HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION 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) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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The New Kawasaki ZX-6R Trading in gets easier and easier

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Filed Under (Kawasaki) by admin on 18-02-2011

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didn’t go to my local Kawasaki shop expecting to trade in the 2004 636 I’d been happily riding. I honestly didn’t expect there to be anything on the floor that would motivate me to bring the bike in. Some of you reading this may be able to relate to what I am saying, the day you don’t look for something is the day that you find exactly what you didn’t know you need. That was the day I decided I needed to take home the new ZX-6R. The reworking of the new ZX-6R is more than just about looking good. According to KMC the engine has been redesigned from the crankcase up for the first time in ten years. Racing technology built into the new bike is a close-ratio cassette transmission that can be removed without the needing to split the main crankcases in case you needed to make repairs or adjustments at the track. They also tell us that the fuel injection system has shorter throttle bodies with a smaller diameter bore which claim to give this new smaller sized engine more torque in the mid-range. It also comes with a GPS – Gear Position Sensor. The new ZX-6R comes stock with a slipper clutch which is one difference between the 2004 and 2007. My 2004′s rear wheel would hop if I geared down before a corner and my engine rpms were too high. The slipper clutch allows quicker downshifts. To experience the gains of a slipper clutch you don’t have to buy a 2007 Kawasaki – it was introduced to the 636 in 2005. A quick glance at the exhaust might leave the impression that the ZX-6R comes stock with stacked twin small diameter exhaust cans but if you look closely you will see it is a single oval pipe with a shotgun styled end cap. The titanium pipe has the pre-chamber and catalyser located below the engine to keep the weight on the bike low and centered and the temperature of the under seat silencer reduced. Looking at the new Kawasaki with its fairing removed, I wonder how much more it would have cost the consumer to have an exhaust system that not only works wonders but would be worth showing off? Even if some of the systems of the new 600 look better hidden by plastic the bike does have a cohesive look and every year the fit and finish of Kawasaki’s bikes seem to get better. You can look at this bike from almost any angle and nothing jumps out at you – unless you are on the right side of the bike looking at the rear brake reservoir. It seems odd to me that they would leave the rear brake reservoir exposed. Another design feature of the smooth body of the 2007 ZX-6R is the lack of tie down points for any luggage. It can be argued that this is a bike intended for Sunday morning canyon rides or track days on weekends but if you want to take the 600 out for a weekend away then there is aftermarket solution. Ventura Racks allow you go on vacation with your bike. A Ventura Rack provides you with a frame that you attach to your bike that you can secure luggage to. There is no drilling of body work and the Ventura rack I got fit onto the bike perfectly the first try. One of the things I really like about the Ventura Rack is that you can easily attach bags that you may already have or you have the option of buying the Ventura luggage system. Just give yourself time before a motorcycle trip to pack

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HARLEY DAVIDSON SPORTSTER BLACK EXHAUST HEAT SHIELDS INSTALLATION MANUAL

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

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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

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

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

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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) 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 TOURING LOW PROFILE REAR SUSPENSION KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Refer to the Service Manual and follow the instructions given to remove the seat. 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) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) 2. Disconnect the battery cables, negative cable first or remove the main fuse if equipped. 3. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 4. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 5. Fasten the air pump, part number 54630-03A to the rear air suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 6. Using the pressure relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 7. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air hose fittings

HARLEY DAVIDSON DERBY COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits are designed for installation on all 1999 and later 1340 Evolution and Twin Cam equipped models.INSTALLATION For models equipped with left side exhaust pipe: 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) NOTE Remove clutch inspection (derby) cover with motorcycle upright, not on side stand. If cover is removed with motorcycle on side stand, primary fluid will leak out of primary chaincase. 1. On models so equipped, remove the left-side passenger footboard. Using a T27 TORX® drive head, remove the derby cover from the primary chaincase. Discard the derby cover and fasteners. NOTE The gasket between the clutch inspection cover and the chaincase cover must be removed and all oil must be wiped from the gasket and groove in chaincase cover each time the cover is removed. 2. Remove the gasket from the groove in the chaincase cover and mounting surface. 3. Inspect gasket for tears or damage. Replace as required with gasket 25416-99C (sold separately). NOTE If installing the Derby cover on a 2006 and later Dyna, 2007 Softail, or 2007 Touring model, the original equipment gasket must be discarded and replaced with Derby Cover Gasket 25416-99C (sold separately). 4. To avoid punching holes in the clutch inspection cover gasket or enlarging the existing holes, install the new derby cover and gasket as follows: a. Align the triangular shaped hole in the gasket with the top hole in the derby cover. Be sure the rubber molding and the words “towards clutch” face the motorcycle. b. See Figure 2. Place a washer (2) from the kit onto the threads of one of the new screws (3). Insert the screw threads through the top hole in the derby cover, and carefully thread it all the way through the triangular shaped hole in the gasket. Do not push the screw through the hole. c. Hang the derby cover on the primary chaincase cover flange by starting the top cover screw. d. Start the remaining four screws and washers. 5. Install gasket (part number 25416-99C) and derby cover (1) on primary chaincase cover using screws and washers from the kit. Tighten screws to 84-108 in-lbs (10-12 Nm) in the sequence shown in Figure 1

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HARLEY DAVIDSON DYNA SLIP-ON ACCESSORY MUFFLERS INSTALLATION INSTRUCTIONS

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

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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. 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. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. -J04263 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required 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. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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