HARLEY DAVIDSON MULTI-POCKET FAIRING POUCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Remove the three outer fairing screws located just below the windshield and remove the windshield. 2. See Figure 1 or Figure 2. Apply adhesive pads to the bottom of the bracket in the locations shown. When the bracket is installed, the pads should rest on the top of the inner fairing and support the bracket. 3. Apply clear tape between the screw opening at the base of the windshield on the inside surface of the windshield. 4. See Figure 3. Pull the outer fairing away from the inner fairing to provide sufficient clearance to slide the mounting tabs of the bracket over the top lip of the inner fairing. 5. Center the fairing bracket along the top of the inner fairing. 3 1 2 is04616 1. Bracket 2. Pads 3. Bracket clips Figure 1. Bottom of 3-Pocket Fairing Pouch Over tightening windshield fasteners can crack windshield and/or fairing. (00451b) 6. Reinstall the windshield and three screws removed in Step 1. Tighten screws snugly, but be careful not to over-tighten screw or the fairing may crack. 3 1 2 is04615 1. Bracket 2. Pads 3. Bracket clips Figure 2. Bottom of 2-Pocket Fairing Pouch 4 2 6 5 1 3 is04614 1. Pouch 2. Windshield 3. Tape, clear 4. Outer fairing 5. Pouch bracket clip 6. Top of inner fairing Figure 3. Fairing Clip Attachment, Side View

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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 SCREAMIN' EAGLE "HEAVY BREATHER" PERFORMANCE AIR CLEANER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 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 service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 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) Original Equipment (OE) Air Cleaner Removal For carbureted models: Refer to the service manual and check the warm-slow idle speed adjustment before removing the OE air cleaner backplate. For EFI (fuel-injected) models: Have a Harley-Davidson dealer recalibrate the ECM prior to air cleaner installation. 2. Remove the air cleaner backplate following the instructions in the service manual. Retain the two breather screws (A) removed from the backplate (see Figure 1). The remaining parts can be discarded. 3. See Figure 1. Remove and discard induction module bracket (B). “Heavy Breather” Air Cleaner Installation NOTE When servicing the air cleaner, apply Loctite 243 (blue) to all threaded fasteners (both male and female threads). 4. Install the new O-rings (4) in the grooves around the breather screw holes on the carburetor or induction module side of the backplate (1 or 2)

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HARLEY DAVIDSON FL REPLACEMENT WIND DEFLECTOR INSTALLATION INSTRUCTIONS

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

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1. Remove the stock windshield. 2. Remove all hardware that secures the mounting brackets to the windshield. The nine screws that must be removed require a T-27 TORX screwdriver. Save all hardware and brackets for installing the new windshield. 3. Remove all old tape from the brackets. Apply tapefrom kit to areas of the new windshield that had tape on the stock windshield. NOTE Using a radiant heat gun on low, will aid in removing the brackets from the windshield. Do not over tighten fasteners in the next step. Over tightening can crack the windshield. 4. Install all brackets and tighten all screws and acorn nuts to 4-5 ft-lbs (0.5-0.6 Nm). 5. Install the windshield on the motorcycle. NOTE See the next page for important care and cleaning instructions.

HARLEY DAVIDSON CHROME FORK COVER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION OF KIT 66440-05 1. Kit 66440-05 , Loosen the fuel tank. Refer to FUEL TANK- PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of the Service Manual. 2. Disconnect the headlight connector from the main harness. 3. Start with one side and remove the screws fastening the trim strip and rear triple clamp cover. Remove trim strip and rear triple clamp cover. Repeat procedure for other side. 4. Remove the nut, washers, lockwashers and bolt holding the headlight housing to the tripletree. Retain all hardware for future use. Remove headlight housing. 5. Remove front panel. 6. See Figure 2. From kit, place front panel (1) into position. 7. Install headlight using the bolt, washer, lockwasher and nut removed earlier. Tighten fastener. Refer to your service manual for torque specifications and headlight alignment procedures. 8. Insert headlight wiring through hole (2) in front panel and connect wiring to main electrical harness. 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) 9. Install fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of your Service Manual. 10. Start with the left side and install the chrome rear triple clamp cover (4), and trim strip using screws removed earlier. Tighten fasteners. 11. Install the headlight switch thru switch hole (5) removed earlier. 12. Install the chrome right side rear triple clamp cover (3) and trim strip and tighten fasteners

HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

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DRAK AIR FILTER KIT INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 21-12-2010

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1. Take off the Air fi lter cover by removing the Button head cap screw in the center. 2. Removed the fi lter element by taking out the three exposed Torx head cap screws. 3. Remove the breather hoses from the Cylinder head breather bolts by pulling on them. 4. Remove the three Bolts that secure the Backing plate to the Carburetor / Throttle body and the two Breather bolts that secure it to the Cylinder heads. 5. Remove the Backing plate and Gasket, on FI models the wiring mount clip should be carefully pulled out of the plastic housing. NOTE: Be sure that the gasket surface is clean and dry and that no gasket material remains stuck to it. 6. None of the OEM parts will be reused for this installation 1. For a clear understanding of this installation it is best to refer to the exploded view diagram while reading these instructions. 2. When installing or servicing the air cleaner, apply Loctite 243 (blue) to threads of all fasteners. 3. Loosely install the gasket (1) and carburetor / throttle body mount bracket (2) using the two cylinder head breather bolts (3) and cylinder head O-rings (4) NOTE: Make sure the gasket is installed in the correct rotation and right side up. The slightly smaller bleed hole should be in the top left hand corner. 4. Using the three 1/4″-20 x 1″ socket head cap screws (5) install the fi lter backing

Suzuki GSX1400FE CHASSIS REMOVAL AND INSTALLATION

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Filed Under (Suzuki) by admin on 17-12-2010

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REMOVAL SEAT Remove the seat with the ignition key. FRAM COVERS Remove the seat. (*Above) Remove the frame cover mounting secrews (left and right sides). Remove the frame covers by pulling on the hooked parts. PILLION RIDER HANDLE Remove the pillion rider handle by removing the pillion rider handle mounting bolts. SEAT TAIL COVER Remove the seat. (*Above) Remove the pillion rider handle. (*Above) Remove the seat tail cover mounting screws. : hooked part 6-4 CHASSIS Remove the fasteners.(*6-5) Disconnect the seat lock cable A. Disconnect the brake light/taillight lead wire coupler. Remove the seat tail cover. REMOUNTING Remount the seat, frame covers, pillion rider handle and seat tail cover in the reverse order of removal. www.GSX1400FE.co.uk
CHASSIS 6-5 FASTENER REMOVAL AND REINSTALLATION FASTENER REMOVAL Depress the head of fasteners center piece 1. Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls 2 close. Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. Push in the head of center piece until it becomes flush with the fastener outside face.

Victory Lowering Kit INSTALLATION INSTRUCTIONS

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Filed Under (Victory) by admin on 04-12-2010

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This kit was designed for use with stock length shocks ONLY! We do not recommend using shorter than stock length shocks with this kit. We highly recommend that your dealer install this kit. If you do not have access to a stand capable of securely supporting/lifting the motorcycle as well as tools capable of removing/replacing the suspension links, please allow your dealer to assist you. INSTALLATION INSTRUCTIONS 1. Support motorcycle securely so that rear wheel is off the ground. 2. Remove #19, #21, #22, & #23. Refer to Fig.1 Secure & support the swing arm before removal of these parts. 3. Re-install #19, #21, & #22 using our kit in place of #23. 4. Torque fasteners to 35 ft. lbs. 5. Check for proper clearance at fender & belt guard. Please note that excessive load or other riding/road conditions could cause the bike to bottom out and potentially cause the tire to come into contact with the rear wiring harness. Adjust the pre-load of the shock per the owner’s manual or relocate the wiring harness as necessary

HARLEY DAVIDSON LOW-PROFILE REAR TOURING SUSPENSION KIT Installation

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Filed Under (Harley Davidson) by admin on 30-11-2010

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1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 2. 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. 3. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 4. 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. 5. Using the pressure-relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Failure to relieve air pressure from the rear suspension could cause injury during shock-absorber removal. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak on to the rear wheel, tire, and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 6. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air-hose fittings. NOTE Press the plastic collar down on the air-hose fitting to remove and install the air hose. 7. Remove the air hose fittings from the shock absorbers. Save the fittings for installation on the new shocks. NOTE Air-suspension shock absorbers are oil filled and must be kept upright at all times to prevent oil leakage. 8. Remove the lower mounting bolts and washers from the shock absorbers

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