HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION 1. Refer to the owner’s manual and follow the instructions given to disarm the security system and remove the left- side cover. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Refer to the owner’s manual and follow the instructions given to remove the main fuse. ALL models: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 3. Refer to the owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 4. Remove the battery from the vehicle. 2 1 3 4 is 01377 1. Three-pin connector on siren harness 2. Three-pin connector [142B] on vehicle harness 3. Siren harness 4. Frame rear crossmember (not visible) Figure 1. Connect the Siren Harness to the Vehicle Harness 5. See Figure 1. Locate the siren connector (2) on the main harness, behind the harness shield forward of the battery location. It is covered by a dust cap. Pull the dust cap from the connector, and feed the connector downward and out from behind the shield. 6. Select the correct siren harness (3) for this model year vehicle from the kit. Route the three-pin connector (1) of the siren harness from the bottom of the motorcycle, between the primary cover and frame tube. Plug the connector into the siren harness connector (2) on the vehicle main harness. 7. Secure the connectors to the diagnostic harness using a cable strap from the kit. Route the long lead of the siren harness over the frame rear crossmember

HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

HARLEY DAVIDSON LED TAIL LAMP WITH BAR AND SHIELD LOGO INSTALLATION INSTRUCTIONS

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

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INSTALLATION For models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and maxi-fuse. Retain all seat mounting hardware. For models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. NOTE Figure 1 shows the original equipment tail/stop lamp mounted to a full fender. The lamp is rotated 180° when mounted to a Bobtail fender. 2. See Figure 1. Loosen the two Phillips head screws (2) retaining the tail/stop lamp assembly (1) to the lamp base (3), and pull the lamp assembly away from the base. 3. Depress the locking tab (button), and disconnect the tail/stop lamp four-way Multilock socket housing [93B] (4) from the circuit board. Remove the lamp from the vehicle. 3 1 4 2 is02969 1. Tail/stop lamp assembly 2. Tail/stop lamp retaining screw (2) 3. Tail/stop lamp base 4. Tail/stop lamp connector [93B] Figure 1. Removing the Tail/Stop Lamp Assembly 7 6 2 5 1 3 4 is02970 1. Socket housing 2. Secondary lock 3. Locking tab (button) 4. Cavity 5. Socket terminal 6. Slot 7. Crimp tails Figure 2. Socket Terminal Installation 4. On the new tail/stop lamp assembly, the Blue wire and socket terminal are not installed in the four-way socket housing. Refer to the original lamp removed in Step 3, and observe which cavity contains the Blue wire. Note that the cavities are numbered on the face of the secondary lock. The Blue wire and terminal must be

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HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 4. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

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HARLEY DAVIDSON XL PREMIUM OIL COOLER KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Refer to Owners Manual to drain engine oil and remove oil filter. 2. See Figure 1. Remove oil feed hose (1) from oil pump. 3. Remove oil feed hose fitting from engine crankcase. Discard oil feed hose. INSTALLATION 1. See Figure 2 and Table 1. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to oil pump. 2. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to crankcase. 3. Tighten fittings to 55-65 in-lbs (6.2-7.4 Nm) . 1 2 3 1 is04015 1. Fitting 2. Oil Hose Cooler Supply 3. Oil Hose Cooler Return Figure 2. Oil Hose Cooler Return and Supply Assmeblies 4. Loosely install oil cooler return hose assembly (3) to crankcase fitting. 5. Loosely install oil cooler supply hose assembly (2) to oil pump fitting. 6. See Figure 3 for proper oil hose routing. The oil supply hose (1) should be the upper hose and the oil return hose (2) the lower hose 1 2 is04018 1. Oil Supply Hose 2. Oil Return Hose Figure 3. Oil Cooler Hose Routing 7. Remove two existing clips holding the clutch cable and wire harness from the left frame downtube. 8. See Figure 4 and Table 1. Position oil cooler clamps (7) in approximately the same position as the clips that were removed from the frame downtube. 9. Loosely attach oil cooler (4) to the clamps (7) using screws (9) and nuts (8). 10. Attach oil return hose (3) to the inboard connection of oil cooler (4) with worm clamp (5).

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