HARLEY DAVIDSON DYNA SECURITY SYSTEM SMART SIREN II KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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This kit fits 1996 through 2003 Dyna INSTALLATION 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 disarm the security system, remove the seat, and disconnect the battery cables (negative cable first). Retain all seat mounting hardware. 2 1 is 01366 1. Siren connector 2. Dust cap Figure 1. Siren Connector 2. See Figure 1. Locate the siren connector (1). It is covered by a black dust cap (2) and is at the end of an unconnected 10 inch (254 mm) long harness leg starting near the rear fender, close to the rear lighting connector. Free the siren connector from its constraints. 3. Remove the dust cap from the connector. 4. See Figure 2. Snap the siren (2) into the siren bracket (3) so that the sounder disc (4) fits the notch in the bracket as shown. Connect the siren connector (1) to the siren.

HARLEY DAVIDSON NOSTALGIC TWIN CAM 88 AIR CLEANER COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. Remove current air cleaner cover and screw. 2. See Figure 1. Coat threads of screw (1) from kit with Loc- tite® 243 (blue) (Harley-Davidson part number 99642-97). Install new air cleaner cover (2) with screw (1). If this kit will be installed with a Screamin’ Eagle Twin Cam 88 high flow air cleaner kit, place the self adhering gasket (must be purchased separately) inside the cover between the air filter and the cover. Tighten screw to 36-60 in-lbs (4.1- 6.8 Nm)

HARLEY DAVIDSON CHROME INNER PRIMARY COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1 2 3 is06139 Figure 1. Remove Three Original Equipment Screws As Shown 1. See Figure 1. Remove the stock fasteners as shown in Figure 1. Save screw (3) for reuse. 2. Install the stock fastener in the rear inner cover. Place a locating washer over the fastener with the rounded side facing toward the hole in the primary chain case. 3. Slide the rear inner cover into place and loosely secure it with the stock fastener. 1 is06416 1. Acorn nut Figure 2. Fasten Front And Rear Inner Primary Covers Together 4. See Figure 2. Position the front inner cover over the rear inner cover and make sure that the hole in the front cover fits over the threaded stud in the rear cover. Secure the covers together with the acorn nut installed finger tight. 5. See Figure 3 and Table 1. Place the new 4.25 inch (5) and 1-1/2 inch (4) screws in the front inner primary cover. Place locating washers (6) over the fasteners with the rounded side of the washer facing toward the hole in the primary chain case. 6. Tighten all three screws to 108-120 in-lbs (12.2-13.6 Nm) . 7. Tighten the acorn nut. 8. Push the Allen hole plugs (7) into the four exposed screw heads

HARLEY DAVIDSON FL BACKREST PAD KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. See Figure 1. If necessary, cut the plastic rain seal away from the three pre-cut screw holes (D) in the backrest pad (1) to prevent the plastic from catching in the threads. 2. On motorcycles with Detachable Sissy Bar Upright installed: a. Install three long spacers (3) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the sissy bar upright (A). On motorcycles with Detachable Short Passenger Sissy Bar Upright installed: a. Install three long spacers (3) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the detachable short passenger sissy bar upright (B), inserting the three spacers through the slots in the sissy bar tabs (C). On motorcycles with Luggage installed: a. Install three short spacers (4) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the upright (A). 3. Place the mounting bracket (2) against the spacers, so that the holes of the mounting bracket align with the spacers. NOTE To avoid misalignment and cross threading of the screws, start all three screws into the backrest before tightening. 4. Insert a screw (5) from the kit through one of the spacers, and carefully thread it 4-5 turns into the mating hole in the backrest pad. Repeat with the other two screws. DO NOT tighten a screw until all three screws have been started. NOTE Spacers must seat squarely against the mounting bracket. 5. Once all three screws have been carefully started into the three holes of the backrest pad, tighten the screws to 7-10 in-lbs (0.8-1.1 Nm)

HARLEY DAVIDSON SOFTAIL SPORT LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-02-2011

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INSTALLATION NOTE Cover the rear fender with a clean shop towel to prevent scratching. Damage to the finish could result. 1. See Figure 1. Remove the four button-head TORX screws attaching the sissy bar (5) to the sideplates (4). Discard the screws 2. Remove the sissy bar and set it aside. For Rigid-Mount Sideplates only: Loosen, but do not remove, the hardware securing the sideplates to the motorcycle. 3. Position the luggage rack between the sideplates. Reinstall the sissy bar into the sideplate channels. 4. Apply Loctite 271 (Red) to the flat head TORX screws (2) from the kit, and insert through the holes in the luggage rack (1), sideplate, and sissy bar. Tighten the screws to 8-10 ft-lbs (10.8-13.6 Nm) . For Rigid-Mount Sideplates only: Apply Loctite 271 (Red) to the screws securing the sideplates to the motorcycle, and tighten to 21-27 ft-lbs (28.5-36.6 Nm) . 5. Remove the backing strip from the two rubber bumpers (3) and install onto the luggage rack. a. Align the notches in the bumper with the bottom edge of the channel on the sideplate. b. Wrap the bumper up the side of the luggage rack channel and across the bottom of the sissy bar. When properly installed the bumpers will cover the lower flat head screws, and will bend around the lower edge of the channel. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg)

HARLEY DAVIDSON SUPPLEMENT ARY 12 VOLT POWER SOURCE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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Installation NOTE This power source can be mounted on either side cover of the motorcycle, except on models with cruise control, which must have the power source mounted on the right side cover. 1. Remove seat and the side cover chosen for installation (see note above). 1 WARNING To avoid accidental start-up of motorcycle, and possible personal injury, disconnect the battery cables (negative cable first) before performing any of the following procedures. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 2. Disconnect battery, negative cable first. 3. See Figure 1. A 7/8 inch diameter hole needs to be drilled in the top of the side cover to mount the power source. It is important that the hole is properly located as follows, before cutting : a. Cut out template on page 3. Line the template up on the outside top of the cover using the top and rear cover edges as guides as shown in the illustration. Tape the template in place. b. After the template is in place, locate the appropriate hole on the template that matches the applicable year and side cover. Check to be sure that the entire hole area is on the flat top surface of the cover. No part of the hole should extend onto the sharply curved edge of the cover. 4. Carefully drill a 7/8 inch diameter hole at the location marked on the template. Drill from the outside of the cover to the inside. 5. See Figure 2. Unscrew outer sleeve of socket assembly (1) from socket body. Place the socket body into the cover hole and secure the socket in place by screwing

HARLEY DAVIDSON BILLET CLOCK, FRONT BRAKE MASTER CYLINDER MOUNT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. See Figure 1. Clean the face of the front master cylinder reservoir with denatured alcohol and a paper towel. 2. Remove the paper backing from the adhesive strip, and line the clock up squarely to the master cylinder reservoir as shown. Press firmly into place and hold for a few seconds. 3. Let the adhesive set for a while before setting the time. SETTING THE TIME ON THE CLOCK 1. Using the hex key included in the kit, remove the two screws securing the faceplate to the clock housing 2. Lift off the faceplate and “O”-ring, and set aside. Lift the clock face and movement assembly out of the housing. 3. Pull out the stem carefully, and turn it until the hands indicate the correct time. Carefully push the stem back in to start the clock. 4. Check that the “O”-ring is in place in the faceplate, and re-install the faceplate to the clock housing. Do not over- tighten. REPLACING THE CLOCK BATTERY The clock battery (Type SR626SW) is a common type, available wherever watch batteries are sold. When storing the motorcycle for a long period, pull out the stem carefully to stop the clock and save battery life

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HARLEY DAVIDSON ADJUSTABLE MALE-MOUNT FOOTPEGS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. 3. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer, along with the mount end of the footpeg, inside the slots of the footpeg supports. Make sure the spring washer is positioned inside the footpeg support with the square edge towards the inside of support as shown at the bottom of Figure 1. 4. Secure each footpeg and spring washer with the screw and locknut removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm) . 5. For each footpeg, loosen the adjusting screw in the recessed hole until the footpeg rotates. Position the footpeg as desired, then tighten the adjusting screw as follows: For Kits 50133-95, 50134-95 or 50500-03: Tighten to 21 ft-lbs (29 Nm) . For Kit 50474-03: Tighten to 14-16 ft-lbs (19-22 Nm)

HARLEY DAVIDSON SECONDARY BELT EMERGENCY KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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The 40101-80 kit, with a 126 tooth belt, fits: •1980-1986 FXB and 1984-1986 FXWG models This kit may also be used on 1989-1992 international Softail models with a 127 tooth belt. The 40171-97 kit, with a 130 tooth belt, fits: •1995 and later domestic Softail models •1994 and later international Softail models •1994 and later international Dyna models The 40109-86 kit, with a 132 tooth belt, fits •1986-1992 and 1994 domestic Softail models •1989-1993 international FLT and FXR models This kit may also be used on the following models with 133 tooth belts: •1991 and later domestic Dyna models •1991-1992 international Dyna models •1994-1995 international FLT models The 40100-85 kit, with a 136 tooth belt, fits: •1985-1994 domestic FXR models •1985-1996 domestic FLT models •1996 international FLT models The 40112-97 kit, with a 139 tooth belt fits •1997 FLT models Installation 1. Put transmission in ‘Neutral’. 2. Loosen rear axle nut. Loosen rear axle adjuster nut on each side of motorcycle, and move rear wheel to full forward position. 3. Remove the damaged/broken belt. 4. Inspect sprockets and belt guard for damage and/or debris. Remove any debris. If sprockets and belt guard are not damaged, proceed with the installation. 5. See Figure 1. Remove belt guard. 6. See Figure 2. Install feeder strip on emergency belt. Feed strip around transmission sprocket in a counterclockwise direction over frame cross support.

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HARLEY DAVIDSON SOFT LOWER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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This kit fits 1980 and later Touring models equipped with engine guards. It does not fit with mustache engine guards INSTALLATION NOTE Soft lowers should not be used in temperatures above 55 degrees Fahrenheit. Engine cooling air flow will be affected and could lead to overheating and possible engine damage. 1. Apply a light coating of silicone grease to cavities of snaps prior to installing soft lowers on motorcycle. 2. See Figure 1. An opening is provided in the soft lowers for mounting highway footrests (1) to engine guard. If using footrests, mount within the opening to prevent buckling of splash guard fabric. 4. Remove adhesive liner from back of reflector. NOTE The ideal temperature should be at least 60° F (16° C) for proper adhesion of the reflectors. 5. Place reflector on fender and press firmly into position. 6. Let the adhesive cure for 24 hours at no less than 60° F (16° C). 7. Repeat steps for other reflector