HARLEY DAVIDSON HERITAGE CHROME FRONT FENDER RAIL INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 21-03-2011

download
INSTALLATION NOTE See Figure 1. Be careful not to crack plastic fender lamp lens (2) or chrome plate when removing lens. 1. Remove fender lamp light lens (2) by placing screwdriver in slot in top of lens and carefully prying cover loose. Retain lens and gasket for later installation. 2. Loosen four hex socket head screws (1) which attach fender (4) to fender mount. 3 2 4 1 is03805 1. Fender mount screws (4) 2. Fender lamp light lens 3. Fender Rail 4. Fender Figure 1. Installed Front fender Rail NOTE When installing fender rail (3), be sure fender rail supports are inside of fender. 3. Place fender rail (3) from kit into position, aligning the front bracket hole of rail with hole in front of fender (4). Fender rail supports will fit snugly inside fender. NOTE Be careful not to damage the fender lamp wire when securing front fender rail into place. 4. Use a magnet to place a 10-32 x 1/2 inch phillips screw through the hole in front fender and through front bracket hole of fender rail (3). 5. Loosely secure fender rail (3) to fender (4) with 1/2 inch flat washer and hex locknut. 6. On right side only, remove two hex socket head screws and nuts. Retain nuts for installation. 7. Replace original two socket head screws with 5/16-18 x 2 inch screws from kit. 8. For vehicles without caliper/rotor covers: On left side of fender (4) only, install a washer between rail (3) and fender for both screws. Replace original two hex socket head screws with 5/16-18 x 2 inch screws from kit. For vehicle with caliper/rotor covers: Do not replace hex socket head screw that supports caliper/rotor cover. On left side of fender (4), install a washer between fender (4) and rail (3) on screw that does not support the caliper/rotor cover (towards the front of the vehicle). Replace remaining hex socket head screw with 5/16-18 x 2 inch screw from kit. 9. Install four original nuts. 10. Tighten front bracket Phillips screw securely. Tighten four hex socket head screws to 14-18 ft-lbs (19-24 Nm). 11. Install gasket and fender lamp lens removed earlier

Incoming search terms:

HARLEY DAVIDSON ROAD KING FORK LOCK COVER INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 18-03-2011

download
INSTALLATION 1. See Figure 1. At the handlebar cover, carefully pry under black plastic area of the lock plate and remove the lock plate. Discard the lock plate. 1 2 is00632 1. Lock plate 2. Pry location Figure 1. Remove Fork Lock Plate 2. See Figure 2. Remove and discard the two Phillips cover screws beneath the lock plate. 1 is00633 1. Cover screws Figure 2. Remove Cover Screws 3. See Figure 3. Obtain the rubber gasket (4) and flat spring (3) from kit. Place the gasket over the mounting location and align the screw holes. Place the flat spring over the gasket and align the screw holes. 4. See Figure 3. Obtain two chrome socket head screws (2) from kit. Place the cover assembly (1) into position, and install screws to secure cover

HARLEY DAVIDSON HEEL/TOE SHIFT LEVER KITS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 18-03-2011

download
INSTALLATION NOTE The shift levers in these kits have opposite counterbored screw holes. When the toe and heel levers are positioned correctly, the socket head cap screws will be installed from the bottom of both levers. 1. Before removing the original shift levers, note the orientation. You may want to replace them at the same position and angle. NOTE The original equipment shift levers may have the socket head screws that secure the shift levers to the splined shifter shaft installed from the top or bottom, depending on your model motorcycle. 2. See Figure 1. Remove the original equipment shifter pegs (A) and retain for re-attachment to the new levers if desired. Remove the socket head screws (3) that clamp the shift levers onto the splined shifter shaft. Remove the original equipment shift levers. 3. First, position the toe shifter lever (1) so the counterbored screw hole is at the bottom. Slide the toe shifter lever onto the splined shifter shaft and position to the desired angle, aligning the screw hole with the notch on the shaft. 4. Install the heel shift lever (2) with the counterbore at the bottom. 5. Add a few drops of Loctite® 243 (blue) to the socket head screws (3), and insert the screws into the counterbored holes. Tighten to 24-26 ft-lbs (32-35 Nm) . 6. Install the shifter pegs onto the new shift levers. If using the original pegs, place a few drops of Loctite blue onto the screw threads prior to installation. Tighten the shifter peg screws. 7. Check for proper operation and clearance

Incoming search terms:

HARLEY DAVIDSON SOFTAIL DETACHABLE SIDEPLATE KIT INSTALLATION MANUAL

0

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

download
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 ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

0

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

download
2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

Incoming search terms:

HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 09-03-2011

download
2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 09-03-2011

download
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

Incoming search terms:

HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 08-03-2011

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

Incoming search terms:

DETACHABLE KING SIZE WINDSHIELD FOR SOFTAIL MODELS WITH CHROME HEADLAMP NACELLE OR STREET STALKER HEADLAMP NACELLE (WITHOUT PASSING LAMPS)

0

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

download
Installation 1. Remove upper screws that attach the chrome headlamp nacelle to the front forks. 2. See Service Parts illustration. Attach the upper docking bushings (22) using washer (21) and mushroom head screws (20) Use Loctite 242 (blue) on screw threads. Torque screws to 19 ft-lbs (25.8 Nm). 3. Remove lower screws that attach the chrome headlamp nacelle to the front forks. 4a. For vehicles equipped with the Chrome Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (23). 4b. For vehicles equipped with the Street Stalker Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (24). Installing/Removing Windshield 1. Carefully lock bottom windshield assembly jaws into grooves of the lower rubber docking bushings. 2. Hook the top windshield assembly jaws into grooves of the upper rubber docking bushings. 3. Firmly press the windshield into place until seated on docking bushings. 4. To remove windshield, grab windshield edges on each side of center brace and firmly pull windshield loose from docking bushings. 1 WARNING Carefully inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. Restricted movement could affect handling, resulting in personal injury. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. 1 CAUTION Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of either or both. 1 CAUTION Do not clean Lexan®polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result. Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan®. Lexan®is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. • Do not use liquid windshield “protectors” on your windshield. Although they may work well on automobile safety glass, Harley-Davidson cannot ensure the results when used on Lexan®Harley- Davidson windshields. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant®. • Do not use benzine, paint thinner, gasoline, or other types of harsh cleaning agents on windshield. They will damage the windshield surface. • Do not use benzine, paint thinner, gasoline, lubricants (including Armorall), or other cleaning agents on the rubber bushings. They will damage the bushing surfaces

Incoming search terms:

HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

0

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

download
INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

Incoming search terms:

Incoming search terms: