HARLEY DAVIDSON HEATED HAND GRIP KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVAL Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. 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) 2. Remove the fuel tank according to the service manual instructions. -J04259 1 of 8 Left-Side Grip Removal 1. See Figure 1. Using a T-25 TORX drive head, remove the upper and lower switch housing screws (1). 2. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp (3) to the clutch lever bracket. Remove the lower clamp screw with flat washer. Loosen the clamp and position the clutch hand lever assembly away from the switch housing. Separate the upper and lower switch housings. 3. With “glueless” grip: Remove the grip from the handlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. 2 2 1 5 4 3 1 is01283 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger diameter of flange Figure 1. Left Handlebar Switch Housing Right-Side Grip Removal Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 2. 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 2. Using a T-25 TORX® drive head, remove the upper and lower switch housing screws. 3. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp to the brake master cylinder housing. Remove the lower clamp screw with flat washer. Loosen the clamp and position the master cylinder assembly away from the switch housing. Separate the upper and lower switch housings. 4. Remove the grip from the handlebar. NOTES The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture, and also serves as a retention device for the throttle grip. To remove the grip, a slight tug may be necessary to release the index pins in the grip from the receptacle in the seal cap. Upon removing the grip, check the location of the seal cap. If the seal cap is still fastened to the index pins inside the old throttle grip, it can be discarded along with the grip. If the seal cap is still fastened to the end of the twist grip sensor: •See Figure 3. Insert a small screwdriver or other flat-blade tool into the flat area on one side of the seal cap. •Press the leg on the underside of the cap to free it from the slot at the end of the twist grip sensor. Pry up one end of the cap. •Repeat on the other side of the cap. •Carefully remove the cap and discard it

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HARLEY DAVIDSON DETACHABLE WINDSHIELD AND DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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

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These kits fit 1984 and later FXST, FXSTB, FXSTC, and 1993 and later FXDWG model motorcycles when equipped with passing lamps. INSTALLATION 1. To protect against scratches, cover gas tank and front fender before installation. is 01985 Figure 1. New Clutch Cable Routing 2. For FXSTB Models: Proceed to Step 3. For all except FXSTB: See Figure 1. Relocate the clutch cable to the inside of the handlebars as follows: a. Locate cable adjuster halfway along clutch cable by the front frame downtube and slide off rubber boot. b. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using a 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever. c. Remove small snap ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin and clutch hand lever from bracket. Remove anchor pin and clutch cable eyelet from clutch hand lever. d. See Figure 1. Route clutch cable to the inside of the handlebars and reconnect clutch cable to clutch lever. e. See Figure 2. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn cable adjuster to obtain 1/16-1/8 inch (1.6- 3.2 mm) free play between end of cable ferrule and clutch lever bracket. f. Hold adjuster with 1/2 inch wrench. Using 9/16 inch wrench, tighten jam nut against cable adjuster. Cover cable adjuster mechanism with rubber boot

HARLEY DAVIDSON XL HAND LEVER INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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These kits fit all 2004 and later XL Sportster® model motorcy- BRAKE LEVER INSTALLATION Removing the Brake Lever Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 1. 5/32 in. (4 mm) Cardboard Insert 1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See Figure 2. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. Save the pivot pin for re-use, discard the retaining ring. 3. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Installing the Brake Lever NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch

HARLEY DAVIDSON CUSTOM HAND LEVER KIT BRAKE LEVER INSTALLATION

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

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1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (B) from the groove in the pivot pin (C). Inspect the retaining ring (part number 11143) and replace if needed. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. 4. Insert the pivot lever bushing (2) from the kit into the new brake lever (1). NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04165 1 of 3
5. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 6. Install the pivot pin and retaining ring removed in Steps 1 and 2. 7. Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is per- missible. A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) 8. To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. 9. Reinstall the master cylinder cover. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Check that the stop light goes on when the brake lever is actuated. CLUTCH LEVER INSTALLATION See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures.

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