HARLEY DAVIDSON CUSTOM TOURING FRONT BULLET TURN SIGNAL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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INSTALLATION Outer Fairing/Windshield and Auxiliary Lamp Bracket Removal To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2 3 1 2 is 01215 1. Six-position connector 2. Four-position connector 3. Auxiliary lamp connector Figure 1. Disconnect Signal and Auxiliary Lamp 1. Remove Maxi-Fuse. Refer to SYSTEM FUSES, MAXI- FUSE in Service Manual. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 2. Remove the windshield and outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual for the outer fairing/windshield removal procedure. 3. Disconnect auxiliary lamp and turn signal connectors. NOTE See Figure 1. On 2005 and prior year models, the left and right turn signals plug into a 6-place connector located on the left fairing support brace. On 2006 and later models, each turn signal plugs into its own 4-place connector located toward the bottom of the inner fairing on each side. 4. Using a T40 Torx® drive head, remove and save the four bolts securing the auxiliary head lamp bracket to the chassis. 5. Remove auxiliary lamp bracket from motorcycle. Turn Signal Assembly 1 is 01217 1. Triangular opening Figure 2. Insertion of Terminals Through Triangular Opening 1. See Figure 2. Insert wire terminals through the triangular opening in the turn signal mounting bracket included in the kit. 2. Fit turn signal housing onto bracket. 3. Apply a small amount of Loctite (243) blue (99642-97) to threads of hex head cap screw. 4. Tighten cap screw to 15-20 ft-lbs (20-27 Nm) . -J03753 1 of 2 Turn Signal Installation 1 is 01218 1. Turn signal wire Figure 3. Turn Signal Wire Routing 1. See Figure 3. Insert turn signal connector and wiring between bottom of fairing and top of outer fairing skirt. 2. Route turn signal wire under cutout on mounting bracket and place bracket onto motorcycle. NOTE Care must be taken so the turn signal wire is not pinched between turn signal bracket and motorcycle chassis. 3. Install washers onto turn signal bracket mounting bolts and apply Loctite 243 (blue) (99642-97) to the bolt threads. 4. Tighten mounting bolts to 15-20 ft-lbs (20-27 Nm) . 5. Route turn signal leads toward harness connector. Secure loose wiring with tie straps so wires do not rub against any sharp objects

HARLEY DAVIDSON SOFTAIL LEFT SIDE LEATHER TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Installation While handling and installing tool box, be careful not to scratch surface. 1. See Service Parts Illustration. Install tool box (1) to mounting bracket (6) using button head screws (2) and washers (5). Screws (2) should be inserted through mounting holes on inside of tool box (1) and then inserted through bracket (6) holes and threaded into weld nuts attached to bracket. 2. Remove and save the two screws that secure left rear fender support to motorcycle frame. 3. Remove two bolts, nuts, and washers that secure debris deflector to motorcycle frame. This will allow you to move debris deflector out of the way when installing new passenger footpeg support bolt. Save hardware for reinstallation. 4. For 1990 to 1999 Softails: If tool box is being installed with passenger footpeg, remove the hex head bolt and left passenger footpeg. Retain footpeg and lockwasher for reinstallation. Discard bolt . If tool box is being installed without passenger footpeg, remove hex head bolt and left passenger footpeg. Discard footpeg. Retain bolt and lockwasher. For 2000 and later Softails: See page 3 . Remove footrest from clevis. Remove clevis from frame by removing cap screw from center of clevis. If tool box is installed with footpegs, keep all hardware. If toolbox is to be installed with footboards, discard hardware. 5. Slide top of mounting bracket (6) between rear fender support and frame. Align top holes in bracket with fender support holes. Align lower bracket hole with footpeg mounting hole in frame. Install the two screws, removed in Step 2, in fender support. Do not tighten screws at this time. 6. For 1990 to 1999 Softails: Place lockwasher retained in step 4 on footpeg support hex head bolt (3) from kit. CAUTION 1 of 3 For 2000 and later Softails with footpegs: Install kit 49352-00 according to instructions included in this kit. Footpeg must fold up at a 45°angle (from vertical) toward rear of motorcycle. This angle allows footpeg to fold up if, by accident, it strikes the ground surface when making a sharp turn. Failure to set footpeg to the proper fold-up angle could result in death or serious injury. 7. For 1990 to 1999 Softails: Position footpeg so it folds up and back at a 45°angle. Install bolt (3) from kit through frame, tool box bracket (6), and spacer (4), into footpeg, as shown. NOTE If vehicle is equipped with saddlebag support bracket, Part No. 90346-90 or 90346-94, position saddlebag support bracket between tool box bracket and spacer.

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HARLEY DAVIDSON ALUMINUM SHIFTER LINKAGE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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REMOVAL 1. See Figure 1. Remove stock shifter rod (D). 2. Adjust new shifter rod in kit to match the length of the removed shifter rod by loosening locknuts (3), adjusting the length of the rod, then tightening locknuts to 20-24 ft- lbs (27-32 Nm) . 3. For models with a straight rear shifter rod lever: Discard spacer (7). Place cover (1) over the shifter rod lever (C). For models with an offset rear shifter rod lever: Place spacer (7) and cover (1) over the shifter rod lever (C). INSTALLATION 1. Apply Loctite® 243 to threads of capscrew (5) and install cap screw through the rear of the shifter rod and into the shifter rod lever. Tighten cap screw to 13-16 ft-lbs (18-22 Nm) . 2. For 1999 and later FLHT, FLHX, FLHR, and FXDWG models: Place the rod end on the outside of the shifter lever, then apply Loctite® 243 to the threads of capscrew (5). Attach the front of the shifter rod (6) to the shifter lever with capscrew (5) and acorn nut (4) (with acorn nut facing out). Tighten acorn nut (4) to 13-16 ft-lbs (18-22 Nm) . For all models except 1999 and later FLHT, FLHX, FLHR, and FXDWG: Place the rod end on the inside of the shifter lever then apply Loctite® 243 to the threads of cap screw (5). Attach the front of the shifter rod (6) to the shifter lever with cap screw and acorn nut (4). Tighten acorn nut (4) to 13-16 ft-lbs (18-22 Nm)

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HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

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HARLEY DAVIDSON TOUR-PAK RACK LIGHT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION 1. Remove all contents from Tour-Pak®. 2. For easier installation, remove Tour-Pak rack, if installed, by removing cap screw, washers and mounting pads. 3. See Figure 1. Remove rubber plug from bottom rear rail on left side of rack. 4. See Figure 2. Use line wire feeder in kit to thread through left rear rack foot and out through the back opening of rail. 5. Attach light harness wires to line wire feeder loop. 6. Carefully pull line wire feeder and light harness wires through rack mounting foot. 7. See Figure 5 and Table 1. Apply foam pads (5) to top surface of light. 8. Secure light (1) to rack with socket head screws (4) and washers (6). 1 is05242 1. Plug Figure 1. Left Side Rack Plug 1 is05244 1. Line wire feeder Figure 2. Thread Wires Through Rack 9. Position rack/light assembly to Tour-Pak lid and route wires through lid, washer and hollow mounting bolt. 10. Attach rack/light assembly to Tour-Pak using instructions and hardware provided with rack except for use of hollow bolt from Step 9. 11. Remove Tour-Pak liner. 12. Thread wires through black vinyl conduit. 13. Ultra Classic models: Follow Steps 14 through 2114. Locate and disconnect three pin AMP connector for Tour- Pak lights. 15. See Figure 3. Attach the Y-harness (2) to the three pin male connector (1) of Tour-Pak harness. 16. Route light wires from back of Tour-Pak along left side to front. Secure conduit with adhesive clips provided in kit. 17. Trim length of light wires and conduit to reach Y-harness. 18. Refer to the Service Manual electrical appendix to install terminal pins (8) to rack light wires and install terminals to three pin housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead 19. Connect rack light to remaining Y-harness connector. 20. Replace Tour-Pak liner. 21. Check operation of Tour-Pak tail and stop light functions before operating motorcycle. 22. Classic models: See Figure 4. If necessary, drill hole in lower left bottom of Tour-Pak and install grommet. Route rack light wires through grommet. 23. Refer to the Service Manual electrical appendix to install terminal receptacle (8) to rack light wires and install terminals to three pin receptacle housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead NOTE To prevent corrosion, fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. As an additional precaution against moisture seepage into the Tour-Pak, apply silicone sealant (not included in kit) to the entrance of the light harness wire tunnel. See figure 2 for location reference. 24. Connect rack light to male connector of two connector wire harness (12) and connect to accessory connector under seat. 25. Replace Tour-Pak liner. 26. Check operation of Tour-Pak tail and stop light functions before operating motorcycle

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HARLEY DAVIDSON TRIKE CHROME REAR GUARD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Set the vehicle parking brake, open the trunk door and remove the trunk liners. 2. See Figure 1. From inside the trunk, locate four screws with washers (A) in the floor of the trunk compartment that hold the body to the rear frame. Leaving the washer in place, remove one of the screws and discard. 3. Obtain a long hex head cap screw (3) from the kit. Apply a few drops of Loctite – Blue to the threads of the screw, about 0.75 in (19 mm) from the screw head (C). 4. Insert the screw through the washer (A) and trunk floor. Thread it all the way through the U-channel on the outboard side of the rear frame (B), but do not fully tighten at this time. 5. Repeat for the remaining three screws. 6. Tighten all four screws to 18 ft-lbs (24.4 Nm) . 7. With an assistant, position the trunk rail assembly to the underside of the frame, fitting the four holes in the rail mounting brackets onto the threads of the screws installed in Step 4. 8. Apply a few drops of Loctite – Blue to the threads of each lock nut (4). 9. Install a washer (5) and locknut to the threads of each screw to hold the rail in place, but tighten only enough so the rail lightly contacts the frame. 10. Align the rear guard evenly to the contour of the lower body for best appearance, and adjust the position of the rail to provide clearance between the rail and the rear of the vehicle body. 11. With an assistant firmly holding the screw heads inside the trunk to keep them from turning, tighten the four lock nuts to 18 ft-lbs (24.4 Nm) . 12. Install an insert (2) into each end of the rear guard. Push firmly until fully seated.

HARLEY DAVIDSON XL DOCKING HARDWARE/ DIRECTIONAL RELOCATION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION 1. See Figure 2. Following directions supplied with saddlebags to relocate rear turn signals, but also use the following exceptions to install the parts contained in this kit: •Use turn signal studs (4) in place of hex bolts supplied with saddlebags. The longer studs are required to accommodate the rear docking points. •On each side, insert relocation pad plate (3), saddlebag mount spacer (12), rear docking point (2), and docking point spacer (11) between relocation pad (supplied with saddlebags), and fender support cover as shown. •Use 4-inch long cap screw (5) in place of hex bolts supplied with saddlebags. The longer cap screws are required to accommodate the rear docking points. •The turn signal wires should be routed under the fender support cover back to the connectors they were removed from following the directions supplied with saddlebags. 7 1 14 2 12 6 9 3 1 11 4 10 8 16 17 15 18 5 13 is03490a 1. Locknut, 5/16-18 inch (3) 2. Rear docking point 3. Relocation pad plate from saddlebag kit 4. Turn signal stud 5. Cap screw, 5/16-18 x 4 inch 6. Spacer from saddlebag kit 7. Turn signal wire 8. Fender support cover 9. Cap screw, 5/16-18 x 2-1/4 inch 10. Front docking point 11. Docking point spacer 12. Saddlebag spacer 13. Washer, 1/4 inch 14. Locknut 1/4-20 inch 15. Cap screw, 1/2-13 x 3-3/4 inch 16. Spacer 17. Saddlebag support 18. Stock washer Figure 1. Installation shown on 2000 model On 1999 and earlier models: See Figure 2. Before mounting saddlebag supports, remove acorn nut from upper shock mount, and install washer (7), and shock mount spacer (8) as shown. Tighten upper shock mount spacer to 21-35 ft-lbs (28-47 Nm). This will properly space out the saddlebags to accommodate the docking points. On 2000 models: See Figure 1. Before mounting saddlebag supports remove button screw from upper stock mounts, and proceed to Step 2.

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2007-2008 Kawasaki ER6 and Ninja 650R Lowering Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Raise the motorcycle so the rear wheel is off the ground. As an example, you can use a motorcycle lift, two car jacks, or upside-down paint buckets placed under the foot pegs, but anything stable should do. ” Stable ” is the key word. Please take all precautions! 2) Using the 19 mm open wrench and the provided 8 mm hex wrench, loosen the button head bolt and locknut as shown This large washer will not be there on 2007 & 2008 models 3) Next, remove the locknut and the small washer from the back, and remove the button head bolt and the large washer from the front. You can pull out the button head bolt by slightly moving the rear suspension up and down at the same time. 4) 5) Lift the shock absorber and insert the spacer where the shock absorber was installed before. Note: The original bolt and washers (if any were on your bike) are not going to be used, but you should keep them for the future, in case you decide to uninstall the lowering kit. Slide over the main kit body and insert the provided hex head cap screw as shown Next, slide the provided hex head cap screw all the way through

KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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HARLEY-DAVIDSON SPORTSTER TURN SIGNAL RELOCATION KIT INSTALLATION AND CLEANING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-10-2010

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Remove turn signals. Observe and mark “left” and “right” for reinstallation. h Turn signal bracket may be oriented forward or backward as required. 4. Install turn signal bracket between license plate and license plate bracket using 1/4”- 20 x 3/4” Hex cap screw, 1/4” SAE flat washers, and 1/4” – 20 locknuts. Note: For Bullet style turn signal light models refer to fig. 3, disassemble and discard turn signal extension and insert 8 x 22 x 5mm black plastic spacer in place of the extension. 5. Mount turn signals directly to bracket using 5/16” – 24 x 3/4” hex cap screws with 5/16” lock washers and 5/16” flat-washers. If original wire was inside stalk, remove plug and reroute wires to outside. For a clean installation remove top center mounting bolt on license plate bracket and run wires through this hole. h Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. h WARNING: Some states may have minimum width requirements on motorcycle turn signals, so check your local laws. 6. Turn signal wires must be extended. We recommend splicing inside turn signal housing. Splice wires, one at a time, while observing color code. 7. Connect battery and test turn signals for function. SADDLEBAG INSTALLATION h Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points.
Leatherlyke Refer to Figure 2. 9. Remove rear fender mounting bolt on each side and replace original bolt with the two 5/16” x 2 1/4” socket head bolts and 5/16” mounting spools with chamfer on spool under socket head bolt. Install 5/16” – 18 locknuts on inside of fender. Verify that adequate clearance exists between the ends of the bolts and tire. 10. Remove upper shock bolt and replace with (2) – 1/2″ x 1″ FLAT WASHERS and 1/2″ x 2 1/8″ hex spool & bolt assy.