HARLEY DAVIDSON LOWER FORK BRACKET (TRIPLE TREE) COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation 1. For models equipped with air baffle: See Figure 1. Remove and discard the two hex screws (2) and flat washers (3) holding the baffle (1) to the fork stem and bracket assembly(4). Retain the baffle for later reassembly. For models not equipped with air baffle: Remove and discard the two plugs from the rear of the fork stem and bracket assembly (4). 2. Remove and discard the hex socket head screw (6) holding the brake line manifold (5) to the underside of the fork stem and bracket assembly. 3. Place the lower fork bracket cover into position covering the brake line manifold. Attach the cover (and the baffle, if so equipped) to the fork stem and bracket assembly with the two 1/4″ self-tapping hex screws from the kit. Tighten securely. 4. Install the 5/16″ self-tapping hex socket screw through the cover and brake line manifold into the stem and bracket assembly. Torque to 10-15 ft-lbs (13.6-20.3 Nm). 5. Verify that the throttle and clutch cables are routed properly and do not interfere with steering the vehicle. After disturbing the brake system, BEFORE moving motorcycle, you must pump brake fluid until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brake will not be available to stop the motorcycle which could result in death or serious injury. After disturbing the brake system, always test motorcycle brakes at low speed. If brakes are not operating properly, or braking efficiency is poor, testing at high speeds could result in death or serious injury

HARLEY DAVIDSON HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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REMOVAL See the service manual for removal procedures. INSTALLATION See the service manual and follow the wiring procedures. NOTE For Non-FXDF Models Only: See Figure 1. Cut the mesh tubing from the kit into two equal length pieces. Slide the switch wire bundles through mesh conduit. Position conduit into switch control housing. Tie each end of conduit with cable tie from kit. Handlebar Installation See the service manual and follow the installation procedures. SAFETY CHECK 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 wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops. 1. Verify that the ignition/light key switch is turned to the OFF position. Install the main fuse. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 2. Turn the ignition/light key switch to IGNITION, but do not start the engine. Test each handlebar switch for proper operation. Before starting engine, be sure thr ottle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or serious injury. (00390a) SERVICE PARTS