HARLEY DAVIDSON SOFTAIL 6 SPEED TRANSMISSION – COMPLETE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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Removal of Original Transmission 1. Position motorcycle on a suitable lift. 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) 2. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 3. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps. 4. Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover. 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) 5. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly. 6. Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. 7. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation. 8. Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch. 9. Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. 10. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. 11. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. 12. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. 13. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation

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HARLEY DAVIDSON FXST BLACK FORK SLIDER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION The fork sliders included in this kit install in the same way as the original equipment parts. NOTE Prior to installation of this kit, check the bores of the new sliders to be certain they are free of dirt and debris or damage to the new sliders may occur. 1. Support the motorcycle so the front end is off the floor and the forks are fully extended. 2. Remove the front fender, front brake caliper(s), and front wheel according to instructions found in the Chassis section of the appropriate Service Manual. NOTE On some models other parts will also need to be removed to access the front forks. See the Service Manual. 3. Drain and remove the front forks. See the Chassis Section of the Service Manual. Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) 4. Disassemble the front fork tubes according to instructions in the Service Manual, and replace the original fork sliders with the black sliders from the kit. 5. Assemble the front fork tubes, replacing worn seals, bushings or other additional items as needed. NOTE Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws. 6. Tighten the drain screws to 52-78 in-lbs (5.9-8.8 Nm) 7. Fill with Harley-Davidson TYPE E FORK OIL according to the instructions found in the Service Manual. 8. Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel, and caliper(s) according to the instructions found in the Chassis section of the Service Manual. 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 is02733 1. Install bottom of reflector 2.0 inches above center of axle Figure 1. Reflector Placement NOTE The front reflectors located on both sides of the fork sliders will be removed, cleaned and installed on the new chrome fork sliders. 9. See Figure 1. Using a piece of dental floss (or similar material) in a back and forth motion, loosen reflector from fork slider at both ends. Rotate reflector from side to side until it can be removed. Retain reflector for future use. See Figure 2. Repeat procedure on the opposite side fork slider. 10. Peel off any excess adhesive from both reflectors. Surface must be clean for reinstallation. 11. Peel off one side of backing on foam double sided tape. Press firmly on tape to secure it to reflector. Repeat double sided adhesive tape installation on remaining reflector. NOTE The bottom edge of reflector should be two inches (50 mm) above the center of the axle shaft. 12. See Figure 1. Remove second side (outside surface) of adhesive backing. Place reflector in position (1) and press reflector firmly into place to activate the adhesive. Repeat for remaining reflector. 13. Pump brakes prior to test riding vehicle.

HARLEY DAVIDSON HAND LEVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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BRAKE LEVER INSTALLATION 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. 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 (4) from the groove in the pivot pin (B) and discard retaining ring. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. NOTE New brake levers come with the pivot lever bushing installed. NOTE Follow the instructions in Steps 3 and 4 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04342 1 of 3 4. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 5. Install the pivot pin removed in Step 2 and new retaining ring (4) from kit. 6. 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) 7. 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. 8. 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) 9. 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. SERVICE PARTS

HARLEY DAVIDSON CHROME FORK SLIDERS REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVAL 1. Support the motorcycle so the front end is off the floor and the forks are fully extended. 2. Remove the front fender, front brake caliper(s) and front wheel according to instructions found in the Chassis section of the appropriate service manual. NOTE On some models other parts will also need to be removed to access the front forks. See the service manual. 3. For All Models EXCEPT Touring: Drain and remove the front forks. See the service manual. 4. For Touring models equipped with air-adjustable suspension: Bleed the air-adjustable suspension according to the instructions in the appropriate service manual. Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) 5. For 2000 and Later Models EXCEPT Touring: See Figure 1. Using a piece of dental floss (or similar material) in a back and forth motion, loosen reflector from fork slider at both ends. Rotate reflector from side-to-side until it can be removed. Save reflector for future use. See Figure 2. Repeat procedure on the opposite side fork slider. Peel off any excess adhesive from both reflectors . Surface must be clean for installation. 6. Disassemble the front fork tubes according to instructions in the service manual. INSTALLATION NOTES The chrome fork sliders included in this kit install in the same manner as the original equipment parts. Refer to the service manual for proper installation procedures. Prior to installation of this kit, check the bores of the new chrome sliders to be certain they are free of dirt and debris or damage to the new sliders may occur. 1. Assemble the front fork tubes, replacing worn seals, bushings or other items as needed. NOTE Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws. 2. Tighten the drain screws: •Early Models with 39 mm forks (see Figure 2): Tighten to 13-17 in-lbs (1.5-1.9 Nm) •Early Models with 41 mm forks (see Figure 2): Tighten to 52-78 in-lbs (5.8-8.8 Nm) •Later Models (see Figure 3): Tighten to 52-78 in-lbs (5.8- 8.8 Nm) 3. Fill with TYPE E FORK OIL (99884-80) according to the instructions in the service manual. 4. Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel and caliper(s) according to instructions in the service manual. 5. For Touring models equipped with air-adjustable suspension: Refill the air-adjustable suspension system after assembly according to the service manual instruc- tions

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HARLEY DAVIDSON SCREAMIN' EAGLE MECHANICAL COMPRESSION RELEASE FIX- TURE

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

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DRILLING AND TAPPING PROCEDURE Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) NOTE Perform the following procedure on both the front and rear cylinder heads. Tool Setup NOTE Due to slight manufacturing differences, it may be necessary to tap the fixture into place with a rubber mallet. Do NOT use excessive force. 1. Align the fixture’s locating pins with the 3/8 inch tooling holes in the head and install the fixture on the head. 2. See Figure 1 and Figure 6. Secure the fixture (1) to the head with two 5/16-18 socket head cap screws (2) and washers (9) included in the kit. Install the screws in the holes marked “F” when modifying the front head or in the holes marked “R” when modifying the rear head. Tighten screws to 80 in-lbs (9 Nm) . 3. See Figure 3 and Figure 6. Install the drill bushing (3) in the bore marked “FRONT” when modifying the front head or in the bore marked “REAR” when modifying the rear head. 4. Tighten drill bushing set screw to 50 in-lbs (5.6 Nm) . 5. See Figure 2 and Figure 6. Install collar stop (4) onto the 1/2 inch diameter shank of the step drill bit (5). Secure the collar stop with the set screw 3.900 inches (9.90 cm) from the beginning of the 3/4 inch diameter step of the drill bi

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

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