HARLEY-DAVIDSON SPORTSTER SHORTSHOTS STAGGERED INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-03-2012

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1. Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 3. Remove the two head pipe mounting nuts from each fl ange, located at the cylinder head. 4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffl er body where they attach to the mounting bar. Carefully remove exhaust pipes from the motorcycle and set aside. 6. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T30 torx driver. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar (save hardware for re-use). 10. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition

HARLEY-DAVIDSON DRESSER BIG SHOT DUALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2012

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1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. Note: On older model Dressers, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er. 4. Remove the stock muffl ers with sliding hangers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Remove the right hand fl oor board. 6. Remove both passenger fl oor boards. 7. Loosen the heat shield clamps on both front and rear exhaust pipes. 8. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 9. Remove the clamp holding the front head pipe to the transmission housing. 10. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 11. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new mounting bracket (stamped 353-P), and torque to (13-16) ft. lbs. (Figure 1). Make sure the battery ground cable is secure and properly routed. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. Note: Pre 1998 dressers do not come with this mounting post. It can be ordered from your local dealer, Harley part number: 65619-98. 12. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them

HONDA VTX 1300 AND 1800 RETRO DRIVER BOARDS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 24-12-2010

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1. Remove the stock driver boards. Looking underneath the boards locate the pins on which the boards pivot. Remove the circlips and washers. Slide the pins out and remove the board from its mount. Note how the spring is installed. 2. Place the new board onto the mount. Slide the pin thru one side of the mount and board. Next install the spring into the open area. NOTE: the spring leg with the bent end should go into the slot or pocket on the board. Push the pin thru the spring’s center hole. Using a screw driver rotate the other leg of the spring up onto the black mount. Continue pushing the pin the rest of the way thru the board and black mount. Re-install the washers and circlips.

HARLEY DAVIDSON SOFTAIL 2 into 1 Pro Pipe Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Loosen the crossover pipe clamp, located between the front and rear head pipes. 3. Remove the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the two nuts from the back side of each muffler. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them. 7. Remove the two bolts that hold the front muffler mounting bar to the frame. Note: FLSTN, FLSTF models require the removal of the stock exhaust system mounting bar. For removal: Remove the right passenger foot peg bolt. Position the motorcycle on it’s side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Replace the pivot bolt and torque it between 120 -150 ft. lbs. 8. Reinstall the foot peg bolt using the 1/2″ x 3″ bolt and spacer tube (both supplied). Tighten the bolt making sure the foot peg folds in the proper direction. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM Note: For easier installation on models with floorboards, it will be necessary to loosen the right side floorboard. 1. Check the stock exhaust gaskets to be sure they’re in good shape. If you have any doubts as to their condition, replace them. 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of each heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the motorcycle. 3. Install the circlips and flanges from the stock system onto both new head pipes. 4. Install the header using the stock nuts, but leave them loose at this time. 5. Install the new mounting bracket to the frame below the right rear foot peg, using the two 3/8″x 3/4″ flange bolts (supplied), and tighten. 6. Slide the dog bone shaped nut plate under the bracket that is welded to the backside of the muffler.

HARLEY DAVIDSON DYNA LongShot Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove both front and rear head pipe clamp bolts. 4. Remove the entire exhaust system and set it aside. 5. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips. 6. Remove the rear head pipe clamp bracket from the transmission cover. Save the bolts, two will be reused. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Locate the muffler mounting bracket (stamped 239). Mount the bracket to the engine case, to the rear of the transmission cover using the two stock bolts. Refer to figure 1. Tighten the bolts at this time. Install the mounting bar (supplied) to the transmission housing using the stock hardware. Refer to figure 1 . Note: The mounting bracket should mount flatagainst the transmission housing. Some motorcycles use a stud to mount the stock rear head pipe clamp, be sure to remove the stud from the transmission housing and replace it when mounting the bracket, this will insure that the bracket is flat against the housing. 2. Locate the muffler clamp bracket (stamped 240). Install the bracket to the outside of bracket 239, using the 5/16″x 1 1/4″ bolt and 5/16″ flat washer (supplied). Refer to figure 1. Leave the bracket loose, it will be adjusted later. 3. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the circlips and flanges from the stock system onto both the new head pipes. 5. Slide the new pipe clamp (supplied) onto the muffler end of the front head pipe. Position the clamp in the approximate mounting location on the pipe. 6. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the rear head pipe.

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HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

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