Harley Davidson Steering Wheel Radio Control Interface Installation instructions

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Filed Under (Harley Davidson) by admin on 03-05-2012

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1) Turn on the ignition to supply power to the SWI-3. 2) Use a pen to depress the “program mode” button. Remove pen when left LED light comes on. 3) Within 10 seconds press and hold one of the steering wheel function buttons. Continue to hold steering wheel button until the left LED turns off. Release the steering wheel button and the right LED turns on. 4) Place the stereo’s IR remote within 3″ of the “IR Input” port on the side of the SWI-3 next to the program button. Press and hold the remote’s button that corresponds to the steering wheel button that was pressed. Continue to hold the remote’s button until the right LED turns off. Release the button and the left LED will turn on. 5) Repeat steps 3 and 4 until all radio steering wheel functions are programmed. 6) When programming is complete, wait 10 seconds and both LED’s will flash 3 times. This indicates an automatic program exit. Do not stop more than 10 seconds while programming or there will be an automatic program exit and you will have to start over at step number 2 above. Turning off ignition before the automatic exit will require starting over at step 2 above. The SWI-3 can be reprogrammed unlimited times. Testing • Test the SWI-3 by holding it’s infrared LED (LED on the end of 4′ lead) close to the stereo and verify that it works properly. Experiment with various locations for the LED. You should be able to find a hidden and convenient mounting location. Try along the top front and /or bottom of the stereo as well as it’s sides. The LED can be replaced with most any IR LED, like Radio Shack’s # 276-143. The longest lead of the LED connects to the red wire of the 4′ cable and the short lead of the LED connects to the black wire of the 4′ cable

Harley-Davidson XL 883 and 1200 MODELS SADDLEBAG SUPPORT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1. 1994-99 models: Remove upper shock absorber nut, washer, shock cover and backing washer. Save nut and washer and discard shock cover and backing washer. 2000-03 models: Remove upper shock bolt, washer and shock cover and save washer. NOTE: Do not remove stock inboard washer that is positioned behind shock cover and against shock absorber. 2. All models: Remove OEM buttonhead screw and flanged nut directly to the rear of the upper shock mount on fender support. Note T-spacer in fender support. Save nut and discard bolt. 3. 1994-99 models: Position saddlebag support (item 1) with front bracket over shock stud and rear mount over hole in fender support. Install ½ * bushing (Item 2) over shock stud and into hole of support front mount. Install saved OEM nut and washer (items 3,4) and tighten securely. 2000-03 models: Apply Locktite to the OEM shock screw (Item 5) and install through the saved washer (Item 6), front bracket of the saddlebag support (Item 1), shock and into the frame. Tighten to 21-35 ft. -lbs torque. NOTE: If installing supports with sissy bar side plates, omit 5/16 * lock washer (Item 8). H-D sissy bar side plate mounts between fender support and fender. Khrome Werks® sissy bar plate mounts outboard of fender support. CAUTION: Be careful to not dislodge T-spacer from its position in fender while inserting screw through fender support and fender. 4. Insert supplied socket head cap screw (Item 7) and lock washer (Item 8) (if applicable) through the rear saddlebag support mount, sissy bar side plate (if applicable) , fender with T-spacer and frame. Apply Loctite to the saved flanged nut and secure. Tighten to 8-13 ft-lbs torque.

Harley-Davidson FLTR/ FLH/ FLHT/ FLHR EFI models 1995-2001 Variable Pressure Fuel Regulator Intallation manual

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1 . Ensure vehicle runs correctly through all rpm ranges and idles correctly before attempting any work. It is highly recommended that a pressure / flow test be carried out before & after installation of the VariReg to determine fuel system condition . Stock HD 300 kPa / 44 psi, VariReg as delivered 360 kPa / 52 psi Note: In some countries gas stations do not “final filter” the fuel & therefore we recommend that the fuel filter canister be replaced every 15,000 klms (10,000 miles). Restriction of the fuel by way of a blocked or partially blocked filter will result in difficulty in tuning or failure to obtain satisfactory results during tuning. Should you experience difficulties in tuning, see Diagnosing fuel filter and pump faults 2. Remove air filter cover, air filter and backing plate. Check Throttle Position Sensor value at completely closed throttle as best performance will be obtained at the nominated settings. This will require backing off the idle screw and cold start idle actuator and screw adjustment as described in the workshop manual. The original T.P.S. values should be recorded for possible future reference. To set TPS values without the HD breakout box see VariReg TPS Setting for Harley-Davidsons The T.P.S. values must be set to 1995 – 1996 175 mV (+/- 25mV) 1997 – 2001 275 mV (+/- 25mV) Record the original TPS value here. ………………..mV YOU MUST ENSURE THROTTLE PLATES ARE COMPLETELY CLOSED AND NO BINDING EXISTS IN CABLES to obtain the correct value setting. 3. Reset idle screws to approximate previous settings, no need to start the engine. 4. Complete full or partial fuel tank removal as described in workshop manual. 5. Remove stock fuel pressure regulator as described in workshop manual and leave Horn removed from vehicle until after tuning, this will allow ease of access to the regulator

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Harley Davidson Honing Plates Installation Manual

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Filed Under (Harley Davidson) by admin on 25-04-2012

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Honing Plate Kits are available for the Harley Davidson Shovel Head, Evolution and Twin-Cam engines. Kits are supplied with a Base Plate, which features side clamping of the spigot area on the Jug to address the recurring problem of spigot deflection during honing. This is especially prevalent in large-bore applications and will eliminate additional clearance that would be necessary to achieve correct piston to cylinder wall clearance. The Plate allows the user to hone straight, round bores through the full length of the Jug. The Plate also has tapped holes in the bottom surface to facilitate clamping onto most honing machines. The Shovel/Evolution Kit is supplied with the above Base Plate machined with a dual bolt pattern to accept both Shovel Head and Evolution Jugs. Two Honing Plates are included, to accommodate each engine type. A Hardware Kit containing all the fasteners needed to simulate the assembled engine condition for both setups is also included. The Twin-Cam Kit is supplied with the above Base Plate machined with the bolt pattern to accept the Twin-Cam Jug and one Honing Plate. A Hardware Kit containing all the fasteners needed to simulate the assembled engine condition is also included.

Harley-Davidson Standard Seat Installation Instructions

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Filed Under (Harley Davidson) by admin on 24-04-2012

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Step 1 – Remove the original seat and place it bottom side up next to your new custom replacement seat. Step 2 – Remove each bracket from your original seat and install it in the corresponding location on your new seat, using the 1/4-20 bolts provided. Place the new bolts through the brackets and into the threaded jacknuts in the new seat bottom. Repeat until all hardware is transferred. Step 3 – Check all fasteners for tightness, 10-15 ft/lbs is recommended, do not over-tighten. Step 4 – Remove rubber bumpers from your original seat and move them to your new custom seat. In some instances we have already installed bumpers that are needed, but some models require the special specific bumpers from your original seat for proper tolerance and fit. The stock bumpers are easily removed by twisting and pulling at the same time. Reinstallation requires drilling a hole of the same diameter as the original into the new seat pan. Rubber bumpers are most easily installed using either water or silicone spray as a lubricant.
Step 5 – Reinstall the seat on the motorcycle. Check to make sure the seat fits properly. The new seat will be more firm than the original seat and will break-in over time to provide greater comfort. During the break-in, the seat will also settle-in, or lower, about ½ to one inch. Older seats may seem substantially lower because of the worn-out, compressed foam that has deteriorated with time on your original seat

HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

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HARLEY DAVIDSON EDITION F 150 LIGHTNING HIGH PERFORMANCE INTAKE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 22-04-2012

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Turn off ignition and remove negative battery connection. 2. Loosen the hose clamp on the OEM intake. 3. Disconnect the MAF sensor off intake 4. Pull out air temp sensor and then pull out intake unit. 5. Install NPT hose barbs in the cold air intake with the 1/4″ in the center position. 9.Connect the hoses to the S&B intake tube 6. Put the 4.5x2hose adapter with #72 hose clamps on the S&B tube . 10. Install the S&B intake on the throttle body, push the air temp sensor into the tube 7. Locate the three vacuum hoses 11. Remove the air box grommets and use the 1/4″-20″ speed nuts 8. Place the small sections of 5/8″ hose on the vacuum hoses. 12. Install the hose adapter onto the MAF sensor assembly

Harley-Davidson feuling Adjustable Pushrods Installation Instructions

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Filed Under (Harley Davidson) by admin on 22-04-2012

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1. Refer to the proper factory service manual for your model and year of engine, for removal of existing pushrods. 2. The Feuling pushrods are designed with a small adjustment parameter for rigidity creating maximum lift – These are not quick install pushrods and may require the removal of the lifter blocks and or loosing of the breathers/rocker arms supports. When loosening the rocker arm supports always remove the breather bolts first. 3. Clean and inspect each new Feuling pushrod including center oil hole 4. Feuling pushrods are marked Intake and Exhaust. The shorter pushrods are Intake and the longer pushrods Exhaust 5. Feuling recommends using new O-rings and gaskets where applicable to prevent oil leaks
6. Always pump up hydraulic lifters before installing them. Use an oil squirt can to fill the lifter with oil through the feed hole on the side of the lifter, push oil through the feed hole until the air bubbles are gone. If needed work the oil back and forth through the feed hole and pushrod seat with the squirt can. Light weight oil can be helpful. 7. Assemble and adjust one cylinder at a time, the servicing cylinder needs to be on TDC of compression stroke so the cam lobes are at their lowest point 8. Install pushrods into proper locations with the adjusting side of the pushrod down, towards the lifter. Slide the pushrods through the pushrod covers up into the rocker housing and set the pushrod on the seat of the lifter. We recommend filling the pushrods with oil then maneuver the pushrod up into the rocker arm seat. 9. Torque rocker arm housings and breathers to factory torque spec’s 10. See the instructions for your lifters for the proper adjustment. All Feuling hydraulic lifters run best at . 090″ – . 100″ of crush.

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CYCLE SOUNDS T-TAP POWER HARNESS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-04-2012

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This t-tap plug is designed to work with Cycle Sounds audio systems. However it can be used to wire many add on 12 volt accessories to you Harley Davidson motorcycle. This plug is rated for 6-8 amps of power and should not be used for adding any product that is rated for more than the t-tap plug is rated for. Take the time to check the products power rating for which you want to install to make sure it is compatible with the t-taps amperage rating. Failure to do so couldlead to electrical failures, which could result in serious injuries or even death. it is possible to overload your motorcycles charging system by adding too many electrical accessories. U se amp meter to verify all power connections. Also check product power ratings for anything you are trying to install. Exceeding the maximum amperage can lead to electrical failures, which could result in serious injuries or even death. INSTRUCTIONS: Step 1: remove seat on bike and locate the wire harness under the seat that matches the plugs on the t-tap harness (2120-0026.) Location may vary between bike models. Step 2: unplug bike harness and snap each end of t-tap harness in correct plug opening. When finished connect power wires to the male plug.(all Cycle Sounds audio systems come pre wired with correct wire colors and terminals). When using this t-tap for any other 12 volt accessory, make sure the red and black wires are snapped into their proper pin connectors. Kit does not come with power terminals for the accessories device. See your local bike dealer for purchase of terminals

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Harley-Davidson DETACHABLE SISSY BAR SIDE STRAPS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 20-04-2012

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1. Remove factory sissy bar upright. Save upright if to be reused. Remove the two factory buttonhead screws and washers from the fender support on each side. Remove factory side plates. Discard side plates and factory hardware. 2. Cement the Plastic Sliders (item #1) into the brackets on the Khrome Werks Side Straps (item #2), using contact glue. 3. Install the special buttonhead screws through the flanged spacers (items #7, 8), then through the fender supports, frame, and into the fender. 4. Assemble the Knurled Knob (item #6) to the Side Strap, using the 1⁄ 4 “-20 x 1⁄ 2 ” screw, chrome washer and compression spring (items #3, 4, 5). The spring goes under the washer and into the counterbore of the knurled knob. 5. Install your sissy bar upright into the Side Straps, using the 1 ⁄ 4 “-28 x 3⁄ 4 ” screws provided (item #9).