HARLEY DAVIDSON CHROME/BLACK FRONT MASTER CYLINDER COVER KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION Do NOT allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205b) NOTE If this is a master cylinder cover replacement, start with step 1. If this is new installation for a hydraulic clutch kit, go to step 3. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Clean front master cylinder cover, then remove the two screws that hold the cover in place. 2. Remove the original cover (with sight glass) and gasket. 3. Put new cover and gasket in position. 4. See Service Parts illustration. Install the new cover screws (1) and tighten to 6-8 in-lbs (.7-.9 Nm). Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) NOTE The cover is lab led for D.O.T. 4 brake fluid. Install this cover on reservoirs filled only with D.O.T. 4 brake fluid. Do not mix grades of brake fluid. as they are not compatible and could cause equipment damage.

HARLEY DAVIDSON REDUCED EFFORT CLUTCH KIT INSTALLATION INSTRUCTIONS

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

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This kit fits all 2005 and earlier model motorcycles equipped with a Twin Cam 88® or Twin Cam 88B™ engine. INSTALLATION Replace Diaphram Spring NOTE Refer to the appropriate Service Manual for detailed information on the following generalized steps. 1. Remove the primary chaincase cover. 2. Partially disassemble the clutch pack in order to remove the diaphram spring. 3. Assemble the clutch pack using the diaphram spring from the kit. 4. Install the primary chaincase cover. Replace Inner and Outer Ramps NOTE Refer to the appropriate Service Manual for detailed information on the following generalized steps. 1. Remove and disassemble the transmission clutch release cover. 2. Clean and inspect transmission clutch release cover components. 3. Assemble and install the transmission clutch release cover, using the inner and outer ramps from the kit. SERVICE PARTS 1 2 3 is00464 Figure 1. Service Parts for Reduced Effort Clutch Kit Table 1. Service Parts Part Number Description (Quantity) Item 25605-00A Outer ramp 1 25604-00A Inner ramp 2 37882-06

KYMCO CLUTCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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Remove the key from the ignition switch. Remove the passenger seat, the plastic cover around the sides of the passenger seat support brackets and the support brackets to gain access to remove the fuel tank. The fuel tank is held in place by 2 straps and 1 center bolt. After removing the straps/bolt the tank will need to be lifted and twisted to slide it forward and out. You need to nearly stand it up on end to get it out from between the braces surrounding it. Next remove the clutch cover bolts (8mm Socket). Note the length of the bolts and their location. Remove the clutch cover being careful not to damage the gasket. Set cover and gasket on a flat clean surface. 2. Once the clutch cover is removed you should be able to see both clutches. Remove the nut (26mm) that holds the primary clutch (front clutch) on. Pull the clutch off the machine and place it face down on a flat clean surface. Carefully slide the inside plate up and out of the clutch. This should reveal eight clutch rollers. 3. Remove all eight of the stock rollers and set them to the side. Press the new weights supplied in the kit into the new roller housings supplied in the kit and then place the complete rollers in the clutch where you removed the stock ones. The weights can only be pushed into the housings one direction, make sure you are inserting them the right way or damage can occur. Make sure you have all eight of the rollers in the proper place and position. Reinstall the inside plate making sure all the rollers are in the proper location. Place clutch out of the way and start working on the secondary clutch. NOTE: IF YOUR KIT INCLUDES 2 DIFFERENT SETS OF 4 ROLLERS, YOU NEED TO BE SURE TO INSTALL EACH MATCHING EPI ROLLER DIRECTLY ACROSS FROM EACH OTHER (OR IN AN EVERY OTHER SEQUENCE) IN THE CLUTCH TO MAINTAIN A BALANCED SET-UP