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 VRSC ACCESSORY SEATS AND PILLIONS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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INSTALLATION Installing Seat and Pillion Kits: 51584-01, 52028-02, 52036-01, 53432-02, or 52927-05 NOTE Proper installation of 53432-02 (Sundowner) and 52927-05 (Tallboy) requires installation of Fender Base Plate Kit 51120- 01 1. Refer to the appropriate Service Manual and remove the stock seat and pillion. 2. See Figure 2. Remove the two mounting bolts (2) from the passenger grabstrap (1). Save the bolts for re-installa- tion. NOTE The grabstrap must loop toward the rear. Check that the “Harley-Davidson” text on the grabstrap can be read from the front of the vehicle. 3. See Figure 2. Install stock grabstrap bolt, and one end of grabstrap as shown. While holding the grabstrap end parallel to the formed line of the fender, tighten the bolt to 8-12 Nm (71-106 in-lb ) . Repeat for opposite end of grabstrap. NOTES The new pillions included in Kits 52028-02 (Custom), 52036- 02 (Badlander) and 51584-01 (Leather Badlander) are installed from front-to-back. The pillion included in Kits 53432-02 (Sundowner) and 52927- 05 (Tallboy) must be installed through the grabstrap from back- to-front. To install the Sundowner or Tallboy Pillion on a motorcycle having a sissybar upright installed on Fender Base Plate Kit 51120-01, remove the upright before installing the pillion. Reinstall the upright after the Sundowner Pillion is installed. For kit numbers 52028-02 (Custom), 52036-01 (Vinyl Bad- lander) and 51584-01 (Leather Badlander) Seat Kits, be aware of the following: The 2003 Model Year 100th Anniversary VRSCA vehicle with two-tone sterling silver and vivid black paint has protective tape covering the rear under-the-seat area of the airbox cover. For the seats listed above, it will be necessary for cosmetic reasons, to carefully remove the protective tape and reapply it so it is in the correct position for these shorter-nose seats. Some trimming of the lower portion of the protective tape may be necessary to eliminate interference with the airbox cover latch. If necessary, reorder protective tape (48403-03). 4. Install new pillion into position through grabstrap. Prevent pinching TSSM control wiring by routing the cable through the channel on the underside of the pillion (see Figure 2) and away from the pillion mounting bolt. Pinched wiring may damage the TSSM system. 1 3 2 is00014 1. Pillion 2. Grabstrap 3. Pillion base mounting hole Figure 3. Pillion Base Mounting Hole 5. See Figure 3. Push the pillion (1) forward through the grabstrap (2) until the pillion mounting hole is approximately 25 mm (1 in.) forward of the hole (3) in the frame. 6. See Figure 2. Push down on the pillion and slide the pillion toward the rear to engage the pillion slot with the fender tongue (5). Push rearward until the pillion mounting holes align. After installing pillion, pull upward to be sure it is locked in position. While riding, a loose pillion can shift causing loss of control, which could result in death or serious injury. (00387a) 7. Install original pillion mounting bolt. Tighten bolt to 11-14 Nm (97-124 in-lb ) . 8. Re-install the sissybar upright, if removed earlier. 9. Position the seat (as if opened) onto the frame. Slide the seat forward to insert the seat-hinge pins into the bushings on the frame. 10. See Figure 1. Clip the plastic seat-hinge sleeve (2) over the seat hinge. 11. See Figure 1. Insert the seat tether (3) into the hole in the motorcycle frame. 12. Refer to the applicable Owner’s Manual and close the seat. Installing Seat Kits: 51595-05, 52024-01, or 51647-06 Kit 51595-05 requires the use of pillion kit 51594-05. Kit 51647-06 requires the use of pillion kit 51648-06. Kit 52024-01 requires the use of either the stock pillion or Touring Pillion 52023-01A. 1. Refer to the appropriate Service Manual and remove the stock seat.

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HARLEY DAVIDSON VRSC SADDLEBAG SUPPORT KIT (WIDE TIRE) REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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REMOVAL Remove Pillion and Rear Fender NOTE If possible, lift the rear of the motorcycle up so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender when installing the mounting brackets. 1. Open the rider seat. 2. See Figure 1. Remove rider seat post (1), nut (2), and washer (3) from passenger pillion. Slide grabstrap (4) forward off pillion. Save mounting hardware for kit installation. 3. Push passenger pillion forward to release slot on bottom of pillion from post on fender tongue. 4. See Figure 2. Lift pillion up to remove lanyard (1) from hole in center of passenger pillion (2). Then lift pillion away from motorcycle. 5. Disconnect turn signal and tail light electrical connections from back of rear electrical caddy. Note position for later installation. 6. See Figure 3. Unsnap rear electrical caddy (1) from rear inner fender. 7. Remove and save two fender support bolts (2), washers (3), and grabstrap (4) from rear fender. 1 2 3 4 is03548 1. Rider seat post 2. Nut 3. Washer 4. Grabstrap Figure 1. Passenger Pillion and Mounting 2 1 3 i03571 1. Seat lanyard 2. Hole in pillion 3. Passenger pillion Figure 2. Seat Lanyard and Passenger Pillion 8. Remove four remaining fender support bolts (2) and washers (3) near center of rear fender. 9. Remove rear fender from vehicle. 3 2 4 2 3 2 3 1 is03544 1. Rear electrical caddy 2. Fender support bolt (6) 3. Washer (6) 4. Grabstrap Figure 3. Grabstrap, Rear Electrical Caddy, and Fender INSTALLATION Install Attach/Release Weldment, Rear Fender, and Grabstrap NOTE Apply Loctite 243 (blue) to last four threads of leave-on bracket screws. 1. See Figure 4. Install leave-on bracket (1) to outside surface of inner fender using two button head screws (2) and nuts (3). Tighten screws to 48 Nm (35 ft-lbs). Repeat for opposite side. 2. See Figure 5. Install release/attach weldment (1) to leave- on brackets (2) using two washers (3) and socket head cap screws (4). Tighten screws to 25 Nm (18 ft-lbs). Repeat for opposite side.

HONDA GL1800 Windshield Panel Light Installation Manual

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Filed Under (Honda) by admin on 04-03-2011

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Note: Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Remove the following per manual instructions. A. Rear view Mirror (Figure 1) -Remove the meter panel. -Remove the trim clip, screw and mirror cover. -Remove the three screws, bracket and mirror. -Disconnect the turn signal light 3P connector. B. Windshield Garnish (Figure 2) -Remove the left and right rearview mirrors per above instructions. -Remove the two bolts, washers and mounting rubbers. -Release the four bosses from the grommets and remove the windshield garnish. 3. Line up the windshield panel light in the windshield vent opening as shown in figure 3. Mark spots for final application. 4. Remove tape backing and carefully apply light at pre-marked spots. 5. Splice wires to mirror light as follows: a. Black to Ground b. Red to Orange/white wire to left mirror. 6. Reassemble all parts removed

HONDA GL1800 BACKREST (INSERT) INSTALLATION MANUAL

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Filed Under (Honda) by admin on 04-03-2011

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1. Place motorcycle on center stand. 2. Remove the two passenger handles and seat. 3. Install the base mount between the seat mounts (picture 1) and mark the two holes on seat base. 4. Drill two 9/32″ holes in the seat base. 5. In the middle of the two seams and in the center of the seat, install the boot (picture 2). 6. With a long serrated knife cut a hole in the seat inside the boot opening. You must clear a path in the foam from the cut to the two 9/32″ holes. 7. Insert the long bar through the hole into the seat from the outside with the hole tube facing forward (picture 3). 8. Bolt the base mount to the long bar using bolts and lock washers. 9. Attach the chrome pad mount to the long bar protruding through seat (picture 4). 10. Attach the pad to the pad mount with the mounting bracket (picture 5). 11. Reinstall the seat and adjust the pad angle (picture 6). Reattach passenger handles

HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION (2000 THROUGH 2002) Refer to the instructions included with kit 53388-03 for installation on 2000 through 2002 models. INSTALLATION (2003 AND LATER) NOTE To keep the fender aligned, completely install the sideplate on one side of the motorcycle before proceeding to the second side. The sissy bar should be installed last. 1. For models equipped with saddlebags: a. Remove the saddlebag, and retain the mounting hardware for later reinstallation. b. See Figure 1. Remove the bolt (A) and washer (4) that secures the rear fender to the fender brace. Discard the bolt and washer. Remove and retain the two saddlebag mounting studs (C) and nut plate (D) for later use. For models NOT equipped with saddlebags: a. See Figure 1. Remove the two rearmost bolts (A), washers (4) and nut plate that secure the rear fender to the fender brace. Discard the bolts and washers. b. Remove the bolt (B) and washer (4) that secure the fender and brace to the frame. Discard the bolt and washer. 2. See Figure 1. Position the correct sideplate to the outside of the fender brace. 3. With saddlebags: Apply LOCTITE 243 (blue) to the 3/8- 16 threads of the saddlebag mounting studs (C) and reinstall the studs through the sideplate, fender brace, frame and fender, and thread into the stock nut plates (D). Install one chrome 3/8-16 screw (3) and chrome washer (4) from the kit through the rear hole in the sideplate, fender brace and fender, and thread into the stock nut plate (D). Without saddlebags: Install three chrome 3/8-16 screws (3) and chrome washers (4) from the kit through the holes in the side plate, fender brace and fender, and thread into the stock nut plates (D). 4. Repeat steps 1-3 for the opposite side. 5. Install a sissy bar (not included in the kit) into the side- plates. Apply LOCTITE 262 (red) to the threads of the chrome 1/4-20 capscrews (5) and insert them into the sideplate holes. Tighten to 8-10 ft-lbs (11-14 Nm) . 6. Tighten the bolts (3) and/or saddlebag mounting studs to 21-27 ft-lbs (28.5-36.6 Nm) . 7. Reinstall the saddlebags

993-192 LED Light, 993-193 Marker Light CHROME RAIL BAR LIGHT INSTALLATION MANUAL

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Filed Under (Honda) by admin on 28-02-2011

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Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Place chrome plate on to the desired position on the rail covering both the top and bottom rail with the chrome plate. 3. Insert light into the hole on the chrome plate and attached with brackets, washer and bolts provided in figure 1. Tighten securely. 4. Wire light into bike’s running or brake lights. If adding more than one light, wire lights in series.

HONDA GL1800 CHROME SPORT SHIFTER INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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1. Place bike on center stand. 2. Remove the two bolts that hold the stock foot pegs and remove foot peg. 3. Install shifter slot over shifter peg. 4. With the longer bolts supplied, sandwich the Sport Shifter plate between the peg and frame. 5. Screw in bolts and secure tightly. Double check tightness per service manual. 6. Install shifter pegs with hardware provided MOUNTING INSTRUCTIONS FOR 45-1620 GL1800 CHROME SPORT SHIFTER

SUZUKI INTRUDER 1500 LC BOTH WHEELS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 27-02-2011

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In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later. Front wheel removal : Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution : there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine. Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal

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HARLEY DAVIDSON STREAMLINER PASSENGER FOOTBOARD KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. See Figure 1. Remove existing passenger footpegs or footboards, brackets and mounting hardware. 1 4 3 2 is04325 1. Screw and washer 2. Bracket 3. Footpeg mount 4. Footpeg pad and bottom Figure 1. Passenger Footpeg Components (FLHX) INSTALLATION NOTES • If necessary, remove any paint from counterbore holes of footboard brackets to ease the installation of the pivot pins. • On 2010 and Later Models: The installation height can be adjusted to one of three positions. To install footboards in a new position, remove plastic plugs from holes in rear swingarm bracket as necessary. • On 2009 and Earlier Models: The lowest of the four holes on the frame is not threaded and cannot be used to mount the footboards. 1. See Figure 2. Insert shoulder bolt (9) or (10) through slot in footboard bracket (1). a. 2010 and Later Models: Thread the 5/16 inch shoulder bolt (9) into the lowest hole in the rear swingarm bracket of the frame. b. 2009 and Earlier Models: Thread the 3/8 inch shoulder bolt (10) into the second lowest hole in the rear swingarm bracket of the frame. Tighten the bolts to 48-72 in-lbs (5-8 Nm.) . 2. At the desired height, install the upper screw (2) and lockwasher (3) through footboard bracket (1). Tighten screw to 36-42 ft-lb (49-56 Nm) . 3. Install spring (4) into retaining hole in footboard bracket. Set the ball (5) on top of spring. 4. Position the detent in the bottom of the footboard pan (8 or 12) over ball in footboard bracket. Be sure not to unseat the ball. Press down on footboard pan so the holes of the footboard pan and footboard bracket align. 5. Insert pivot pins (7) through two mounting holes on footboard bracket and into footboard pan. 6. Align footboard insert (6 or 11) in footboard pan. Press insert firmly until the footboard pan tabs are firmly seated in the footboard insert. 7. Fold footboard up and install set screw (13) to secure footboard pad. 8. Pivot footboard assembly up and down to verify proper operation. 9. Repeat all steps for opposite side