HARLEY DAVIDSON HALF HELMET STEREO HEADSET KIT/ AUDIO CABLE CONNECTION OPERATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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AUDIO CABLE CONNECTION 1. See Figure 3. Obtain the larger clip (4) and the coiled headset audio cable (2) from the kit. Install the 3.5 mm stereo jack end of the cable into the clip. 2. Connect the 3.5 mm stereo jack from the headset audio cable to the audio output socket on the Road Tech riser radio, satellite radio or other audio device. Position the clip in the area indicated in Figure 1, and rotate as needed to allow easy insertion and removal of the cable jack and audio output socket. 2 1 is04347 1. For FLHT models 2. For FXD, FXST, FLST, FLHR and FLTR models Figure 1. Clip Location NOTE Ambient temperature should be at least 60 °F (16 °C) for proper adhesion of the clip to the mounting surface. 3. Clean the clip mounting area with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Peel the liner from the adhesive backing of the clip. Carefully position the clip to the mounting surface, and press firmly into place. Hold the clip in position with steady pressure for 30 seconds. 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 audio connection harness or headset audio cable do not pinch, bind or interfere when handlebars are turned fully to left or right fork stops. 5. See Figure 3. Use the small clip (5) from the kit to retain any excess headset cable to the side of the console. Attach per Step 4. NOTES Allow AT LEAST 24 hours after applying the clip before exposing the area to vigorous washing, strong water spray or extreme weather. -J04930 1 of 2 PERATION 1. Plug in the coiled audio cable at the headset and audio source. 2. See Figure 2. Put the headset on as shown, with the headband across the back of the head, above the neck. Put the helmet on, and fasten securely

HARLEY DAVIDSON DECORATIVE TRIM FOR HEAVY BREATHER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-04-2011

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INSTALLATION NOTES To avoid exposure to grease, oil, dust, dirt and skin oil, do not remove the backing film from the medallion or medallion insert until the moment of application. For maximum adhesive bond, the intake tube surface under and immediately surrounding the medallion must be clean and dry. 1. Clean the surface of the intake tube with a mixture of 50- 70 percent isopropyl alcohol and 50-30 percent distilled water. Allow to dry thoroughly. NOTE Ambient temperature should be 70-100 °F (21-38 °C). 2. See Figure 1. Remove backing film from medallion insert (1) and install on medallion (2). 3. With the backing film still in place, trial fit the medallion (2) to the intake tube. 4. Remove the backing film from the back of the medallion. Press the medallion firmly into position for about five sec- onds. 5. After releasing pressure, avoid direct contact with the medallion for at least 20 minutes. NOTE Allow AT LEAST 24 hours before exposing the air cleaner to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature

HARLEY DAVIDSON NOSTALGIC SADDLEBAG GUARD RAILS REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. If desired, remove the saddlebags. 2. Remove screws (C) and locknuts (D). Save for installation. 3. Remove reflectors with fishing line or dental floss. Use a sawing motion to remove the adhesive. Clean the surface thoroughly with an equal mixture of isopropyl alcohol and distilled water. Allow the surface to dry thoroughly. INSTALLATION 1. See Figure 1. Position the correct saddlebag guard rail (1 or 2) over the saddlebag guard and support assembly (A). Loosely install the screw (C) through the saddlebag-to- fender support bracket (B), through the saddlebag support (A) and through the inner hole of the saddlebag guard rail bracket. Install nut (D). Tighten finger-tight. NOTE Position the saddlebag guard rail as low as possible on the stock saddlebag guard and support assembly. 2. Install screws (6) and washers (5) through the clamp end of the saddlebag guard rail. Position clamp end around the upright of the saddlebag guard and install the clamp (3 or 4). Tighten screws finger-tight. 3. Align the saddlebag guard rail (1 or 2) parallel to the bottom of the saddlebag and muffler. Tighten the cap screw (C) and locknut (D) to 15-20 ft-lb (20-27 Nm) . 4. Tighten the clamp screws (6) to 22 in-lb (2.5 Nm) . NOTE The reflectors are location-specific. There are markings on the back of the reflector – “L BOTTOM” or “R BOTTOM”. 5. Peel the backing from the base of the new reflector (7 or 8). Without touching the reflector to the saddlebag guard, position the reflector and press the reflector to the saddlebag guard above the clamp (3 or 4) and press for 30 seconds. After releasing pressure, avoid direct contact with the reflector for at least 20 minutes. 6. Repeat all steps for the other side of the motorcycle. NOTE For ease of use, move the saddlebag buckles to the highest hole on the strap. 7. Install the saddlebags, if removed

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2003 SUZUKI SV 1000 Service Manual

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Filed Under (Suzuki) by admin on 26-02-2011

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections . 2. The section titles are listed in the GROUP INDEX . 3 . Holding the manual as shown at the right will allow you to find the first page of the section easily . 4. The contents are listed on the first page of each section to help you find the item and page you need . COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view . Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided . Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40 . If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart . BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result . Do not use any brake fluid taken from old or used or unsealed containers . Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil . GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only . WATER FOR MIXING Use distilled water only . Water other than distilled water can corrode and clog the aluminum radiator . ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze . Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator . LIQUID AMOUNT OF WATER/ENGINE COOLANT

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Suzuki SV1000 COOLING AND LUBRICATION SYSTEM REPAIR MANUAL

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Filed Under (Suzuki) by admin on 25-02-2011

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At the time of manufacture, the cooling system is filled with a 50 :50 mixture of distilled water and ethylene glycol anti-freeze . This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above -31 °C (-24 °F) . If the motorcycle is to be exposed to temperatures below -31 °C (-24 °F), this mixing ratio should be increased up to 55 % or 60 % according to the figure. CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water . Do not mix an alcohol base anti-freeze and different brands of anti-freeze. • Do not rut in more than 60%anti-freeze or less than 50 %. (Refer to the right figure.) • * Do not use a radiator anti-leak additive. A WARNING COOLING AND LUBRICATION SYSTEM 5-3 20 40 60 80100 0 10 20 30 40 50 60 Density (%) Fig .2 Engine coolant density-boiling point curve • * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot . After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off . • * The engine must be cool before servicing the cooling system . • * Coolant is farmful; • * If the comes in contact with skin or eyes, flush with water. • * If swallowed accidentally, induce vomiting and call physician immediately . • * Keep it away from children . Anti-freeze density Freezing point 50% -31 °C (-24 °F) 55% -40 °C (-40 °F) 60% -55 °C (-67 °F) 50 % engine coolant including reservoir tank capacity Anti-freeze 1 100 ml (2.3/1 .9 US/Imp-pt) Water 1 100 ml (2.3/1.9 US/Imp.pt) Density (%) Fig.1 Engine coolant density-freezing point curve (°F) (°C) 302 150 (kgf/cm2) 284 140 1.5 c Q 266 130 0.9 0) a) :0 248 120 0.5 0) m Z3 230 110 0 (7 212 100 (F) (C) 32 0 14 -10 -4 -20 C 0 Q -22 -30 O) C N -40 -40 a) a) U- -58 -50 -76 -60 -94 -70 5-4 COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT THERMOSTAT RESERVOIR TANK RADIATOR NO. 1 CYLINDER HEAD NO . 1 CYLINDER NO. 2 CYLINDER NO. 2 CYLINDER HEAD WATER PUMP INSPECTION Before removing the radiator and draining engine coolant, inspect the cooling circuit for tightness. • * Remove the body cowling. (=6-6) • * Remove the radiator cap ® . • * Connect the tester 02 to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 110 kPa (1.1 kgf/cm 2, 15 .6 psi) and see if the system holds this pressure for 10 seconds. • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged

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HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. 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) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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HARLEY DAVIDSON LOCKING GLOVE BOX DOOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. Unsnap the original equipment (O.E.) left-side glove box door, and unfasten the tether by bringing the aglet end (see Figure 1, B) out through the retaining hole. Always wear proper eye protection when drilling or grinding. Flying debris could cause serious eye injury. (00402e) 2. Using an 3/16 inch (5 mm) bit positioned in the center of each snap, drill out the four plastic snaps surrounding the glove box opening. NOTE The glove box door, hinge and frame assemblies are side- specific. The assemblies install so that the tether retaining hole (C) in the door frame is to the inboard side. 3. Obtain the new left-side glove box door, hinge and frame assembly (1), a lock (2) and a tether assembly (8) from the kit. Remove the nut (3) from the lock. 4. Insert the lock through the hole in the glove box door as shown. Assemble the tether over the lock threads with the tab (A) on the inboard side of the lock, same as the retaining hole in the door frame. Tighten securely. 5. Open the left-side door, and position the door assembly at the glove box opening, lining up the holes. 6. Insert a screw (9) through each of the holes in the door frame and glove box. Install a hex nut with washer (10) onto the threads of each screw. Tighten finger-tight. NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the gaskets to the glove box door frame. 7. Clean the glove box door frame with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. NOTE The glove box gaskets are side-specific. With the paper backing facing the door frame, the oblong hole at the top of the gasket is to the outboard side. 8. Obtain the left-side gasket (6) and a hinge gasket (7) from the kit. Install the gaskets to the glove box door frame. a. The gasket liner on the large gasket is split to aid alignment. Peel one half of the liner from the adhesive backing of the left-side gasket. b. Using the frame edges and screw heads as a guide, carefully position the gasket to the glove box door frame and press firmly into place. c. Peel the remaining half of the liner from the gasket backing, and carefully position the rest of the gasket to the door frame. Press firmly into place. d. Apply steady pressure for a few seconds at all areas of the gasket to verify proper adhesion. e. Peel the liner from the hinge gasket. f. Carefully position the gasket to the door frame above the hinge, and press firmly into place.

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