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 V-ROD Fi2000 Fuel Injection Module Installation Manual

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Filed Under (Harley Davidson) by admin on 15-11-2010

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1. Flip up seat, to gain access to radiator reservoir area. 2. Remove Dzus fastener to remove simulated fuel tank cover, over airbox housing. Depending on which model V-Rod is being worked on, the front shrouds covering the upper front frame section may also need to be removed. 3. Place Fi2000 in under-seat area, run fuel injector connector harness up right side frame rail between top right frame rail, and radiator overflow tank, see Figure 1. At the rear of the airbox, route the harness below the airbox, and downward next to the inner radiator hose. Unplug both stock fuel injector connectors, on the front and rear injectors between the engine cylinders, see Figure 2. These are disconnected, by depressing the metal springs that are on the end of each female connector. The stock female connectors are marked “F” and “R”, noting which connector goes to the front and rear injector, be sure to pay attention to this. Now connect the longer male Fi2000 connector to the front female H.D. connector. Plug shorter Fi2000 male connector into the stock rear female H.D. connector. Then plug the longer female Cobra connector onto the front stock H.D. injector. Plug the shorter Fi2000 female connector onto the rear injector. Each injector connector pair should rest underneath each respective injector. 4. It is now time to install the oxygen sensor eliminator modules. This product is designed to eliminate the “check engine” light from coming on when the stock oxygen sensors are disconnected on Harley Davidson Motorcycles utilizing fuel injection. The motorcycle has a full “open loop” fuel injection map written in its ECU and the motorcycle reverts to this default map after the oxygen sensors have been removed or just disconnected. 5. Locate the rear oxygen sensor and follow the harness up to the under-seat area behind the radiator overflow tank. Pull the stock connectors up from below the overflow tank and disconnect, see Figure 1. Plug one of the supplied Oxygen sensor eliminators on to the stock male connector. Tuck the connectors back underneath the bracket behind the radiator overflow tank. 6. Now locate the front oxygen sensor on the front headpipe, and trace the oxygen sensor harness back to the connectors tucked between the left front frame rail and plastic radiator shroud, see Figure 3. Pull these connectors out, and disconnect them. Plug the remaining supplied oxygen sensor eliminator on to the stock male connector. Tuck the connectors back in between the frame rail and plastic shroud

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S&S Pistons Installation Instructions

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Filed Under (S&S) by admin on 31-10-2010

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For maximum piston and ring life, fit pistons using close fit dimensions. Close fit requires absolute adherence to new engine break-in as described on page 7. 2. For immediate drag strip use, fit pistons using loose fit dimensions. Break in rings and pistons with 50 easy miles if possible. Piston and ring life will be reduced with loose fit dimensions. 3. Measure all pistons at widest point across thrust face, perpendicular to wristpin hole. Several measurements should be taken to locate widest point. Typically, this will be at bottom of piston skirt for pre-1984 big twins, and approximately 1⁄ 2 ” below level of wristpin hole in pistons for Harley- Davidson®Evolution®and Twin Cam 88®engines. If pre-1984 piston is notched for placement in rear cylinder, use measurement directly above notch for skirt measurement. 4. S&S®recommends #220-#280 grit stone for final honing of stock bore and Sidewinder®, S&ST124 and S&S big bore cylinders. #320 grit stone is recommended for engines using S&S 92-4500, 92-4510, or 92-4520 pistons. 5. Follow procedure recommended in Harley- Davidson®service manual for boring and honing stock bore big twin and Twin Cam 88®cylinders. Follow instructions included with S&S Cylinder Torque Plate Kit when boring and honing S&S 35⁄ 8 ” or 4″, 41⁄ 8 “bore cylinders. Torque plates must be used to simulate compressive stress in an assembled engine. Cylinders will distort if torque plates are not used.

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