HARLEY DAVIDSON FLSTN MUFFLER SLIP-ON KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-04-2011

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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. Remove mufflers according to applicable Service Manual instructions. 3. Install clamps onto mufflers and slide onto headpipes. Install muffler with the Harley Davidson script in the top position. 1 WARNING 1 WARNING 1 of 2 4. See Service Parts Illustration: Reuse fasteners and tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm), and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 5. Connect negative battery cable. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

HARLEY DAVIDSON SOFTAIL MUFFLER SLIP-FIT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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1. Disconnect negative battery cable. Perform this installation when the engine is cool. Installing these mufflers when the engine is hot could cause burns which could result in moderate to minor injury. 2. Remove mufflers according to applicable Service Manual instructions. Shotgun exhaust mufflers will come off the vehicle as a pair, attached together. Staggered dual mufflers will come off the vehicle attached to the interconnect tube. 3. For a shotgun exhaust, skip to Step 6. 1 CAUTION 1 WARNING 1 WARNING 1 of 2 4. Remove mufflers from interconnect tube and discard gaskets and mufflers. 5. Install mufflers to interconnect pipe using new gaskets (6) and existing screws. Slip muffler clamps (1) on mufflers and install assembly back on vehicle. Tighten screws to 96-120 in-lbs (10.8-13.6 N-m). Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm). Attach the interconnect tube to the frame using the existing flange lock nuts and washers. Tighten to 30-33 ft-lbs (40.7- 44.7 Nm). 6. On shotgun style assemblies, assemble top and bottom mufflers using interconnect seal. Torque screws to 96-120 in-lbs (61-81.3 Nm). Attach interconnect tube to frame using existing flange locknuts and washers. Torque to 30-33 ft-lbs, (40-7-44.7 Nm). 7. Replace fasteners and tighten as follows: muffler clamps to 45-60 ft-lbs (61-81.3 Nm), flange locknut on carriage bolt to 30-33 ft-lbs (40.7-44.7 Nm) and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 8. Reconnect negative battery cable. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Gabilan Manufacturing, Inc. warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

HARLEY DAVIDSON COMFORT PROFILE REAR SADDLEBAG GUARD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-03-2011

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REMOVAL 1. Remove saddlebags from motorcycle following the instructions in the service manual. 2. See Figure 3. Remove grab strap screw and washer (G). Remove grab strap (H). Remove seat following the instructions in the service manual. 3. Remove left and right side covers (located in front of saddlebags) by removing screw from bottom of side cover. Save hardware and side covers for final assembly. 4. Support muffler assembly with a block of wood or other suitable method. For FLTR and FLHX Models 1. See Figure 3. Remove the screws (F) securing saddlebag guards to muffler supports. 2. Remove bolt (M) and nut (P). Save bolt (M) for installation. Discard nut (P). 3. Remove screws (B and C) and nut (E). Save screws (B and C) for installation. Discard nut (E). 4. Remove stud receptacle (I) and save for installation. 5. See Figure 1. Remove antenna bracket (1), mounting fasteners (2), antenna mounting nut (5), washer (4) and antenna adapter (3). Save the antenna and hardware, discard the bracket. 6. Remove support (D) and discard. 7. Repeat Steps 1 through 4 for other side. For FLHTCU and FLHTC Models 1. Remove and discard screws (X) and guard rail mounts (W and V). 2. Remove screw (Q) and rear guards (U). Discard rear guard assembly including screws (T) and clamps (R and S). Discard screw (Q). 3. Remove and discard screw (K) and nut (L). 4. Remove screws (N and C) and nut (E). Save screw (C) for installation. Discard nut (E), screw (N) and forward guard. 5. Repeat Steps 1 through 5 for other side. For All Other Models 1. Remove screws (N and C) and nut (E). Save screw (C) for installation. Discard nut (E) and screw (N). 2. Remove and discard screw (K) and nut (L). 3. Remove forward guard and discard. 4. Repeat for other side

HARLEY DAVIDSON FRONT FENDER SKIRT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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1980 and later Touring •1986 and later FLSTC •1993-1996 FLSTN •2006 and later FLST This kit is not designed for FLSTF model vehicles. Kit Contents Table 1. Kit Contents Quantity Description 1 Fender skirt 6 Screw, pan head 6 Locknut, hex 6 Washer, flat 1 Adhesive foam strip (Heritage models only) INSTALLATION 1. See Figure 1. Remove fasteners (2) from stock fender skirt. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) NOTE Some early models have rivets for fasteners. These rivets will need to be drilled out. Drill the rivet heads to a sufficient depth to remove the head from the rivet shaft. Do not attempt to drill the rivet all the way through. This may scratch the fender?s painted surface. 1 5 3 2 4 is 01097 1. Fender skirt 2. Screw, panhead 3. Locknut, hex 4. Flatwasher 5. Adhesive foam strip (Heritage models only) Figure 1. Front Fender Skirt and Assembling Hardware 2. Remove stock fender skirt (1). 3. Thoroughly clean the fender under the skirt. At this point it may be a good idea to wax this portion of the fender to prevent rust in the future. 4. For Concho style and Bar and Shield style fender skirts, cut the adhesive foam strip (5) into three equal parts. Remove the backing from the adhesive strips and apply adhesive on middle and two sides at the inside/bottom of the skirt. The foam strips will prevent rattling and unwanted noise. For V-Logo style skirts, cut foam strip into three pieces; however make two slightly larger to cover the heads of the screws that hold the V-Logos in place. Use the remaining smaller piece on the middle, inside/bottom of the skirt. NOTE On some FLT models, there may not be enough fender skirt support to allow the application of adhesive strips. If this is true for your motorcycle, you may install this kit without the adhesive strips. 5. Place the fender skirt in position, aligning fastener holes. 6. Install the screws (2) from the outside of the fender. Install the washers (4) and nuts (3) inside the fender

HARLEY DAVIDSON V-ROD CHROME REAR TURN SIGNAL INSTALLATION MANUAL

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

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INSTALLATION Prepare the Motorcycle 1. Remove the right cover and the maxi-fuse. 2. Follow Service Manual instructions to remove the air box cover. Remove the Existing Rear Turn Signals 1. For 2006 and Earlier Models: See Figure 1. Insert a screwdriver into middle of hole of license plate light cover. Push forward to release tail lamp housing retaining clip. 2. See Figure 3. Identify the white left [19] (1) and black right [18] (2) 2 pin rear turn signal connectors. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To remove the rear turn signal wires from the socket terminal housing, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. 6. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 7. Repeat for the opposite turn signal. 1. For 2007 and Later Models: See Figure 2. Open seat and remove the nut and washer (3), seat post (2), passenger pillion and passenger seat (1) per the instructions in the Service Manual. 2. See Figure 4. Identify the left (1) and right (2) rear turn signal wires and 6 pin rear turn signal connector [94]. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. See Figure 5. Remove the turn signal wires from the 6 pin socket terminal housing. To remove the wires, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. Repeat for all four turn signal wires. Do not remove the license light wires from the socket terminal housing. 6. Gently pull the loose turn signal wires through the sheath toward the rear of the vehicle until completely removed from the sheath. 7. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 8. Repeat for the opposite turn signal

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HARLEY DAVIDSON AIR WING SADDLEBAG LID RAIL LIGHTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. If saddlebag rails have not yet been installed: Perform the Air Wing Saddlebag Rail installation up to the point of final assembly of the rails to the saddlebag lids. If saddlebag rails are already installed: Open one saddlebag and remove all loose contents. Remove one saddlebag from the vehicle per service manual instructions. From the underside of the saddlebag lid, remove the fasteners retaining the saddlebag rail to the lid. Note fastener position and save all components for installation. 2. ALL installations: See Figure 3. Obtain a saddlebag rail light assembly (1) from the kit. 3. Insert the light wires through the hole (B) in the side of the saddlebag rail (A) mounting post, and out through the bottom of the post. 4. Install the light to the underside of the saddlebag rail rear cross bar with two screws (4) from the kit. Tighten the screws >securely. 5. Insert the light wires through the left rear saddlebag rail mounting pad (C) and the left rear hole (H) in the saddlebag lid (G). Assemble the saddlebag rail to the lid per the instructions in the Air Wing Saddlebag Rail Kit, feeding the wires through the left rear saddlebag rail nylon washer (D), plain washer (E) and the hex head hollow screw (F). Tighten the two Phillips head screws to 27-31 in-lbs (3.1- 3.5 Nm) . Tighten the hex head hollow screw to 30-50 in- lbs (3.4-5.6 Nm) .

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HARLEY DAVIDSON CHROME INNER PRIMARY COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1 2 3 is06139 Figure 1. Remove Three Original Equipment Screws As Shown 1. See Figure 1. Remove the stock fasteners as shown in Figure 1. Save screw (3) for reuse. 2. Install the stock fastener in the rear inner cover. Place a locating washer over the fastener with the rounded side facing toward the hole in the primary chain case. 3. Slide the rear inner cover into place and loosely secure it with the stock fastener. 1 is06416 1. Acorn nut Figure 2. Fasten Front And Rear Inner Primary Covers Together 4. See Figure 2. Position the front inner cover over the rear inner cover and make sure that the hole in the front cover fits over the threaded stud in the rear cover. Secure the covers together with the acorn nut installed finger tight. 5. See Figure 3 and Table 1. Place the new 4.25 inch (5) and 1-1/2 inch (4) screws in the front inner primary cover. Place locating washers (6) over the fasteners with the rounded side of the washer facing toward the hole in the primary chain case. 6. Tighten all three screws to 108-120 in-lbs (12.2-13.6 Nm) . 7. Tighten the acorn nut. 8. Push the Allen hole plugs (7) into the four exposed screw heads

HARLEY DAVIDSON SCREAMIN' EAGLE VENTILATOR PERFORMANCE AIR CLEANER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the main fuse. Refer to the service manual. 2. Remove the existing air cleaner backplate. Refer to the service manual. Save the original equipment (OE) button head screw that secures the air cleaner cover. Discard the remaining parts. 3. Remove the fuel tank. Refer to the service manual. 4. See Figure 1. Remove and discard the induction module support bracket. is05912 Figure 1. Remove Induction Module Support Bracket INSTALLATION Air Cleaner Installation Use only supplied air cleaner cover. Use of another air cleaner cover could cause element failure and detachment of the air cleaner cover, which could distract the rider and result in death or serious injury. (00596b) NOTE When servicing the air cleaner, apply Loctite 243 – Blue to the threads of all fasteners. 1. See Figure 3. Install two O-rings (1) from the kit in the grooves around the breather bolt holes on the induction module side of the backplate assembly (2). Install the remaining two O-rings in the grooves in the underside of the heads of the breather bolts (5). 2. Remove the liner from the adhesive backing of the gasket (3). Carefully position the adhesive side of the gasket to the backplate, aligning to the equally spaced screw holes, and press the gasket firmly into place. 3. Insert new breather bolts (5) through the backplate. 4. Apply Loctite 243 – Blue to the breather bolt threads and the mating tapped holes in the cylinder head. 5. Thread the bolts into the cylinder head, but do not tighten. 6. Thread the air cleaner mounting studs (4) all the way through the backplate (2) until the screw threads are captured in the induction module. Do not tighten completely at this time. 7. Alternately tighten the two breather bolts to 120-144 in- lbs (13.6-16.3 Nm) . 8. Tighten the three air cleaner studs to 55-60 in-lbs (6.2- 6.8 Nm) . 9. Install the fuel tank. Air Cleaner Element and Cover Installation

HARLEY DAVIDSON SISSY BAR LUGGAGE INSTALLATION MANUAL

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

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INSTALLATION Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00095a) Harley-Davidson cannot test and make specific recommendations regarding every accessory or combination of accessories sold, the rider must assume responsibility for safe operation of the motorcycle when installing accessories or carrying additional weight. Use the following guidelines when equipping a motorcycle or carrying passengers and cargo. •The Gross Vehicle Weight Rating (GVWR) is shown on the information plate located on the frame steering head. GVWR is the sum of the weight of the motorcycle and accessories and the maximum weight of the rider and cargo that may be carried safely. Do not pull a trailer with this motorcycle. Do not exceed the GVWR as indicated on the frame label. •Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle’s center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. •Do not exceed the maximum load (indicated on the label inside) in the bag. Do not exceed the capacity of the luggage rack. •Be sure cargo is secure and will not shift while riding. Periodically recheck the load. •Ensure that the bag strap buckles are secure •Large surfaces, such as fairings, windshields, backrests and luggage racks, can affect handling. These items should be designed and approved by Harley-Davidson specifically for the motorcycle model and be properly installed. 1. Disconnect the quick-disconnect buckle on the bottom mounting strap, and undo the D-ring fasteners on the back straps. Add enough slack to the straps to wrap around the luggage rack and backrest pad. 2. See Figure 1. Center the bag on the luggage rack with the closure buckles facing the back of the motorcycle. Bring the mounting strap on the bottom of the bag around the underside of the luggage rack

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1999-2010 Yamaha Roadstar 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 14-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n Remove the horn located on the lower left side. Also remove the Remote Adjustable Pre-Load adjuster knob by removing the screw located in the center of the knob, then pull it straight off. n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the opening behind where the horn was located on the left side of the bike – see figures 2 and 3. Do not loosen or attempt to rotate the line between the shock and the adjuster. n Reinstall the adjuster knob, and torque the screw to 50 in/lbs. (5.65 N-m). n Make sure the shock rebound adjustment is at the rear facing the left side of the motorcycle and the pressure valve is facing up. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the stock two drive-belt cover bolts – as shown in figure 4. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. Reinstall horn. To adjust the ride height, simply turn the adjuster knob clockwise (looking at it from the back of the bike) to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height