Harley-Davidson Evolution Engines S&S Billet Rocker Cover Assemblies Installation Instructions

0

Filed Under (Harley Davidson) by admin on 30-10-2010

download
1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of rocker housings. Refer to authorized Harley-Davidson®Service Manual as necessary. Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. Gasoline is toxic if fumes are inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson®Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head. NOTE: Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 3 CAUTION WARNING WARNING CAUTION 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

Harley-Davidson Twin Cam 88 S&S Billet Rocker Covers Installation Instructions

0

Filed Under (Harley Davidson) by admin on 30-10-2010

download
Failure to confirm pushrod/lifter placement before proceeding with installation can result in damage to rocker arm support plates and other parts. With pushrods at lowest point, front piston will be at TDC on Compression stroke. 4. Remove breather cover and baffle assembly. See Picture 2. 5. Remove rocker arm/rocker support plate. See Picture 3. NOTE – Gradually loosen rocker arm support bolts in following sequence (See Figure 1): 1. Left (driveside) rear 2. Right (camside) front 3. Right (camside) rear 4. Left (driveside) front Loosen bolts in sequence and in 1⁄ 4 -turnincrements for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 6. Remove lower rocker housing bolts. NOTE – Gradually loosen lower rocker housing bolts in following sequence (See Figure 2): 1. Right (camside) front 2. Left (driveside) rear 3. Left (driveside) front 4. Right (camside) rear 5. Center front 6. Center rear Loosen bolts in sequence and in 1⁄ 4 -turn increments for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 7. Remove lower rocker housing and gasket from head. Remove oil and any remaining gasket material from cylinder head gasket surface and clean gasket surface with lacquer thinner

1984-1999 Harley-Davidson Evolution Engines Replacement Cylinder Heads Installation Instructions

0

Filed Under (Harley Davidson) by admin on 28-10-2010

download
Installation of an S&S Super Stock cylinder head kit is easy and can be performed by any Harley-Davidson®repair shop equipped to do engine overhauls. No special tools other than those used in normal overhaul repair work are required. Read instructions thoroughly before starting work. When they are completely understood proceed with installation. 1. Remove Components and Inspect Parts Follow procedures outlined in appropriate Harley-Davidson® service manual to prepare motorcycle for top end service. NOTE: Disconnect batteryand drain all gasoline from gas tanks beforedoing any work. Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. A. Remove gas tanks and all other parts required to perform top end service. B. Remove carburetor, rocker covers, pushrods and pushrod tube assemblies, cylinder heads and cylinders. Also remove piston rings from piston. Do not remove pistons. NOTE: Be careful not to introduce any dirt or other foreign material into crankcase during disassembly of engine. Metal filings, dirtand any other foreign contamination in engine may cause premature wear and/or irreversible damage to bearings and other internal engine components. C. Thoroughly clean and inspect all parts that are to be reused. Any parts that show signs of wear or damage should be replaced. WARNING CAUTION 2. Check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result isthat the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as blue printing, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore.

Harley-Davidson CHROME/ BLACK FRONT MASTER CYLINDER COVER KITS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 28-10-2010

download
if this is a master cylinder cover replacement, start with step 1. If this is new installation for a hydraulic clutch kit, go to step 3. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Clean front master cylinder cover, then remove the two screws that hold the cover in place. 2. Remove the original cover (with sight glass) and gasket. 3. Put new cover and gasket in position. 4. See Service Parts illustration. Install the new cover screws (1) and tighten to 6-8 in-lbs (.7-.9 Nm). Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) NOTE The cover is lab led for D.O.T. 4 brake fluid. Install this cover on reservoirs filled only with D.O.T. 4 brake fluid. Do not mix grades of brake fluid. as they are not compatible and could cause equipment damage. SERVICE PARTS See Figure 1 and Table 1

Harley-Davidson Style Rocker Cover Assemblies installation Instructions

0

Filed Under (Harley Davidson) by admin on 27-10-2010

download
Installation 1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of OEM rocker housings. Refer to authorized Harley-Davidson Service Manual as necessary. WARNING – Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. WARNING – Gasoline is toxic when fumes inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head.
3 Picture 3 Picture 4 Right Left Rocker shaft reliefs must align with these holes. NOTE – Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. CAUTION – Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

Incoming search terms:

Harley-Davidson Road King Classic Saddlebag Locks INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 24-10-2010

download
1. Cut off the back stud (at the pointed end of the emblem) with a hacksaw. Hacksaw must have a fine tooth metal cutting blade. Allow blade to slide along the flat edges of the emblem as shown. 3. Place washer (J) over emblem stud and insert threaded stud through the hole in the backing plate (L). Place cloverleaf spring (K) over the stud and onto the backing plate with the dome facing up. Place flat washer (J) and nylon cap nut (I) on the stud and tighten until a smooth open/close rotation is achieved. See illustration at right. Emblem should snap in place and not rattle* 2. Thread the front stud with the tap provided. OIL THE STUD FIRST. Thread the stud square, using a socket or wrench. Make no more than a half turn at one time, always backing up one-half turn each time. 4. Pin template on the bag with #10 screws (T) provided. Make two 5/16″ holes where shown. Make one 3/4″ hole where shown with a punch, hole saw or drill bit. If drilling the 3/4″ hole always cut the leather off first using a sharp knife. Punches, either knock-out type or gasket type do the best job without removing the leather layer

Harley Davidson V-Rod SUPERCHARGER KIT Installation Manual

0

Filed Under (Harley Davidson) by admin on 24-10-2010

download
Your Sprintex® Supercharger Installation can only be carried out by an Authorised Sprintex® Approved Supercharger Specialist. No unauthorised service or alteration may be undertaken to the Sprintex Supercharger kit or standard motorcycle Specification. Any modification or alterations from the Sprintex or Harley-Davidson specification shall affect your Warranty. 2. FUEL SPECIFICATIONS V ROD® Minimum 95RON Premium Unleaded Fuel 3. SUPERCHARGER BELT AND PULLEY Must be inspected at every routine service and the belt replaced when required. 4. OIL SPECIFICATION (ENGINE ONLY) Harley-Davidson Type Viscosity Harley-Davidson Rating Lowest Ambient Temperature Cold Weather Starts Below 50F (10C) HD Multigrade SAE10W40 HD360 Below 40°F (4°C) Excellent HD Multigrade SAE20W50 HD360 Above 40°F (4°C) Good 5. SPRINTEX V ROD SUPERCHARGER The Sprintex V Rod® Supercharger warranty provides a guarantee against any manufacturing defect during the warranty period, 12 months from the date of purchase or 20,000 Kms, whichever occurs first. The warranty guarantees the replacement of any parts of the Supercharger Installation which fail as a result of a manufacturing defect in normal operating conditions and excludes circuit racing, speed trials, drag racing and any form of motor sport activities. In addition, any unauthorised alteration to the motorcycles original specification or failure to meet the approved service requirements will affect your warranty. 6. EXCLUSIONS The following items will void your Sprintex Warranty: a. Alteration from standard specification b. Unauthorised Service or repair works c. Fitting of non Sprintex approved replacement parts d. Use of non standard air filter e. Installation by any non Approved Sprintex Agent

Incoming search terms:

HARLEY DAVIDSON 2008-2009 FLHR, FLHRC, FLHT, FLHTC FLHTCU, FLHX, FLTR 1584CC INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 24-10-2010

download
1. Start the engine with the transmission in neutral or park. Listen for air leaks or odd noises. For air leaks secure hoses and connections. For odd noises, fi nd cause and repair before proceeding. This kit will function identically to the factory system except for being louder and much more responsive. 2. Test drive the vehicle. Listen for odd noises or rattles and fi x as necessary. 3. If road test is fi ne, you can now enjoy the added power and performance from your kit. 4. K&N Engineering, Inc., suggests checking the air fi lter element periodically for excessive dirt build-up. When the element becomes covered in dirt (or once a year), service it according to the instructions on the Recharger® service kit, part number 99-5050 or 99-5000. ROAD TESTING: • 1455 CITRUS ST., P.O. BOX 1329, RIVERSIDE, CA., U.S.A. 92502 • TECH SERVICE 800-858-3333 • FAX 951-826-4001 • e-mail: tech@knfi lters.com® • WWW: http://www.knfi lters.com® 10. Install the provided K&N® air fi lter and secure with the provided hose clamp. A black hose clamp is being supplied with kit. This clamp is intended to clamp the fi lter to the intake tube. NOTE: The K&N® high fl ow intake system is a performance product that can be used safely during mild weather conditions. During harsh and inclement weather conditions, you must install the K&N® Drycharger® onto the air fi lter.

Incoming search terms:

HARLEY-DAVIDSON SPORTSTER TURN SIGNAL RELOCATION KIT INSTALLATION AND CLEANING INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 23-10-2010

download
Remove turn signals. Observe and mark “left” and “right” for reinstallation. h Turn signal bracket may be oriented forward or backward as required. 4. Install turn signal bracket between license plate and license plate bracket using 1/4”- 20 x 3/4” Hex cap screw, 1/4” SAE flat washers, and 1/4” – 20 locknuts. Note: For Bullet style turn signal light models refer to fig. 3, disassemble and discard turn signal extension and insert 8 x 22 x 5mm black plastic spacer in place of the extension. 5. Mount turn signals directly to bracket using 5/16” – 24 x 3/4” hex cap screws with 5/16” lock washers and 5/16” flat-washers. If original wire was inside stalk, remove plug and reroute wires to outside. For a clean installation remove top center mounting bolt on license plate bracket and run wires through this hole. h Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. h WARNING: Some states may have minimum width requirements on motorcycle turn signals, so check your local laws. 6. Turn signal wires must be extended. We recommend splicing inside turn signal housing. Splice wires, one at a time, while observing color code. 7. Connect battery and test turn signals for function. SADDLEBAG INSTALLATION h Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points.
Leatherlyke Refer to Figure 2. 9. Remove rear fender mounting bolt on each side and replace original bolt with the two 5/16” x 2 1/4” socket head bolts and 5/16” mounting spools with chamfer on spool under socket head bolt. Install 5/16” – 18 locknuts on inside of fender. Verify that adequate clearance exists between the ends of the bolts and tire. 10. Remove upper shock bolt and replace with (2) – 1/2″ x 1″ FLAT WASHERS and 1/2″ x 2 1/8″ hex spool & bolt assy.