Honda GL1500 EZ Steer Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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1. Use the Parts Checklist included with your hardware to verify the contents of the box 2. Remove the front wheel, fender, forks and triple clamps as shown in the Honda Shop Manual. Torque head bearings to 30 ft-lb. 3. Replace the stock fork caps using new seals with the extended caps provided. If you do not already have Progressive fork springs we suggest they be installed for the best results. 4. Install the new triple clamps. Remember to grease the new lower steering bearing. 5. Install the forks into the new triple clamps. Be sure to torque all pinch bolts to factory specifications. Do not over tighten as this can cause undue stress on the new triple clamps. 6. Check the steering lock action by turning the forks fully in both directions. Because of manufacturing tolerances in the fairing mounting bracket the fork tubes sometimes make contact with it at full lock. Usually this can be overcome by giving the handlebar a slight push while engaging the lock. 7. Because the fork tubes are now longer than stock, DO NOT use the clamps that held the brake lines to the stock lower triple clamp. Some models have a temperature sensor mounted under the fairing that may interfere with the plastic cable guide. If interference is noted trim the guide as required. 8. Install the fender and wheel assembly. Be sure the brake hoses are routed to allow full travel of the forks. It is necessary to trim the two upper ears off of the fender upper cover to prevent contact with the fairing during turns. 9. If you have questions please call our EZ-Steer Maintenance The bearings in your EZ-Steer rake kit are normal wear items, not subject to replacement under Champion’s one year Limited Warranty for the product. Failure to follow your motorcycle manufacturer’s recommendations for periodic OEM triple-tree maintenance will accelerate the wear on these bearings. Checking/adjustment of the steering stem nut torque, with the front end lifted, in accordance with your motorcycle manufacturer’s recommendations, is key to reliable bearing service

HARLEY DAVIDSON FOUR-POINT DETACHABLE DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 3. Remove the screw (A) retaining the rear of the chrome cover to the rear frame extension on each side of the vehicle. 2. Place a washer (7) over the threads of each of the larger TORX® head screws (6) from the kit. Apply 2 or 3 drops of Loctite 262 Threadlocker and Sealant – Red to the threads of each screw. Install the screws through the docking plates (1) and fender covers, and into the threaded holes in the frame extensions on each side of the vehicle, and tighten to 17 ft-lbs (23 Nm) . NOTE See Figure 1. The docking points must be attached to the docking plates (2) with the chamfer (1) facing the plate and the flat side facing out. 1 2 is05506a 1. Docking point chamfer (bevel) 2. Mounting plate Figure 1. Docking Point Installation 3. See Figure 3. Slide a spacer (2) onto the longer pin (B) of each docking plate. Install the four docking points (3), chamfer end first, onto the long and short docking plate pins using the washers (5) and smaller TORX screws (4). Tighten to 10.5 ft-lbs (14.2 Nm) . NOTE Protective tape must be installed to the rear saddlebag mounting bracket to prevent damage to the saddlebag finish when the lid is opened. 4. See Figure 2. Apply protective tape (2) to the rear mounting bracket (1) on the saddlebag in the location shown. Repeat for the other side. 2 1 is05533 1. Rear saddlebag bracket (2) 2. Protective tape %lengthT=0

HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

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HARLEY DAVIDSON SOFTAIL TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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REMOVAL 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 remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 2. Raise the motorcycle on a floor jack to lower the rear wheel for fender hardware access. 3. See Figure 1. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 1. Remove Tail Lamp Lens 4. See Figure 2. Using a Terminal Pick Tool (1), press locking tabs and disconnect turn signal connectors (2-place, Items 2 and 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. NOTE FXST/S/B tail lamp and connectors are positioned 180° from orientation shown in Figure 2. 6. Reach under fender to locate clips fastening turn signal wires in place. Carefully pull wires out of clips, and pull turn signal connectors and wires out from under fender. a. Remove two-inch (51 mm) section of conduit 4 inches (102 mm) from turn signal connectors. b. Cut black turn signal wire about 5-1/2 inches (140 mm) from its connector. c. Cut violet/brown turn signal wire about 4-1/2 inches (114 mm) from its connector. d. Save cut wires with respective turn signal connectors. 7. Remove the sissy bar and/or sideplate assembly, if equipped

HARLEY DAVIDSON V-ROD CHROME TURN SIGNALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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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. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Follow Service Manual instructions given to remove the negative (-) battery cable from the negative (-) battery terminal. Remove the Existing Rear Turn Signals 1. 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 2. Identify the white left [19] (1) and black right [18] (2) 2 pin turn signal connectors. is 00231 Figure 1. Tail Lamp Housing 2 1 is00232 1. Left turn signal connector [19] (white) 2. Right turn signal connector [18] (black) Figure 2. Rear Turn Signal Connectors 3. See Figure 3. Press the button (1) and separate the pin terminal housing from the socket terminal housing. -J03601 1 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To release the socket terminal and wire, 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 4. 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 (3) and remove turn signals. 7. Repeat for the opposite turn signal. Install Chrome Rear Turn Signals 1. See Figure 5. Assemble a chrome turn signal assembly (1) to a chrome lamp support (2) by feeding the wire leads through the wire hole in the lamp support. 2. Feed the wire leads and conduit through the front hole in the license plate bracket and through hole in the support plate (4) towards the front of the motorcycle. 3. Thread the bolt (3) through the center hole in the support plate, through the center hole in the license plate bracket, and through the hole in the chrome lamp support into the chrome turn signal. 4. Tighten the bolt to 100-150 in-lbs (11.3-16.9 Nm). 5. Route the turn signal wires between the license plate bracket and the inner fender. Access the wires through the tail lamp opening in the outer fender. 6. See Table 1. Identify the left and right connector socket housings and match the socket terminated colored leads to the cavities in the socket housing which correspond to the colored leads in the pin housing

HARLEY DAVIDSON TOURING PILLION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION 1. Remove stock pillion from motorcycle according to applicable Service Manual instructions. 2. For FLSTN models: Remove the rear mounting bracket from the stock pillion, and save all the hardware. For all other models: Skip to Step 4. 3. See Figure 1. Install the rear mounting bracket (D) removed in Step 2 onto the touring pillion using the stock mounting screws (C). Tighten screws to 19 in-lbs (2.1 Nm) . 4. Install touring pillion (1) to double mounting studs (A) behind seat (B) by sliding the two slots in the pillion base into the grooves on the double mounting studs. 5. For kit 52930-05: Use the stock screw to fasten the rear seat bracket to the fender. For all other kits: Fasten the rear seat bracket to the fender using screw (6) in kit. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 6. Install grabstrap (2) using screws (3), washers (4) and spacers (5). SERVICE PARTS A 6 D C B 1 4 2 3 5 is00221 Figure 1. Service Parts: Touring Pillion Kit Table 1. Service Parts: Touring Pillion Kit Part Numbers Description (Qty) Item Not sold separately Touring pillion 1 51186-89B Grab strap 2 4180 Screw (2) 3 6379W Washer (2) 4 6019 Spacer (2) 5 2952A Rear mounting screw (2) (Not needed for Kit 52930-05) 6 Items in text not in kit: Double mounting stud (2) (stock) A Seat (stock) B Rear seat bracket screws (2) (FLSTN only) C Rear seat bracket (stock)

HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY DAVIDSON SOFTAIL SADDLEBAG KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTES Maximum saddlebag weight capacity is 7 lbs (3.18 kg) for each bag. Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. 2000-2002 Models with Wide Tire Kit 1. See Figure 1. Remove and discard stock screws (1) and washers (2) from fender support. Button head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b) 2. See Table 3. Determine appropriate screw from wide tire kit. 3. See Figure 2. Install saddlebag using screw (from wide tire kit) (1), washer (2) and nut (3). The screws are installed from inside to outside of fender. NOTE If you do not have the appropriate screw from the wide tire kit, it can be purchased from a Harley-Davidson dealer. Table 3. Wide Tire Kit Screws (3/8-16) Wide Tire Kit 44490-00, Hardware Kit 43763-00 Wide Tire Kit 44490-00, Hardware Kit 43761-00 Part Number and Length X X 4030 – 2-1/2 inch X X 4225 – 3-1/2 inch X X 4224 – 1-1/2 inch X X 4044 – 1-1/4 inch X 4215 – 2 inch X 3912 – 2-3/4 inch X X 4228 – 2-1/4 inch X X 4229 – 3-1/4 inch Failure to tighten saddlebag mounting bolts to specified torque could result in damage to saddlebags. (00406c) 4. Tighten all saddlebag hardware to 22 ft-lbs (30 Nm). NOTE Check that front screws have at least one thread exposed beyond the nut after proper torque has been applied. 5. Install reflectors on saddlebag. Refer to Install Reflectors subtopic.

HARLEY DAVIDSON SOFTAIL RIGID MOUNT SADDLEBAGS INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Maximum saddlebag load is 10 lbs. (4.5 kg) for each bag. Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTE Saddlebag hangers must be mounted with the bend in the hanger facing out from the motorcycle. NOTE The saddlebags are symmetrical and can be mounted on either side. 1. See Figure 1. Remove the fender support cover screws from locations shown for mounting saddlebags. 2. Place lock washers (6) on two cap screws (5) and insert through the top holes of the saddlebag hanger. NOTE The FXSTC Does Not use narrow spacers (8) in Step 3 for the saddlebag installation. 3. With the cap screws in place on the hanger, place a wide spacer (7) followed by a narrow spacer (8) on each screw. 4. Thread the cap screws into the location of the original screws previously removed in Step 1 and tighten screws to 22 ft-lbs (30 Nm) . 5. From the inside of the saddlebag install two button head screws (2) with washers (3) through the upper mounting holes in the saddlebag and the hanger. 6. On the backside of the hanger install hex nuts (4) to the screws from previous step and tighten to 22 ft-lbs (30 Nm) . 7. Insert two button head screws through the lower two holes on the backside of the hanger and into the saddlebag. 8. From the inside of the saddlebag install washers and hex nuts to screws and tighten to 22 ft-lbs (30 Nm) . 9. Repeat Steps 1 through 8 for installation of the other saddlebag. Installation with Docking Points 1. If you choose to use the docking points from Kit 53930- 03, repeat the installation of previous Steps 1-8 and substitute the front and rear docking points for the spacers (7) in this Kit. You must use narrow spacers (8) from this kit for both the FLSTSB and the FXSTC when using the docking points. Install Reflectors

HARLEY DAVIDSON SPORTSTER LEATHER SADDLEBAG KIT INSTALLATION INSTRUCTIONS

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

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SADDLEBAG INSTALLATION 1. See Figure 3. Remove the rear shock absorber bolt (Figure 1, Item 1). Position the 0.531 x 0.75 x 0.25 inch spacer (7) and the front saddlebag bracket attachment hole over the rear shock absorber bolt location. Secure with the 1/2- 13 x 3.75 inch screw (5). 2. See Figure 3. Position the 0.325 x 0.75 x 0.25 inch spacer (8) and the rear saddlebag attachment hole over the second hole on the rear of the fender, fender support cover, and relocation pad. From the underside of the fender, insert a 5/16-18 x 3.00 inch screw (6) and secure with locknut (10). Tighten locknut (10) to 24-27 ft-lbs (32.5-36.6 Nm) . 3. Tighten the front screw (5) to 21-27 ft-lbs (28.5-36.6 Nm) . 4. See Figure 3. Assemble an isolator washer (12) onto an isolator bushing (13). Place a screw (15) through the bushing. 5. Place the screw and bushing assembly into the top hole inside the saddlebag back. 6. See Figure 3. Push a saddlebag isolator (14) over bushing with cone shape toward saddlebag. 7. Place saddlebag in position on bracket and insert the new screw (15) into the bracket. Do not tighten. 8. Repeat steps 4 through 7 for remaining holes. With all isolators in place, tighten screws to 96-120 in-lbs (10.8- 13.6 Nm) . 9. Repeat Steps 1 through 8 for the opposite saddlebag. 10. Raise rear wheel until the rear shock absorbers align with shock absorber mounting holes on the swingarm. Support the wheel to prevent it from falling during the following step. 11. See Figure 1. Attach rear shock absorber to swingarm by installing bolt (1), washer (2) and nut (4). Tighten bolt to 45-50 ft-lbs (61.1-67.9 Nm) . Repeat step on opposite side of motorcycle. INSTALL REFLECTORS Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) 1. See Figure 3. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Mark hole location. 2. Using appropriate tool, make two 3/16 in. holes in sad- dlebag. 3. Install reflector mount (3) on saddlebag using two pushnuts (2). 4. Remove adhesive backing from reflector (4) and install on mount. 5. Repeat steps 1 through 4 for the opposite saddlebag. INSTALL SEAT After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1. See Service Manual instruction to install the seat