Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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HARLEY DAVIDSON FL SOFTAIL REAR BRAKE LEVERS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-03-2011

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REMOVAL 1. See Figure 1. Remove the cotter pin (5) and washer (E) from the master cylinder clevis pin (B). Discard the cotter pin. NOTE The clevis pin has a slight interference fit. It may be necessary to use pliers to pull the clevis pin from the push rod. Be careful not to damage mating parts. 2. Remove the clevis pin (B) from the brake rod. Thoroughly clean and examine parts for wear. Replace if necessary. 3. Remove the brake lever mounting screw (A) and flat washer (D), and save for reinstallation, if necessary. Remove and discard the outer O-ring (2). 4. Remove the brake lever by rotating counter-clockwise and lifting the master-cylinder clevis if necessary. Pull the lever from the shaft. Remove and discard the inner O-ring. 5. Thoroughly clean the lever mounting shaft of grease and dirt. INSTALLATION NOTE These levers are equipped with self-lubricating bushings. It is not necessary to lubricate the mounting shaft or bushings inside the lever prior to installation. 1. See Figure 1. Insert the new O-rings (4) on either side of the lever bushings (2). Install the new brake lever (1) onto the mounting shaft. NOTE There is insufficient clearance to install the clevis pin from the outside, so it must be installed from the inboard side of the brake lever. 2. Align the holes in the lever and brake rod and insert the stock clevis pin (B) from the inboard side. 3. Install the small flat washer (E) onto the clevis pin and insert the new cotter pin (5). 4. Place the large flat washer (D) onto the brake lever mounting screw (A). Apply Loctite 243 (blue) to the threads of the screw, and reinstall into the brake lever mounting shaft. Tighten the screw to 12-16 ft-lbs (16.3-21.7 Nm) . 5. Install the brake pedal pad (C) to the brake lever. After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 6. Check the brake lever for proper operation and clearance through its full travel

HARLEY DAVIDSON SOFTAIL REAR AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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INSTALLATION 1. 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. 2. All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. 3. 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. 4. All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. 5. All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. 1 2 4 3 is04788 1. Axle adjuster screw 2. Jamnut 3. Castle nut 4. Cotter pin (or spring clip) Figure 1. Rear Axle Hardware

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HARLEY DAVIDSON TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTES Refer to the service manual for more information on these generalized steps. Save all removed parts (unless otherwise noted) for installation of this kit or for motorcycle operation without the sidecar. 1. For TLE-Ultra Models: Remove both lower fairings. 2. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. 3. Remove the three right side exhaust heat shields. Some models may require removal of the right side exhaust pipes. 4. Remove stock clutch cable. 5. Remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and brake pedal. Discard cotter pin. 6. Cut the cable straps holding front oxygen sensor connector to frame bracket. 7. Remove wire harness/brake line clip from right lower frame tube. INSTALLATION New Clutch Cable Installation 1. Refer to the service manual and follow instructions to remove stock clutch cable. 2. Refer to the service manual and follow instructions to connect the new clutch cable to clutch hand lever. 3. For FLHT/C/CU: Follow the instructions in the service manual to route new clutch cable through fairing. 4. For FLHR/C Models: Capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. 5. See Figure 1. Route clutch cable down along left frame downtube (1). 6. Continue to route cable down between left front engine isolator and crankcase. Clutch cable will cross to the right side of motorcycle beneath the crankcase, to the clutch release cover on the right side of the transmission. 7. Install clutch cable fitting into clutch release cover. Refer to the service manual. NOTES The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. Verify that the clutch cable and the rear brake line do not make contact. Damage could result. 1 2 3 is05785 1. Downtube 2. Clutch cable 3. Route clutch cable behind left front engine iso- lator Figure 1. Route Clutch Cable Relocating Oil Pressure Sending Unit NOTES Perform this procedure on all models equipped with an oil pressure gauge or Police models. All other models proceed to “Master Cylinder Assembly/Rear Brake Pedal Modification.” 1. Remove cable strap securing oil pressure wire harness to frame. 2. Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and disconnect connector from oil pressure sender. 3. Remove the oil pressure sender using a 1-1/16 inch open- end crowfoot wrench. 4. See Figure 16. Coat threads of elbow (44) with Loctite 565 and install into crankcase oil pressure sender threads. 5. See Figure 2. Install elbow (1) until snug so open end is in the five-o’clock position (2). Do not over-tighten or crankcase may be damaged. 6. Coat threads of oil pressure sender with Loctite 565 and install into 90 degree brass elbow. Use a 1-1/16 inch open- end crowfoot and tighten to 96-120 in-lbs (11-14 Nm) . 7. Install connector on oil pressure sender unit. Verify that slight clearance to the right engine isolators is present. Adjust position of elbow as required to provide clearance

HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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DRIVER PEGS HONDA ADAPTOR INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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1. Assemble the peg onto the peg adaptor by removing the allen bolt from the end of the foot peg you are using. Remove the clevis assembly (folding mechanism) from the peg itself. Assemble the peg and allen bolt on to the peg adaptors. 2. The original peg pivots or folds up on a pin and has a return spring. Note how the spring is assembled into the peg. Remove the cotter pin, washer and pivot pin and foot peg. Install the new peg and adaptor assembly onto the motorcycle in the same manner and using the same spring, pin, washer and cotter pin. Set the angle of the new peg as desired and tighten the allen bolt securely. 3. Use the small set screws located at the end of the adaptors to raise and lower the foot pegs resting position.

Yamaha Roadliner And Stratoliners Brake Pedal Relocation Kit

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Filed Under (Yamaha) by admin on 27-12-2010

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1. This kit replaces the original rear brake actuating rod that connects the pedal to the master cylinder (see photo 1A) and the brake light switch spring (see photo 1B). Remove the two allen screws which attach the switches mounting plate to the frame (1C). Remove the spring. 2. Remove the cotter pin and washer from the forward end of the rod where it connects to the brake pedal (photo2A). Slide the rod over off of the brake pedal. Unscrew the rod from the threaded stud on the master cylinder. 3. Thread the new rod onto the stud until the end of the stud appears in the middle of the small sight hole that is cross drilled thru the rod (1D). Place the forward end of the rod back onto the brake pedal. Next check the distance between the bottom of the brake pedal and the top of the floorboard, this should be approximately 1 ¾”. If not, slide the rod off the pedal and thread it in or out to adjust the pedal height. With the rod on the pedal re-install the washer and cotter pin (Note: the cotter pin should go into the hole from the top down) then bend the cotter pin open. 4. Replace the brake light spring with the new one supplied. (Pushing down on the switches rubber cover will push the pin out). Re-install the switch bracket. Turn on the ignition and adjust the threaded collar on the brake switch so that the brake light comes on just as you feel some resistance when pushing on the pedal (when the brakes begin to drag).

YAMAHA XJR1300 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 21-11-2010

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LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur- faces. 1 Bearing EAS00025 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft 1-4 GEN INFO CHECKING THE CONNECTIONS NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. If the pin 1 on the terminal is flattened, bend it up. 4. Connect: lead coupler connector Make sure that all connections are tight. 5. Check: continuity (with a pocket tester) Pocket tester 90890-03112 If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores

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