HARLEY DAVIDSON SLOTTED HANDLEBAR RISER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Cover the fuel tank with a clean shop towel to prevent scratching. Damage to the finish could result. 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for re-assembly. Retain all additional hardware components that become dislodged from the riser when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers, and carefully allow the handlebar to rest on the fuel tank. 3. Obtain the new slotted risers (1) and hex head cap screws (2) from the kit, and the split lockwashers and hardware components removed in Step 1. NOTE The upper cup washer (A) must be oriented with the flat side up , and the lower cup washer (D) with the flat side down . The ground wire (G) and internal tooth lockwasher (H) are mounted to the right-side riser. 4. Refer to Figure 1 for the correct orientation and reassembly sequence. Install the new risers onto the upper fork bracket using the saved hardware and new screws. Snug the riser screws, but do not fully tighten at this time. 5. Center the handlebar on the risers. To make sure that the handlebar is centered, verify that the knurled areas on the outboard side of each riser are equal. 6. Position the new handlebar upper clamps (3) from the kit, and install with new hex socket head screws (4). Snug the upper screws, but do not fully tighten. Improperly aligned handlebars can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372a) 7. Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is attained. 8. Tighten the upper handlebar-clamp screws as follows: a. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . b. Tighten the rear screws to 12-15 ft-lbs (16-20 Nm) . c. Tighten the front screws to 12-15 ft-lbs (16-20 Nm) . NOTE The gap between the upper clamps and the risers should be equal at the front and rear of the handlebar after tightening. 9. One at a time, remove the riser bolts installed in Step 4. Apply two drops of Loctite® 271 (Red) to the bolt threads and re-install. Tighten the riser bolts to 50-60 ft-lbs (68-81 Nm)

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HARLEY DAVIDSON REAR FLOATING BRAKE DISC KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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This kit is designed to fit all late 1987 through 1999 XLH, FXR, Dyna and Softail models. Installation 1. See the appropriate Service Manual for all removal, assembly and disassembly procedures. NOTE A Service Manual for your vehicle is available from your Harley-Davidson dealer. NOTE The floating disc screw holes are countersunk to accept the retaining screw heads. Be sure you install the screws prop- erly. 2. Assemble brake disc and pads as described in appropriate Service Manual. 3. See Service Parts Illustration. Install new pan head screws. Tighten screws to torque values given in Service Manual.

HARLEY DAVIDSON ROAD TECH XM SATELLITE RADIO RECEIVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION NOTE Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) -J03989 1 of 8
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 Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Receiver Mounting Bracket Installation When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. ALL models: See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 3. Using a T-27 TORX drive head, remove the two screws that retain the clutch-lever clamp to the handlebar. 4. See Figure 4. Obtain the correct mounting bracket (2) for your vehicle, and two button-head screws (3) and spacers (4) from the kit. Insert the button-head screws into the mounting bracket, through the holes above and below the slot. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the clutch lever clamp removed earlier. 5. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) . Receiver and Antenna Bracket Installation 6. Obtain the satellite radio receiver (1), antenna bracket (6), and four lock nuts (8) from the kit. Insert the four studs on the back of the receiver through the four holes in the receiver mounting bracket. 7. See Figure 4 for mounted position of the antenna bracket to the receiver mounting bracket. Assemble a lock nut to each of the bottom two studs. Install the antenna bracket onto the top two studs, and assemble a lock nut to each top stud. Tighten the locknuts securely. Antenna Installation 8. Obtain the XM radio antenna (5) and two-sided adhesive tape (7) from the kit. 9. Use isopropyl alcohol to clean the horizontal antenna mounting surface of the antenna bracket, and the bottom (mounting) surface of the antenna. 10. Peel the liner from one side of the tape, and apply the tape squarely to the bottom surface of the antenna. 11. Peel the liner from the exposed side of the adhesive tape on the antenna base. 12. Position the antenna over the bracket without touching the adhesive to the bracket. Center the antenna over the bracket with the antenna cable toward the center of the vehicle. 13. Press the antenna squarely and firmly onto the bracket, and hold pressure for about 60 seconds. After releasing pressure, avoid direct contact with the antenna for about 20 minutes. HARNESS ROUTING AND CONNECTION

HARLEY DAVIDSON DETACHABLE DYNA SIDEPLATE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Additional Parts Required The appropriate docking hardware and possibly a directional relocation kit must be installed prior to installation of this side- plate kit. These kits must be purchased separately from a Harley-Davidson Dealer. Table 1. Docking Hardware Kits Model Year Docking Hardware Kit FXDWG 53964-06 only Table 2. Directional Relocation Kits Model Year Docking Hardware and Directional Relocation Kit All except FXDWG 53961-06 and 53968-06 If mounting this kit with Saddlebags, part number 53968-06 is not required. Loctite® 262 (red), Part Number 94759-99, is available from your Harley-Davidson Dealer. Kit Contents Table 3. Kit Contents Part Number Description (Quantity) 52869-06 Side Plate, detachable, right 52870-06 Side Plate, detachable, left 94592-98 Button head screws (4) SISSYBAR INSTALLATION 2 3 1 4 1 is 01079 1. Sideplate 2. Sissybar 3. Buttonhead screw 4. Rotary latch Figure 1. Detachable Sissybar Sideplate Assembly See Figure 1. Install new or existing sissybar (2) to detachable sideplates (1) using four buttonhead screws (3). Apply Loctite® 262 (red) to screws before installation. Tighten screws to 96- 120 in-lbs (11-14 N-m)

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HARLEY DAVIDSON SOFTAIL BACKREST KIT Installation Instructions

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Filed Under (Harley Davidson) by admin on 29-01-2011

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These kits are designed for use on all Softail models equipped with Sissy bar Uprights, part number 52735-85. See Service parts below for kit contents. Installation 1. With your hand, feel through the backrest material to locate mounting holes. 2. Carefully cut holes in material at mounting locations as applicable. Cut only enough material away for screw to enter backrest. 3. See Service Parts Illustration. Secure backrest (4) to sissy bar using bracket (3) and pan head screws (1). 4. Install flat head screw (2) through center hole into backrest (4). 5. Tighten all screws securely. Do not overtighten

HARLEY-DAVIDSON LARGE LED SILVER BULLETS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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PROCEDURE STEP 1*Remove the stock turn signal fixtures and cut the wires in a convenient and inconspicuous splice location. STEP 2**Place the split lock and flat washers on to the hollow bolts as shown in PIC. 1. Run the power leads through the hollow bolts and assemble the Silver Bullets to their mounts. See PIC. 2. STEP 3*Install the new Silver Bullet assemblies to the Mount Bar on the motorcycle. The stock 10-24 x 1/2″ socket head screws are to be re-used. PROCEDURE fOR AMBER DUAL CIRCUIT (fRONT WIRING) LED SILVER BULLET WIRE COLOR CODING IS AS fOLLOWS: Black — Ground Blue — Running Lights (power) Violet — Turn Signal (power) STEP 1 Turn key on. Test OEM stock front turn signal wiring with test light. STEP 2 Locate and mark the running light (power) wire. STEP 3 Individually activate the turn signals and mark the side-appropriate wires. STEP 4 Use the color code above to solder/connect the corresponding Silver Bullet wires to your Join like colored wires on the Silver Bullets and the bike’s turn signal harnesses. Insulate your connections. Route the wires safely out of harms way and tie the wires in place with nylon cable ties. 1995-EARLIER MODELS With a test light, probe the two black wires leading to each of the stock front turn signals. On each side, the wire that has power only when the turn signal button is depressed is the turn signal positive wire. The wire that is “hot” constantly when the key is on is the running light wire. Connect the violet wire from the Silver Bullet to the bikes turn signal wire, and the blue Silver Bullet wire to the bikes running light wire. Connect the black wire from the Silver Bullet to a known good chassis ground (bare metal). Insulate your connections. Route the wires neatly out of harms way and secure them with nylon cable ties. When replacing stock incandescent turn signals with LED lights, it may be necessary to add a load equalizer to make the turn signals flash properly. NOTE: When using Amber Dual Circuit Silver Bullets in rear applications, blue running lights (power) wire will not be used. To avoid corrosion, tape off bare wire. Test the lights for run and flash functions. If they light, but do not flash in the turn mode, add the load equalizer. The load equalizer has one black and two violet wires. The violet wires are not side specific. NOTE: LED Turn signals require the use of one Load Equalizer PER PAIR OF LED TURN SIGNALS to achieve the proper flash function. It is perfectly normal for the equalizer to get warm (about 140 degrees) during turn signal operation.

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YAMAHA ROAD STAR HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 29-01-2011

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1. Place a blanket folded several times over the fuel tank to prevent any damage during the installation of the risers. Loosen the two 19mm riser mounting nuts located on the bottom side of the upper steering head. Pry out the chrome plugs from the heads of the four handlebar top clamp bolts using a knife blade. Loosen the four handlebar top clamp 6mm socket head screws. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four screws from the clamps and then the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the nuts from the bottom of the risers and remove the risers. Insert the two supplied spacer tubes into the riser mounting holes on the upper steering head. Using the bolts, lock washers and washers supplied install the new risers making the bolts finger tight only. (Take care not to scratch the top surface of the upper steering head while installing the new risers.) 4. Place the handlebars back up onto the new risers. Reinstall the top clamps using the four socket head screws removed earlier. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs. There should be no gap between the riser and clamp at the front side.) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.) 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. Also check that the throttle returns freely on it’s own

TRIUMPH AMERICA AND SPEEDMASTER SOLO RACK FITS INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Remove the 8mm bolt from the rear of the passenger seat. Remove the passenger seat by pushing the seat forward and lifting up at the front edge of the seat. Remove the 12mm bolt from the rear of the drivers seat. 2. From the supplied hardware locate the two socket head screws and washers, place the large washers onto the screws with the polished side of the washer facing the head of the screws. Place the small screw and washer thru the small hole in the rear of the solo rack, place the black plastic spacer supplied onto the screw on the bottom side of the solo rack. Holding the rack in place on the rear fender, start the screw in the rear hole. Install the remaining large screw with its washer into the front hole and tighten both screws securely.

TRIUMPH AMERICA AND SPEEDMASTER HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Loosen the two 14mm riser mounting nuts located on the bottom side of the upper steering head. Loosen the four handlebar top clamp 6mm socket head screws. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four screws from the clamps and then remove the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the nuts from the bottom of the risers and remove the risers carefully without allowing the risers to rotate, as this will scratch the clear coating on the upper steering head. Using the bolts, lock washers and washers supplied install the new risers making the bolts finger tight only. (NOTE; again, take care not to allow the risers to rotate as this will scratch the clear coating on the upper steering head). 4. Place the handlebars back up onto the new risers. Install the new top clamps supplied using the four M8 X 30mm socket head screws supplied. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs.) (There should be no gap between the riser and clamp at the front side) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. YOU MUST! Check to see that the throttle returns freely on its own when the handlebars are at full left and full right turn THIS STEP IS VERY IMPORTANT FOR OBVIOUS SAFETY REASONS! If you have a windshield installed it may be necessary to reroute the throttle cables, wires or hoses around the other side of the windshields mounting hardware to obtain adequate free play and free throttle return. You may also wish to remove the plastic clips or cable tie which secure the wiring to the handlebars and secure them to the brake hose and clutch cable (not the throttle cables) for a cleaner appearance

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TRIUMPH AMERICA AND SPEEDMASTER FRONT TURN SIGNAL RELOCATORS

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Filed Under (Triumph) by admin on 29-12-2010

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1. Remove the front turn signals as follows. The turn signal wire plugs are located inside the handlebar switch housings. Remove the two Phillips screws located on the forward facing side of the switch housing, remove the covers, unplug the turn signals and reassemble the switch housings. Unbolt the signals from their black mounting brackets, remove the brackets from the bottom side of the switch housings, reinstall the nuts and tighten securely. 2. Disassemble the two halves of the turn signal mounting clamps supplied, place the M6 X 25mm button head screws thru the hole in the side of the clamp from the inside, place the spacers supplied over the screw threads. Screw the clamps and spacers onto the turn signals. Hold the signal/clamp assemblies up to the front fork, position the signals so that the housing/lens seam is vertical and straight, carefully remove the assemblies from the forks and tighten the screws securely. Install the signal/clamps onto the forks, set to the desired height and angle and tighten the clamp screws securely. 3. Using a sharp knife slit the black wire loom from the turn signal plug back 7″. Pull the turn signal wires and plugs out from the loom. Fold the wires along the loom going down towards the headlight. Leave 2-3″ of the wire next to the plug exposed and neatly tape the rest of the wire to the loom and the loom closed back up to the handlebar switch. 4. Connect the signal wires to the plugs from the wire loom. Using the cable ties supplied tie up any loose or unconcealed wire and the plugs.

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