2007 KTM EXC LED Taillight and Turn Signal Kit Installation Instructions

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Filed Under (KTM) by admin on 31-01-2012

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Remove the seat & fuel tank. Photo 1 Unplug 2. Unplug the two three-pin connectors that mate the taillight & turn signal power leads to the stock wiring harness on top of the airbox. See Photo 1. 3. Unbolt and remove the stock taillight & rear turn signal assembly from the rear fender. The wires & connectors will pull through the gap in the fender/airbox plastic with a little finesse. 4. Unplug the two small white plastic connectors near the upper edge of the stock taillight lens and separate the wire extension from the taillight. See Photo 2. Photo 2 Unplug these two connectors and remove wire extension Photo 3 Remove 5. Using a sharp blade or cut-off wheel, remove the two molded mounting bosses on the bottom of the fender. See Photo 3. 6. Attach the new LED taillight to the fender as shown using the provided countersunk mounting hardware. Use the two longer bolts for the front mounts. The LED cluster should not protrude beyond the edge of the fender

HARLEY DAVIDSON "LIVE TO RIDE" HANDLEBAR GRIPS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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installation Do not lubricate the left grip of handlebar in any way before installation. This could allow grip to come off while riding which could result in loss of control of vehicle and death or serious injury. 1. Remove existing left handlebar grip by carefully cutting it away from the handlebar using a sharp blade or knife. Remove right grip/throttle sleeve assembly following instructions in appropriate Service Manual. After removal, make sure that left and right handlebar ends are clean and smooth. 2. Check that end caps are securely fastened to grips. Tighten screw inside grip to secure end caps. 3. Assemble new throttle sleeve to handlebar. Refer to appropriate Service Manual for detailed procedure. NOTE Surfaces to be glued must be clean, dry, and free from oil. If surfaces are not clean, dry, and free from oil, then the new application may not adhere as desired. Please observe the following WARNINGS when using the adhesive contained in this kit. FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWALLOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS METHYL ETHYL KETONE. Use only in well ventilated areas. Avoid contact with eyes, mucous membranes, and prolonged skin contact. KEEP OUT OF REACH OF CHILDREN. If swallowed, do not induce vomiting. Call a physician immediately. This product contains a chemical(s) known to the State of California to cause cancer, birth defects or other reproductive harm. 4. Liberally apply a coating of Harley-Davidson Adhesive (Part No. 99839-95) to the inside of left handlebar grip using the cotton swab. Make sure adhesive fully covers all inside surface area of the grip. Also, apply a coat of adhesive to the handlebar end. 5. Check how the rectangular pattern is oriented on the throttle (right) grip. Align pattern on left grip to match right grip and immediately push the new grip completely onto handlebar end. 6. Rotate the end caps so the “Live to Ride”text is positioned at the top of both grips. NOTE Do not hesitate when installing left grip or adhesive will dry before installation is complete. Allow 6-8 hours at 70°F to achieve full cure of the adhesive. Prior to starting engine, verify that the throttle control will snap back to the idle position when released. A throttle control that prevents the engine from automatically returning to idle can lead to a loss of control of vehicle which could result in death or serious injury. Cleaning

HARLEY DAVIDSON SPORTSTER HAND GRIPS INSTALLATION MANUAL

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

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Remove and Install the Left Grip 1. See Figure 1. Using a T27 TORX®drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX®drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX®drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9.0 Nm). 9. Using a T25 TORX®drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm). Remove and Install the Right Grip 1. Refer to the RIGHTHANDLEBARSWITCH section of the service manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLECONTROL section of the service manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the service manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

HARLEY DAVIDSON SMOKED AND CLEAR FENDER TIP LENS KITS Preparation MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) 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) 1. Disconnect the battery cables, negative cable first. 2 . See Figure 1. Insert blade of small screwdriver into slot at top of front fender tip lamp lens (2). Rotate end of screwdriver to unsnap lens from lamp bracket. Repeat for rear fender tip lamp lens. 3. Remove bulb (3) from socket (4). 4. From the kit, find the LED marked “Amber” (5) and install into front fender tip lamp assembly.lamp socket. 5. From the kit, find the LED marked “Red” (5) and install into rear fender tip lamp assembly.lamp socket. Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 6. Connect the battery cables, positive cable first. 7. Apply power and check for proper function of front and rear fender tip lamps

HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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HARLEY DAVIDSON HANDLEBAR GRIPS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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INSTALLATION Remove and Install the Left Grip 1. See Figure 1. Remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Loosen, but do not remove, the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lb (6.8-9 Nm) . 9. Tighten first the lower, then the upper switch housing screws to 35-45 in-lb (4-5.4 Nm)