLATION Preparation 1. Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 3. Remove the battery from the vehicle per the instructions in the service manual. 4. Raise the rear of the vehicle to relieve the load on the shock absorbers. 5. Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle. Save the fasteners for later assembly. 6. Raise the rear of the vehicle further to allow access to the underside of the rear fender. 7. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. Rear Fender Removal NOTE Note the location and orientation of rear fender mounting hardware, and save for later assembly. 1. Refer to the service manual and follow the instructions given to remove the rear fender, with the following exceptions: a. Removal of the tail lamp from the fender is not necessary. Rear Lamp Wiring 1. Cut off and discard the socket housings and terminal ends from the turn signal wires. 2. See Figure 1. Unscrew and remove the turn signal stalk (15) from one of the turn signal lamps, and discard. Remove and retain the turn signal lamp and support (14) from the rear fender support cover. 3. Insert the blade of a small screwdriver into the slot at the bottom of the turn signal lamp lens (2), and twist to unsnap the lens from the housing (1)

HARLEY DAVIDSON FLHTCUSE TOUR-PAK INSTALLATION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 26-03-2011

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INSTALLATION Prepare Motorcycle for Service 1. See the Owner’s Manual and remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 2. Remove the bolt and negative (-) battery cable from the battery. 7 6 5 4 3 1 2 is01951 1. Loading coil assembly 2. Nut 3. Lock shroud 4. Clip, locking (Sold Separately) 5. Nut 6. Screw 7. Tour-Pak lockset Figure 1. Antenna Loading Coil and Tour-Pak Lock Installation 3. Remove the bolt and positive (+) battery cable from the battery. 4. Install a Tour-Pak Rack kit (53276-04, 53118-98A or 53260-02) according to the Instruction Sheet contained in the kit. 5. For FLHX and FLTR models: Install Antenna Relocation kit according to the instruction sheet in that kit. NOTE Discard antenna mounts from antenna relocation kit and use mounts supplied with this kit. To open the Tour-Pak prior to installing the Tour-Pak lock, insert a flat head screwdriver into the lock location and turn clockwise while pulling up on the lid. 6. Install the Tour-Pak onto the Tour-Pak Rack using the hardware included in the Tour-Pak Rack kit according to Instruction Sheet included with that kit. Install Tour-Pak Components

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

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HARLEY DAVIDSON DYNA BATTERY COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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INSTALLATION 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Follow instructions in applicable Service Manual to loosen and lower battery tray. 4. Remove top and side covers and discard. 5. See Figure 1. Install cover from kit as follows: a. Align bottom of cover with tray (2) making sure that three clips on bottom properly seat (center) on both sides of retaining lip (6) at the base of the battery tray. b. Position top of cover (5) under the frame tube. 6. Raise tray and cover following instructions in Service Manual and tighten bolts (3,4) securely. 5 3 2 1 4 6 is 01648 1. Battery 2. Battery tray 3. Upper mounting bolt 4. Lower mounting bolt 5. Battery cover 6. Retaining lip Figure 1. Battery Cover and Mounting Hardware Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 7. Connect battery cables, positive cable first. 8. Install seat

HARLEY DAVIDSON PASSING LAMP/DIRECTIONAL SIGNAL RELOCATION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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INSTALLATION 1. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) NOTE There are two possible methods of connecting the directional signal wires; using the 6-place connector, or by splicing the wires using connectors supplied in the kit. If the splicing method is selected, it will not be necessary to remove the fuel tank. However, the splices will be visible. Proceed to Step 4. 3. Remove the fuel tank according to the procedure in the appropriate Service Manual. 4. See Figure 1. Remove the existing right directional signal according to the procedure in the appropriate Service Manual. Save the internal-tooth lockwasher (1) and spacer (2). 5. Place the internal-tooth lockwasher (1) and spacer (2) (saved in Step 4) on the mirror shaft, and install the mirror (3) in the mounting bracket. Secure the mirror using an internal-tooth lockwasher (4) and acorn nut (5) (both supplied in the kit). If the acorn nut (5) “bottoms” without tightening, add a spacer (6) from the kit in the location shown. 6. Repeat Steps 4 and 5 for the left directional signal.

HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. A Service Manual is needed to install this kit. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation of this kit could result in death or serious injury. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

HARLEY DAVIDSON KING TOUR-PAK WRAP AROUND LIGHT UNIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the negative battery cable (-) following the instructions in the owner’s manual. 2. Locate the two-sided template (part number 50002-01) printed on a 11 x 17 inch sheet of poster board. Cut out the template as indicated. 3. If the motorcycle is radio equipped, separate the antenna cable from terminal at antenna base. Remove the nut, lockwasher and ground ring terminal from antenna terminal. Remove phillips head screw threaded into antenna base. Remove mast and antenna base. Detach mast from antenna base by turning counterclockwise with adjustable wrench across flats. 4. See Figure 10. Shield threads of antenna terminal stud with strip of light cardboard. Remove terminal with pliers across cardboard strip. Save terminal and mast for later installation. 5. See Figure 1. Open Tour-Pak top and remove all loose contents. Remove Tour-Pak. Align the template as follows: a. Place center line template (4) along rear top edge of Tour-Pak (1) with curved end against one corner. b. Mark centerline at top edge of Tour-Pak. c. Reverse center line template and mark center with curved end against opposite corner. d. If centerlines overlap, mark center one half the distance between the two lines. e. Place a square against lip at top of Tour-Pak and draw a 3 in (76 mm) line down from the center mark

HARLEY DAVIDSON ROAD KING FAT HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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PREPARATION – ALL MODELS To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled D.O.T. 4 brake fluid. 2. See the service manual and drain the brake fluid from the front brake reservoir. ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 1. Using a T-40 TORX® drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the service manual. 3. Remove the old brake lines from the motorcycle. 4. Using a T27 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies (refer to CLUTCH CABLE in the service manual) from the stock handlebar.

HARLEY DAVIDSON VRSC TURN SIGNAL RELOCATION KIT INSTALLATION MANUAL

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

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INSTALLATION Removing Turn Signals To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Remove the 40 amp Maxi-Fuse or disconnect the battery cables, negative cable first. Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Grab the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210a) 2. For VRSCA models, remove headlamp assembly. For VRSCB models, continue to Step 4. a. While facing the headlamp from behind (looking toward front of motorcycle), reach behind the headlamp bucket and twist the headlamp bulb approximately 45 degrees counterclockwise, then gently pull straight out of the headlamp. Repeat for remaining bulb. Temporarily secure bulbs out of the way for the following steps. b. See Figure 1. Remove the two mounting screws securing the headlamp bracket to the upper triple clamp and remove headlamp assembly. Save hard- ware

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the owner’s manual and follow the instructions given to disarm the security system and remove the left- side cover. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Refer to the owner’s manual and follow the instructions given to remove the main fuse. ALL models: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 3. Refer to the owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 4. Remove the battery from the vehicle. 2 1 3 4 is 01377 1. Three-pin connector on siren harness 2. Three-pin connector [142B] on vehicle harness 3. Siren harness 4. Frame rear crossmember (not visible) Figure 1. Connect the Siren Harness to the Vehicle Harness 5. See Figure 1. Locate the siren connector (2) on the main harness, behind the harness shield forward of the battery location. It is covered by a dust cap. Pull the dust cap from the connector, and feed the connector downward and out from behind the shield. 6. Select the correct siren harness (3) for this model year vehicle from the kit. Route the three-pin connector (1) of the siren harness from the bottom of the motorcycle, between the primary cover and frame tube. Plug the connector into the siren harness connector (2) on the vehicle main harness. 7. Secure the connectors to the diagnostic harness using a cable strap from the kit. Route the long lead of the siren harness over the frame rear crossmember