HARLEY DAVIDSON FAT HANDLEBAR RISER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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INSTALLATION NOTES The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. See Figure 1 for the following procedure. 1. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the internal tooth lock washer (H) are located on the right side only. Do not tighten the riser mounting screws (I) at this time. 2. If an appropriate Harley-Davidson 1-1/4 inch handlebar has not been installed, install one according to the Instruction Sheet included with the kit, or re-install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers using four socket head screws (3) as shown. 4. Ensure that the risers stay properly aligned with the handlebar and tighten the riser mounting screws (I) to 50-60 ft-lbs (68-81 Nm) . 5. Adjust handlebar to the desired position, ensure that it is centered on the risers, then, starting with the front screws, tighten the four socket head screws (3) to 12-15 ft-lbs (16- 20 Nm) . 6. Turn the handlebars full right and left. Check that: •The handlebars and triple tree clamps do not contact the fuel tank. •The steering stops function properly. •The wiring and brake line are not pinched or kinked in the steering assembly. •Throttle returns from full open to close at both fork stops. Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) •If you are installing different handlebars, measure the change in distance that will be required from the end of the stock brake line to the brake master cylinder. •Compare this revised length to the brake line provided in your kit. •If the line is more than 2.0 in. (50.8 mm) longer or more than 1.0 in. (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct brake line length

HARLEY DAVIDSON HANDLEBAR POLYURETHANE RISER BUSHING KIT INSTALLATION MANUAL

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

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INSTALLATION NOTES • Cover fuel tank with blanket or towels to keep paint from being scratched. • See the Touring Service Manual for the Fairing Removal procedure in order to gain access to the handlebar assembly. 1. For Touring Models: See Figure 1. Remove and save the the existing capscrews (C). Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard cup washers (D), rubber bushings (E) and spacers (F). Install the new bushings. For All Models Except Touring: Remove and save the two capscrews (C) from underneath the upper fork bracket that hold the existing lower clamps (risers) (B) in place. Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard the existing cup washers (D), rubber bushings (E) and spacers (F). NOTE The upper bushing and lower bushing must be oriented with flat side opposite from each other as shown. 2. Install the new polyurethane riser bushings (1) in place of the removed cup washers, bushings, and spacers. 3. Align components as shown in Figure 1. 4. Secure components with two hex head capscrews removed in Step 1. Insert the capscrews, from the bottom, thru the upper fork bracket, thru the bushings (1) and into the clamps (risers). See the service manual for the torque specification. 5. See the service manual and install the handlebars

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HARLEY DAVIDSON PULLBACK RISER KIT FOR 1.25-INCH HANDLEBARS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVAL NOTES Cover the fuel tank with clean shop towels to prevent scratching. If replacing the handlebar, refer to the service manual to remove controls, hand levers, handlebar and risers. If only the risers are being replaced, proceed as follows: 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for assembly. Retain all additional components from the riser assembly when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers and carefully set the handlebar on the fuel tank. INSTALLATION NOTES See Figure 3. The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. 1. See Figure 3. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the lock washer (F) are located on the right side only. Do not tighten the riser mounting screws (4) at this time. 2. If an appropriate Harley-Davidson 1-1/4 inch handlebar has not been installed, install one according to the Instruction Sheet included with the kit, or install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers with the Bar & Shield toward the front of the motorcycle (Figure 1, Item 1). Install four socket head screws (3) with four washers (6). 1 is05253 1. Bar & Shield (install toward front of motorcycle) Figure 1. Bar & Shield on Riser and Cap 4. Check that the risers stay properly aligned with the handlebar and tighten the riser mounting screws following the instructions in the service manual. 5. Adjust handlebar to the desired position, verify that it is centered on the risers, then tighten the front socket head screws (3) to 12-15 ft-lb (16-20 Nm) . There should be no gap at the front of the risers.

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Kawasaki Versys Handlebar Riser Removal and Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove four plastic screw caps with a small screwdriver or by hand, and keep them for the future Create PDF files without this message by purchasing novaPDF printer Unscrew the four handlebar screws with the 6 mm Allen wrench, as shown 3) Place a towel on the tank area to protect it and pull back the handlebar assembly, as shown 4) Position the handlebar riser as shown, so the top holes are spread further apart than bottom ones Create PDF files without this message by purchasing novaPDF printer C MOTOWERK ™ 3 5) Insert the handlebar riser in between the two existing handlebar assembly parts as shown Create PDF files without this message by purchasing novaPDF printer Copyright Screw the two M-8 screws provided into the top holes with the 6 mm Allen wrench, as shown 7) Screw the two M-8 screws provided into the bottom holes with the 6 mm Allen wrench, as shown