HARLEY-DAVIDSON SPORTSTER SHORTSHOTS STAGGERED INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 24-03-2012

download
1. Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 3. Remove the two head pipe mounting nuts from each fl ange, located at the cylinder head. 4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffl er body where they attach to the mounting bar. Carefully remove exhaust pipes from the motorcycle and set aside. 6. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T30 torx driver. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar (save hardware for re-use). 10. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition

HARLEY-DAVIDSON SOFTAIL STRAIGHTSHOTS 2-2 INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 21-03-2012

download
1. Under the oil tank on the right hand side, locate the rear O2 sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifi er on front of the frame to gain access to the front O2 sensor connector. Unplug sensor from harness. Remove cable tie holding wire to frame and feed the end of the wire through, freeing it from motorcycle. 3. On FLSTC, FLSTF, FLSTN and FLSTSC models, loosen the right hand fl oor board mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the two mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTN, FLSTF and FXSTD models, you will need to remove the right side passenger footpeg and hanger, as this is attached to the exhaust mount bracket. Remove hanger, and replace the passenger foot peg assembly using the 3/8″ x 2 1/2″ Allen bolt (supplied). 8. If equipped, unbolt the carriage bolt and clamp attached to the bracket under the right side transmission cover. 9. Remove the entire exhaust system and set it aside. 10. If equipped, remove the bracket from under the right side transmission cover. 11. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 12. Remove the two lower mounting studs from the frame (Figure 1). 13. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A

HARLEY-DAVIDSON DRESSER BIG SHOT DUALS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 18-03-2012

download
1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. Note: On older model Dressers, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er. 4. Remove the stock muffl ers with sliding hangers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Remove the right hand fl oor board. 6. Remove both passenger fl oor boards. 7. Loosen the heat shield clamps on both front and rear exhaust pipes. 8. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 9. Remove the clamp holding the front head pipe to the transmission housing. 10. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 11. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new mounting bracket (stamped 353-P), and torque to (13-16) ft. lbs. (Figure 1). Make sure the battery ground cable is secure and properly routed. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. Note: Pre 1998 dressers do not come with this mounting post. It can be ordered from your local dealer, Harley part number: 65619-98. 12. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them

HARLEY-DAVIDSON SPORTSTER SHORTSHOTS STAGGERED BLACK INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 17-03-2012

download
1. Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 3. Remove the two head pipe mounting nuts from each fl ange, located at the cylinder head. 4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffl er body where they attach to the mounting bar. Carefully remove exhaust pipes from the motorcycle and set aside. 6. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T30 torx driver. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar (save hardware for re-use). 10. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A.

2001 Honda GL1800 Oxygen Sensor Replacement Manual

0

Filed Under (Honda) by admin on 05-04-2011

download
REPAIR PROCEDURE 1. Remove the top shelter (see page 2-10 in the Service Manual). 2. Remove the left and right O 2 sensors from the exhaust pipes. • You do not have to remove the exhaust pipes to remove the O 2 sensors. • Be sure to note the wire routing for proper reassembly. 3. Install the new O 2 sensors and route the wires properly (see pages 1-33 and 1-34 in the 2001- Service Manual). 4. Connect the black 4P female coupler of the sub- harness kit to the wire harness side black 4P male coupler (for the left-side O 2 sensor). 5. Connect the new left O 2 sensor to the black 4P coupler on the sub-harness. 6. Route the sub-harness from left to right, across the front edge of the fuel tank and secure it with the clip on the cruise actuator 7. Cut off the right 4P male O 2 sensor coupler (on the wire harness side). 8. Install a PVC cap onto the end of the Black/yellow wire and Green/red wire (these are the wires that were connected to the coupler that was removed in step 7). Fold each cap back and tape it securely to its wire; these wires are no longer used. • Do not cut the wires off, just tape them back. • The tape is supplied in the replacement kit. 9. Strip the ends of the White and Black/red wires (which were connected to the coupler that was removed in step 7) on the wire harness side and the 2P coupler on the sub-harness. Install a heat shrink tube on each wire of the sub harness. 10. Twist the ends of the White and Black/red wires of the sub-harness 2P coupler to the White and Black/red wires of the main harness. 11. Solder the wires using the solder from the kit. 12. Use a heat gun to secure the heat-shrink tubing over the soldered wires. 13. Connect the right O 2 sensor coupler to the white 4P male coupler on the sub harness.

HARLEY DAVIDSON SPORTSTER BLACK EXHAUST HEAT SHIELDS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 14-02-2011

download
INSTALLATION Remove Original Equipment (OE) Heat Shields Avoid contact with exhaust system and wear protective clothing that completely covers legs while riding. Exhaust pipes and mufflers get very hot when engine is running and remain too hot to touch, even after engine is turned off. Failure to wear protective clothing could result in burns or other serious injury. (00009a) 1. Allow the motorcycle to cool. 2. Identify the position of the OE clamp screws securing the black heat shields to the exhaust pipes. NOTE The clamp screws are positioned on either side of the exhaust pipe for clearance. 3. See Figure 1. Open the heat shield clamps (1) and spread the bands to remove front and rear heat shields (2) from the exhausts. Retain the heat shield clamps Install Black Heat Shields 1. See Figure 2. Matching the OE position of the heat shield clamps, open the clamps bands and thread the bands through the brackets of the front (1) and rear (2) black heat shields. 2. Spread the band around the exhaust pipes and push the end of the bands to engage the clamp screws. Tighten to hold the heat shields in place. 3. Adjust the shields and heat shield clamps to access clamp screws and to avoid contact with other components. 4. Tighten the heat shield clamp screws

Incoming search terms:

HARLEY DAVIDSON SPORTSTER® ACCESSORY SLIP-ON MUFFLER KITS INSTALLATION MANUAL

0

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

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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. Disconnect negative (-) battery cable. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 2. Remove mufflers using appropriate Service Manual instructions. 3. Discard gaskets and mufflers. 4. Install new gaskets on mufflers. 5. Slip muffler clamps on mufflers. 6. Loosely attach mufflers to the interconnect tube using existing screws and washers. 7. Position the ends of the front and rear exhaust pipes into front and rear cylinder heads and align exhaust system while tightening all nuts and bolts; begin at the cylinder head exhaust ports and work back toward the mufflers. a. Finger tighten the upper nuts to the mounting studs. b. Tighten the lower nut to 9-18 in-lbs (1.0-2.1 Nm) . c. Tighten the upper nut to 60-80 in-lbs (6.8-9.0 Nm) . d. Tighten the lower nut to 60-80 in-lbs (6.8-9.0 Nm) . 8. Tighten the acorn nut on the rear exhaust pipe support clamp to 15-19 ft-lbs (20.3-25.8 Nm) . 9. Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm) . 10. Tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm)

HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

0

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

download
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

Incoming search terms:

HARLEY DAVIDSON SPORTSTER MUFFLER SLIP-ON KITS INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 04-02-2011

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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. Disconnect negative (-) battery cable. 2. Remove mufflers using appropriate service manual instructions. 3. Discard gaskets and mufflers. 4. Install new gaskets on mufflers. 5. Slip muffler clamps on mufflers. 6. Loosely attach mufflers to the interconnect tube using existing screws and washers. 7. Position the ends of the front and rear exhaust pipes into front and rear cylinder heads and align exhaust system while tightening all nuts and bolts, beginning at the cylinder head exhaust ports and work back toward the mufflers. a. Finger tighten the upper nuts to the mounting studs. b. Tighten the lower nut to 9-18 in-lbs (1.0-2.1 Nm) . c. Tighten the upper nut to 60-80 in-lbs (6.8-9.0 Nm) . d. Tighten the lower nut to 60-80 in-lbs (6.8-9.0 Nm) . 8. Tighten the acorn nut on the rear exhaust pipe support clamp to 15-19 ft-lbs (20.3-25.8 Nm) . 9. Tighten muffler clamps to 45-60 ft-lbs (61.0-81.3 Nm) . 10. Tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm) . 11. Connect negative (-) battery cable.

HARLEY DAVIDSON DYNA BLACK EXHAUST SHIELDS INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 30-01-2011

download
1. Allow the motorcycle to cool. 2. Note the position of the OE clamp screws securing the exhaust shields to the exhaust pipes. NOTE The clamp screws are positioned on either side of the exhaust pipe for clearance. 3. See Figure 1. Open the band clamps (1) and spread the bands to remove the exhaust shields (2) from the exhaust. 4. Remove the clamps from the exhaust shields and save for installation. Install Black Exhaust Shields 1. Install the OE clamps to the new exhaust shields. 2. See Figure 2. Spread the band around the exhaust pipes and push the end of the bands to engage the clamp screws. Tighten the screws to hold the exhaust shields in place. 3. Adjust the shields and band clamps to access clamp screws and to avoid contact with other components. 4. Tighten the clamp screws