HARLEY-DAVIDSON SOFTAIL STRAIGHTSHOTS 2-2 INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2012

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1. Under the oil tank on the right hand side, locate the rear O2 sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifi er on front of the frame to gain access to the front O2 sensor connector. Unplug sensor from harness. Remove cable tie holding wire to frame and feed the end of the wire through, freeing it from motorcycle. 3. On FLSTC, FLSTF, FLSTN and FLSTSC models, loosen the right hand fl oor board mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the two mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTN, FLSTF and FXSTD models, you will need to remove the right side passenger footpeg and hanger, as this is attached to the exhaust mount bracket. Remove hanger, and replace the passenger foot peg assembly using the 3/8″ x 2 1/2″ Allen bolt (supplied). 8. If equipped, unbolt the carriage bolt and clamp attached to the bracket under the right side transmission cover. 9. Remove the entire exhaust system and set it aside. 10. If equipped, remove the bracket from under the right side transmission cover. 11. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 12. Remove the two lower mounting studs from the frame (Figure 1). 13. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A

Harley Davidson Softail with Detachable Backrest Brackets Installation Manual

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Filed Under (Harley Davidson) by admin on 20-03-2012

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Installation video explaining the installation and use of the EDGE™ Quick Release Detachable Saddlebag System with Mustang Hard Saddlebags. Please click the “Read more…” button below to play the video

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2001-2003 EFI Harley Davidson Softail Deuce Power Commander Installation Manual

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Filed Under (Harley Davidson) by admin on 14-03-2012

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1 Remove the seat. 2 Remove the two bolts that hold the relay bracket (Fig. A). Fig.A Remove these bolts 3 Fig.B 3 Pull straight upwards on the bracket. Lift the bracket enough to expose the 3 zip ties that hold the wiring harness to the bracket (Fig. B). Cut these 3 zip ties. 4 Pull upwards on the retaining plate (which holds the relays) enough to clear the battery (Fig. C). Fig.C Cut these 3 zip ties 4 9 Fig.D Adjusting Your Power Commander Your Power Commander has been programmed with a base map for your application. You can adjust the base map or install an alternate map using your Computer. Please refer to the supplied CD-Rom for more information. You can also adjust your Power Commander using the face plate buttons as described below. 1. With the ignition off, hold down all three buttons on the Power Commander III unit. 2. While still holding down the buttons, turn the ignition on. 3. Release buttons. 4. Select the range you wish to adjust: Low, Med, High, by pushing the corresponding button once. 5. At this point holding that button down will move the lights down ( leaning out the mixture). 6. Pushing the button repeatedly will move the light up (richening the mixture). 7. When the two center light are lit up this is the “0″ setting. After making your adjustments wait 20 seconds before starting the bike or turning it off. This allows the settings to be saved to memory. To verify that it is safe to start the bike, move the throttle and watch to see if the lights move up and down the scale. If they do, you may start or turn off the bike. Tabs 5 Rotate this plate forward to locate the relay retaining tabs (Fig. D). Bend these tabs so they are flush with the plate. This allows the relays to sit lower in the slots

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2009 Harley Davidson Softail POWER COMMANDER V INPUT ACCESSORY INSTALLATION

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Filed Under (Harley Davidson) by admin on 26-02-2012

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1 Remove the seat 2 Uplug the stock wiring harness from the ECM (Fig. A) 3 Remove the 4 nuts that hold the ECM to the bracket and remove the ECM. 4 Remove the bolt that holds the seat strap to the rear fender. 5 Remove the ECM bracket from the fender. Remove one nut at a time or the bracket will fall into the tire. Reinstall the nuts to support the inner fender bracket. Due to the limited amount of room on this bike the seat strap and ECM bracket can NOTbe re-used. 6 Connect the PCVharness in-line of the stock wiring harness and ECM (Fig. B). 7 Place the BLACK PCVto GREYstock connector as close to the fuse box as possible. This connection will NOT lay flat against the frame. 8 Using the supplied velcro secure the ECM to the rear fender. Place the ECM as far down as possible. The upper part of the ECM will just overlap the bolt hole for the seat strap. Make sure to clean both surfaces with the alcohol swab before attaching. If using the Autotune kit offset the ECM about 1″ from center to the right side of the bike. 9 Remove the security module from the top of the battery (Fig. C). This unit slides to the right of the bike.

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HARLEY DAVIDSON SOFTAIL CHROME REAR AXLE ADJUSTER AND COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Block the motorcycle underneath the frame so the weight of the vehicle is off of the rear wheel, but do not raise the rear wheel off the ground. 2. Some models require loosening or removal of the muffler or mufflers in order to remove the rear axle. See the EXHAUST SYSTEM REMOVAL section of the Service Manual. Remove the saddlebags if desired for extra working clearance. See SADDLEBAG REMOVAL in the Service Manual. 3. See Figure 1. Remove the original axle adjustment bolts (1) and jam nuts (2) from both sides of the motorcycle and discard. NOTE On a bike that has been previously serviced, ensure that the axle has not been removed and re-installed from the left side (with the castle nut to the right of the wheel). If it has, the axle MUST be inserted from the right side of the motorcycle. 4. Remove the retaining pin (7), castle nut (5) and washer (4) from the left side of the axle (6). Discard the washer, but save the pin and nut for later re-assembly. 5 7 1 4 6 2 3 is04101 1. Axle adjust bolt 2. Jam nut 3. Axle adjuster collar 4. Washer 5. Castle nut 6. Rear axle 7. Retaining pin Figure 1. Rear Axle Hardware (Left Side Shown) 5. Tap the axle toward the right side of the motorcycle and remove. The belt adjuster collars (3) will fall loose as the axle is removed. The collars can be discarded. The wheel bearing spacers may also fall loose or be dislodged. Be sure to return these to their original position on the vehicle (short spacer on the right side, long spacer on the left). 6. Inspect axle components for damage or excessive wear, and replace as required

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HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

HARLEY DAVIDSON SOFTAIL PASSENGER FOOTBOARD SUPPORT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION Remove Existing Equipment 1. Remove existing footpeg and attaching hardware. 2. Remove chrome swingarm pivot covers, if so equipped. 3. Do not remove tool box, if so equipped. Install Passenger Footboard Support Kit 1. See Figure 1. Install footboard mounts (1) and (2) as fol- lows: a. Position footboard mount and insert screw (3) through part and into footpeg mounting hole. b. Position semi-circular cutout in mount extending from side of mount around nut of swingarm pivot bolt. c. Tighten screw (3) to 45-50 ft-lbs (61-67.8 Nm). 2. Position footboard support (4) on mounting stud so that bolt hole aligns with machined groove in stud. 3. Insert screw (5) through left side in split hub of footboard support. Thread into tapped hole (right side) of split hub. 4. Tighten screw (5) to 10 ft-lbs (13.6 Nm). 5. Place spring (6) into retaining hole in footboard support. Rest ball (7) on top of spring. 6. Refer to appropriate I-Sheet for instructions to install the footrest (A) and pivot pins (8) for your motorcycle

HARLEY DAVIDSON SOFTAIL DETACHABLE SIDEPLATE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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Kit Contents See Figure 5 and Table 1. INSTALLATION Sissy Bar Installation to Sideplates 1. See Figure 5. Insert the legs of the sissy bar upright (A) all the way into the channels (B) of the sideplates (1 and 2) as shown. 2. Apply a few drops of Loctite 262 – Red to the threads of the button head screws (4). Thread the screws into the holes in the sideplate channels, and tighten to 96-120 in-lbs (11-14 N-m) . Sissy Bar and Sideplate Installation to Docking Points 3. See Figure 1. While standing behind the motorcycle, place the left-side and right-side front sideplate notches (2) into the front docking points (4) on the fender supports (3). See Figure 2 for views of correct and incorrect sideplate engagement. NOTE Failure to properly align the front docking points and sideplates may result in damage to the rear docking points. 1 3 2 4 is05682 1. Sissy bar and sideplate assembly 2. Front notch 3. Right side fender support 4. Front docking point Figure 1. Place Front Notches into Front Docking Points 4 4 3 2 2 1 1 1 2 is00963 1. Sideplate (right side) 2. Right front docking point 3. Correct: sideplate fully engaged in docking point 4. Incorrect: sideplate NOT fully engaged in docking point Figure 2. Sideplate Fit to Front Docking Points

HARLEY DAVIDSON SOFTAIL EXTENDED REACH CONTROLS KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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PREPARE THE MOTORCYCLE 1. For models equipped with saddlebags: Remove the saddlebags following the instructions in the appropriate Service Manual. 2. Remove the seat following the directions in the Owner’s Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect the negative battery cable. 4. Secure motorcycle in upright position. NOTE This kit is not compatible with engine guards. 5. If the engine guard is present, remove and discard it. LEFT SIDE Component Removal 1 3 4 2 7 5 6 8 2 is05048 1. Pretzel clip 2. Bushing (2) 3. Screw (6) 4. Jiffy stand bracket 5. Bumper 6. Jiffy stand leg 7. Clevis pin 8. Spring Figure 1. Jiffy Stand 1 2 3 5 4 is05053 1. Jam nut 2. Shifter rod end 3. Acorn nut 4. Shifter rod 5. Shifter arm Figure 2. Shifter Linkage 1. For HDI Vehicles: Remove the left side foot control support, and jiffy stand sensor, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. For all other models: Remove the left side foot control support, jiffy stand and spring, shifter linkage, shift lever and footpeg following the instructions in the appropriate Service Manual. NOTE Two bearing sleeves will remain inside the footrest bracket. The extended controls bracket from the kit will include two sleeves pressed into the bore of the shift lever arm support. 2. Remove rod ends and jam nuts from the shifter rod. Save the rod ends and jam nuts for installation. Component Installation 1. See Figure 9. Select shifter mounting assembly (6), O- rings (5), nylon washer (4) and the shift rod (1) from the kit. 2. Install the shift arm and new O-rings in the bracket. 3. Apply LOCTITE 243 Threadlocker and Sealant to the three mounting screws and mount the shifter bracket with shift arm to the frame. Tighten the mounting screws to 25-30 ft-lbs (33.9-40.7 Nm)

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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)