HARLEY DAVIDSON VRSCD SADDLEBAG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Prepare Bike for Hardware Installation 1. Use a suitable lift to support the motorcycle under the frame until the rear suspension is fully extended. NOTE To remove the tether from the hole in the frame, reach under the frame tube to align the metal tee (located on the end of the seat tether) with the tether cable. 2. See Figure 1. Unlatch and open seat. Remove tether (4) by sliding small clip (3) sideways through hole in frame. NOTE To remove the tubular plastic seat-hinge sleeve from the hinge, turn the sleeve to reveal the slotted length. Push on the slot with your finger to pop the sleeve off the hinge pins. Closing the seat slightly allows the sleeve to fall from the hinge-side of the seat, so be prepared to catch the sleeve. 3. Remove plastic sleeve (2) from hinge pins (1) and slide pins toward rear of bike. Remove seat. 2 1 4 3 is 00449 1. Hinge 2. Sleeve 3. Clip 4. Remove tether from frame Figure 1. Remove Seat 3 1 2 is 00450 1. Grabstrap 2. Passenger Pillion 3. Screw and Washer Figure 2. Remove Passenger Pillion 4. See Figure 2. Remove screw and washer (3) securing passenger pillion to frame. Slide pillion under grabstrap (1) and forward to disengage from tongue to remove. Save pillion mounting screw and washer for later use

HARLEY DAVIDSON FLSTC & FLSTS DOCKING HARDWARE WITH SADDLEBAG SUP- PORTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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The rear docking points in kit part number 90366-03 provide the rear mounting points for the Solo Rack. The rear mounting points from this kit ( 53931-03A ) will need to be installed to provide the clearance for the Solo Rack to be mounted. Table 2. Turn Signal Relocation Kit Requirement Turn Signal Relocation Kit Required Accessory Part Number 2003 and later FLSTC Not required 53815-00 Detachable Sideplates Not required 53066-00A Detachable Tour Pak Rack REMOVAL FLSTS Saddlebag Assembly Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Repeat steps 1 – 2 on the other side of the vehicle. FLSTC Saddlebag and Fixed Mount Sissybar Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts, but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Remove and discard fixed mount sideplates. Retain sissy bar for use with detachable sideplates. 4. Repeat steps 1 – 3 on the other side of the vehicle. 1 is06914 1. Saddlebag support studs Figure 1. Original Equipment Hardware (FLSTS model shown) INSTALLATION Docking Hardware Installation – For Detachable Sideplates or Tour-Pak Rack NOTE See Figure 15. The rear docking point (8) is wider than the front docking point (2). -J02425 1 of 5 1. Place front docking point (2) on front stud (1), with countersunk end of docking point facing fender support. 2. Place spacer (6) for side plates or mid docking point (for detachable sideplate kit) on rear stud (1). 3. Place rear docking point (8) on bolt (7), with countersunk end facing fender support. 4. Insert front stud (1) through front docking point (2), fender support and into bracket underneath fender as shown. 5. Insert rear stud (1) through fender support and into bracket underneath fender as shown. 6. Install bolt (7) through fender support and into bracket underneath fender as shown. 7. Tighten front and rear studs (1) and bolt (7) to 27 ft-lbs (37 Nm) . 8. Repeat steps 1-7 on the other side of the vehicle.

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HARLEY DAVIDSON ILLUMINATED CHROME COVER KIT FOR FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION Preparation Models with main fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. Models with main circuit breaker: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. Installation NOTE Cover the work surface with an H-D Service Cover or clean shop towels to prevent scratching the finish of the outer fairing. 1. Remove the outer fairing per the instructions in the service manual. Lay the fairing face down on a sturdy work sur- face. 2. See Figure 2. Remove the mirrors (2), flange nuts (3) and plastic backing plates (4) securing the mirrors to each side of the inner fairing (1), and retain all items 3. Measure one inch (25 mm) straight down (5) from the large mirror stud hole in the inner fairing, and make a mark. 4. Drill a 1/4 inch (6 mm) diameter hole (6) through the inner fairing at the mark. 5. See Figure 1. Obtain a chrome wire collar (3) from the kit, and press it into the new hole from the outside of the inner fairing. Gently tap into place with a soft-faced hammer. 6. Repeat Steps 3 through 5 on the opposite side of the inner fairing. NOTE Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the mirror cover to the mirror. 7. Clean the back surface of the mirrors with the alcohol pad (7) provided. Allow to dry thoroughly. 8. Obtain the primer tube (8) from the kit, and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back surface of one mirror. 3 6 2 1 4 5 is06091 1. Inner fairing 2. Fairing mount mirror 3. Flange nut (2) 4. Plastic backing plate (2) 5. Measure one inch (25 mm) down 6. Drill 1/4 inch (6 mm) hole (2) Figure 2. Fairing Drill for Illuminated Mirror NOTE The Illuminated Chrome Mirror Covers are side-specific. The covers install with the wire harness exiting from the bottom. 9. Obtain the correct mirror cover from the kit. Rub the liners on the three pads on the back surface of the mirror cover to activate the adhesive, then remove the liners. 10. Place the mirror cover over the back surface of the mirror and press into place for a minimum of 60 seconds. 11. Repeat Steps 8 through 10 for the remaining mirror and cover. NOTE The plastic backing plates (removed earlier) are identified with a letter “L” (left) or “R” (right) stamped on the post. The mirrors are marked with a letter “L” or “R” stamped on the swivel block. Use the correct backing plate for each mirror by matching the letters. 12. Position the mirror on the outer face of the inner fairing, with the rounded side of the mirror outboard and the Bar & Shield logo upright. a. Insert the mirror cover wiring harness through the chrome wire collar installed in Step 5. b. Insert the mirror post through the original mirror mounting hole. c. Place the correct plastic backing plate against the inner face of the inner fairing, engaging the two holes in the backing plate with the threaded stud and index pin on the mirror swivel block. d. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . e. Repeat for the remaining mirror on the other side of the fairing

Ultima Billet Rear Shocks Installation Instruction Sheet

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Filed Under (Tips and Review) by admin on 30-11-2010

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Unloading the rear suspension Use a jack under a flat part of the motorcycle and lift until the rear tire is barely resting on the surface. This ensures that the shocks are unloaded. They are now ready for removal. Remove the old shocks Refer to the service manual specific to your motorcycle for this process. Unbolt the old shocks. Save the necessary hardware if you have not purchased new hardware. Installation Shocks should be installed with the preload adjuster on top (see Preload Adjustment). With the new shocks in hand; please go over the hardware configuration diagram (Figure 3) to decide which configuration best fits your application. Spacers are included to provide clearance between the shocks and your motorcycle (Figure 4). Typically start on which ever side the final drive is located. This side normally causes the clearance issues. Each eye and each side should be configured the same way. Make sure to use the proper hardware so that the shock- bushings fit the shock-bolts as snugly as possible. Shocks come with a 1/2″ ID bushing installed. This is needed for all applications. An optional bushing is included and should be used in addition when 3/8″ bolts are used instead of the larger 1/2″bolts. Unless new hardware was purchased, you will use the stock bolts from your old shocks to install the new shocks. Use Red Locktite (or equivalent) and use a torque wrench to tighten as follows: Models that use 1/2″ bolts: 65ft-lbs Models that use 3/8″ bolts: 30ft-lbs (Figures 1 & 2) Be sure to check clearance between the shock and the belt-guard. If there is any contact you will need to alter your spacer arrangement to accommodate this. Check tire to fender clearance as well. This clearance will be reduced when lowering shocks are used. Preload Adjustment Your new Ultima Billet Shocks are preload adjustable. Adjustment should be done once the shocks are installed. To adjust use a strap wrench and turn the top part of the shock (Figure 6) clock-wise to tighten or provide more preload (this stiffens the suspension), or counter-clockwise to loosen or subtract preload (this softens the suspension). Hand adjustments may be sufficient on models with smaller spring rates while the strap wrench will be required on the high spring rate shocks. You will see notches (Figure 6) that appear on the shock as the shock is preloaded. These should help you obtain the same preload for both sides of the motorcycle. Both shocks should be adjusted to the same level of preload.

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