HARLEY DAVIDSON LIGHTED CHROME DIRECTIONAL BAR INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 15-03-2011

download
INSTALLATION 1. Disconnect turn signal wires at connectors located in directional bar. On 1994 and later models there are two wires for each turn signal lamp. Earlier models have only 1 wire per lamp. 2. Remove existing directional bar from motorcycle. Save all hardware for reattachment. If the turn signal connector is too large to be removed from the directional bar, remove the wires from the connector as follows: Bend back the connector latches on the sides of the connector slightly to free the secondary lock. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing. With a paper clip sharpened to a chisel point, insert the paper clip into the connector housing cavity until it stops. Pivot the end of the paper clip and gently tug on the wire to pull the terminal from the cavity. Do not tug on the wire until the tang that holds the terminal in the cavity is released. Take your time, a few tries may be required before you develop a feel for releasing the terminal from the connector. 3. Remove screws that mount turn signals lamps to existing directional bar. Remove lamps and turn signal wires (with their attached connector halves) from existing bar. 1 2 3 4 is02199 1. Ground wire 2. Hold lamp in place 3. Backing plate 4. Self-tapping screw Figure 1. Remove Backing Plate 4. See Figure 1. For each end of new directional bar, remove self-tapping screw that holds corner of backing plate and ground wire in place and remove backing plate. 1 2 is 02200 1. Hold lamp in place with this screw 2. Turn signal connector(s) are behind LED Figure 2. Assembling Directional Bar 5. See Figure 2. For each end of bar, place turn signal lamp in position with wires routed as shown. Move LED light out of the way and thread 5/32 inch Allen socket screw into lamp to hold lamp in place. Tighten screw.

HARLEY DAVIDSON ADVANCED AUDIO COMMUNICATION SWITCH KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 10-03-2011

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 2. Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. 3. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. 4. On the fairing cap, remove the inner left side hole plug. See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch. If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. b. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. c. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B] 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. 6. Install the new left-hand control switch assembly (3) from the kit. 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) 7. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) • Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops. 8. Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. 9. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse

Incoming search terms:

HARLEY DAVIDSON DETACHABLE TOUR-PAK LIGHT HARNESS KIT INSTALLATION MANUAL

0

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

download
INSTALLATION Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. 2. ALL models: Install the Detachable Tour-Pak Rack Kit per the instructions in that kit, up to the point where the saddlebags are to be re-installed. NOTE Make note of the cable strap locations before releasing the harness from the upper frame tube. New straps will be fastened in the same location. 3. Cut the larger cable strap fastening Tour-Pak circuit [12] (see the Service Manual Wiring Diagram) of the vehicle main harness to the left-side upper frame tube, rearward of the shock absorber. Cut the small cable strap at the end of the circuit [12] conduit. 4. Slit the conduit open along its length to expose the final ten inches (0.25 M) of main harness circuit [12] wiring. Cut the three wires (Black, Blue, and Red with Yellow tracer) nine inches (0.23 M) from the three-way Multilock socket housing [12B]. The socket housing and cut wires can be discarded. 5. Obtain the socket housing, secondary lock (locking wedge), and three socket terminals from the kit. See the illustration at DEUTSCH ELECTRICAL CONNECTORS: REMOVING/INSTALLING SOCKETS in the Service Manual. Refer to CRIMPING INSTRUCTIONS in the Service Manual, and follow the instructions to install the terminals to the three wire leads of main harness circuit [12]. 6. Per the instructions under DEUTSCH ELECTRICAL CONNECTORS, insert the Blue lead and terminal into Cavity 1 of the new socket housing. Insert the Red/Yellow lead and terminal into Cavity 2. Insert the Black lead and terminal into Cavity 3. 7. Cut the excess conduit from main harness circuit [12]. 8. Obtain the two cable straps from the kit. As noted in Step 3, use one strap to bind the end of the main harness circuit [12] conduit. Use the second strap

HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 06-03-2011

download
1995 Models 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) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. 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) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

Incoming search terms:

HARLEY DAVIDSON FRONT TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 23-02-2011

download
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. Purge the high-pressure fuel line and disconnect the fuel line following the instructions in the appropriate Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse following the instructions in the appropriate Service Manual. 3. Remove the seat following the instructions in the appropriate Service Manual. Save all seat mounting hardware. NOTE When moving the fuel tank back, do not damage the fuel gauge wires clipped to the frame under the left side of the fuel tank. 4. Remove the front and rear fuel tank mounting hardware following the instructions in the appropriate Service Manual. Move the fuel tank back on the frame to gain access to the tabs on the steering head harness shield. 5. See Figure 1. Disengage the tabs (2) from the holes (3) on each side of the frame and remove the shield (1). 6. Pull the wire harness down from inside the frame enough to disconnect the white (left) [31L] and black (right) [31R] 3-place turn signal connectors. Set aside the frame-side connector halves. 7. Remove the socket terminals from the lamp-side connector halves following the instructions in the appropriate Service Manual. Make note of the wire colors installed in the cavities of each connector, which should be: Left side (white connector): a. Black [BK] wire in cavity 1 b. Violet [V] wire in cavity 2 c. Blue [BE] wire (if installed) in cavity 3 Right side (black connector): a. Black [BK] wire in cavity 1 b. Brown [BN] wire in cavity 2 c. Blue wire [BE] (if installed) in cavity

HARLEY DAVIDSON LED TAIL LAMP WITH BAR AND SHIELD LOGO INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 10-02-2011

download
INSTALLATION For models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and maxi-fuse. Retain all seat mounting hardware. For models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. NOTE Figure 1 shows the original equipment tail/stop lamp mounted to a full fender. The lamp is rotated 180° when mounted to a Bobtail fender. 2. See Figure 1. Loosen the two Phillips head screws (2) retaining the tail/stop lamp assembly (1) to the lamp base (3), and pull the lamp assembly away from the base. 3. Depress the locking tab (button), and disconnect the tail/stop lamp four-way Multilock socket housing [93B] (4) from the circuit board. Remove the lamp from the vehicle. 3 1 4 2 is02969 1. Tail/stop lamp assembly 2. Tail/stop lamp retaining screw (2) 3. Tail/stop lamp base 4. Tail/stop lamp connector [93B] Figure 1. Removing the Tail/Stop Lamp Assembly 7 6 2 5 1 3 4 is02970 1. Socket housing 2. Secondary lock 3. Locking tab (button) 4. Cavity 5. Socket terminal 6. Slot 7. Crimp tails Figure 2. Socket Terminal Installation 4. On the new tail/stop lamp assembly, the Blue wire and socket terminal are not installed in the four-way socket housing. Refer to the original lamp removed in Step 3, and observe which cavity contains the Blue wire. Note that the cavities are numbered on the face of the secondary lock. The Blue wire and terminal must be

Incoming search terms:

HARLEY DAVIDSON NARROW CHROME DIRECTIONAL BAR INSTALLATION INSTRUCTIONS

0

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

download
This kit is designed for installation on 1986 and later FLST®, FLSTC®, FLSTN®and 1991 and later Touring models. (Except 2004 and later FLHRS®and FLTR®) NOTE: Will not fit when equipped with Flat Lens Turn Signal Module (Part Number 91699-99A). Installation 1. Disconnect turn signal wires. For 1999 and later models: See Figure 1. Remove taillight cover and disconnect turn signal wires at connectors shown in illustration. For 1998 and earlier models: Disconnect turn signal wires at connectors located in directional bar. On 1994 and later models there are two wires for each turn signal lamp. Earlier models have only 1 wire per lamp. 2. Remove existing directional bar from motorcycle and save hardware for re-installation. If the turn signal connector is too large to be removed from the directional bar, remove the wires from the connector as follows: Bend back the connector latches on the sides of the connector slightly to free the secondary lock. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing. With a paper clip sharpened to a chisel point, insert the paper clip into the connector housing cavity until it stops. Pivot the end of the paper clip and gently tug on the wire to pull the terminal from the cavity. Do not tug on the wire until the tang that holds the terminal in the cavity is released. Take your time, a few tries may be required before you develop a feel for releasing the terminal from the connector. 3. Remove screws that mount turn signals lamps to existing directional bar. Remove lamps and turn signal wires (with their attached connector halves) from existing bar. 4. Position directional bar in mounting location at rear fender and secure bar to motorcycle using original hardware removed in step 2. Route turn signal wires from motorcycle back into directional bar, or up to taillamp (if 1999 and later model) and mate connectors. If the wires were removed from the connector in step 2, insert the terminal ends of the wires into the connector until they snap in place, then mate connector halves.