HARLEY DAVIDSON CUSTOM TOURING FRONT BULLET TURN SIGNAL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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INSTALLATION Outer Fairing/Windshield and Auxiliary Lamp Bracket Removal To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2 3 1 2 is 01215 1. Six-position connector 2. Four-position connector 3. Auxiliary lamp connector Figure 1. Disconnect Signal and Auxiliary Lamp 1. Remove Maxi-Fuse. Refer to SYSTEM FUSES, MAXI- FUSE in Service Manual. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 2. Remove the windshield and outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual for the outer fairing/windshield removal procedure. 3. Disconnect auxiliary lamp and turn signal connectors. NOTE See Figure 1. On 2005 and prior year models, the left and right turn signals plug into a 6-place connector located on the left fairing support brace. On 2006 and later models, each turn signal plugs into its own 4-place connector located toward the bottom of the inner fairing on each side. 4. Using a T40 Torx® drive head, remove and save the four bolts securing the auxiliary head lamp bracket to the chassis. 5. Remove auxiliary lamp bracket from motorcycle. Turn Signal Assembly 1 is 01217 1. Triangular opening Figure 2. Insertion of Terminals Through Triangular Opening 1. See Figure 2. Insert wire terminals through the triangular opening in the turn signal mounting bracket included in the kit. 2. Fit turn signal housing onto bracket. 3. Apply a small amount of Loctite (243) blue (99642-97) to threads of hex head cap screw. 4. Tighten cap screw to 15-20 ft-lbs (20-27 Nm) . -J03753 1 of 2 Turn Signal Installation 1 is 01218 1. Turn signal wire Figure 3. Turn Signal Wire Routing 1. See Figure 3. Insert turn signal connector and wiring between bottom of fairing and top of outer fairing skirt. 2. Route turn signal wire under cutout on mounting bracket and place bracket onto motorcycle. NOTE Care must be taken so the turn signal wire is not pinched between turn signal bracket and motorcycle chassis. 3. Install washers onto turn signal bracket mounting bolts and apply Loctite 243 (blue) (99642-97) to the bolt threads. 4. Tighten mounting bolts to 15-20 ft-lbs (20-27 Nm) . 5. Route turn signal leads toward harness connector. Secure loose wiring with tie straps so wires do not rub against any sharp objects

HARLEY DAVIDSON SOFTAIL DETACHABLE TWO-UP TOUR-PAK LUGGAGE RACK INSTALLATION MANUAL

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

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TOUR-PAK LUGGAGE INSTALLATION TO RACK 1. Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage.  Remove the rubber mat from the luggage floor. 2. If holes ARE NOT pre-drilled in the floor of the luggage,       see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites.  Use the four inboard holes (3) in the metal base of the luggage (2) as a guide, and carefully drill four 11/32 inch (9 mm)  holes through the floor of the luggage. 1 2 3 is04249 1. Front of motorcycle 2. Tour-Pak 3. Drill four 11/32 inch (9 mm) diameter holes Figure 1.  Drill Attachment Hole Locations in Tour-Pak NOTE See Figure 3. When installing the luggage to the rack in the following steps, note that holes in the luggage rack (2) provide forward (A) and rearward (B) positions for mounting the lug- gage. 3. Place the luggage on the luggage rack.  Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. 4. ALL applications: Obtain the hex head cap screws (9), lock nuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw, and insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage.  If the screws are installed from the bottom, the screw ends can tear the rubber mat and scratch objects, such as helmets, stored inside the luggage. 5. From the underside of the rack, install a washer and lock nut onto the threads of each screw.  In a crosswise pattern, incrementally tighten each screw to 19 ft-lbs (25 Nm) . 6. Install the rubber mat into the luggage.  Close and latch the lid. 7. If not already in place, install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit

HARLEY DAVIDSON PULLBACK RISER KIT FOR 1.25-INCH HANDLEBARS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVAL NOTES Cover the fuel tank with clean shop towels to prevent scratching. If replacing the handlebar, refer to the service manual to remove controls, hand levers, handlebar and risers. If only the risers are being replaced, proceed as follows: 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 assembly. Retain all additional components from the riser assembly 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 set the handlebar on the fuel tank. INSTALLATION NOTES See Figure 3. The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. 1. See Figure 3. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the lock washer (F) are located on the right side only. Do not tighten the riser mounting screws (4) at this time. 2. If an appropriate Harley-Davidson 1-1/4 inch handlebar has not been installed, install one according to the Instruction Sheet included with the kit, or install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers with the Bar & Shield toward the front of the motorcycle (Figure 1, Item 1). Install four socket head screws (3) with four washers (6). 1 is05253 1. Bar & Shield (install toward front of motorcycle) Figure 1. Bar & Shield on Riser and Cap 4. Check that the risers stay properly aligned with the handlebar and tighten the riser mounting screws following the instructions in the service manual. 5. Adjust handlebar to the desired position, verify that it is centered on the risers, then tighten the front socket head screws (3) to 12-15 ft-lb (16-20 Nm) . There should be no gap at the front of the risers.

HARLEY DAVIDSON TRIKE CHROME REAR GUARD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Set the vehicle parking brake, open the trunk door and remove the trunk liners. 2. See Figure 1. From inside the trunk, locate four screws with washers (A) in the floor of the trunk compartment that hold the body to the rear frame. Leaving the washer in place, remove one of the screws and discard. 3. Obtain a long hex head cap screw (3) from the kit. Apply a few drops of Loctite – Blue to the threads of the screw, about 0.75 in (19 mm) from the screw head (C). 4. Insert the screw through the washer (A) and trunk floor. Thread it all the way through the U-channel on the outboard side of the rear frame (B), but do not fully tighten at this time. 5. Repeat for the remaining three screws. 6. Tighten all four screws to 18 ft-lbs (24.4 Nm) . 7. With an assistant, position the trunk rail assembly to the underside of the frame, fitting the four holes in the rail mounting brackets onto the threads of the screws installed in Step 4. 8. Apply a few drops of Loctite – Blue to the threads of each lock nut (4). 9. Install a washer (5) and locknut to the threads of each screw to hold the rail in place, but tighten only enough so the rail lightly contacts the frame. 10. Align the rear guard evenly to the contour of the lower body for best appearance, and adjust the position of the rail to provide clearance between the rail and the rear of the vehicle body. 11. With an assistant firmly holding the screw heads inside the trunk to keep them from turning, tighten the four lock nuts to 18 ft-lbs (24.4 Nm) . 12. Install an insert (2) into each end of the rear guard. Push firmly until fully seated.

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)

2007-2008 Kawasaki ER6 and Ninja 650R Lowering Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Raise the motorcycle so the rear wheel is off the ground. As an example, you can use a motorcycle lift, two car jacks, or upside-down paint buckets placed under the foot pegs, but anything stable should do. ” Stable ” is the key word. Please take all precautions! 2) Using the 19 mm open wrench and the provided 8 mm hex wrench, loosen the button head bolt and locknut as shown This large washer will not be there on 2007 & 2008 models 3) Next, remove the locknut and the small washer from the back, and remove the button head bolt and the large washer from the front. You can pull out the button head bolt by slightly moving the rear suspension up and down at the same time. 4) 5) Lift the shock absorber and insert the spacer where the shock absorber was installed before. Note: The original bolt and washers (if any were on your bike) are not going to be used, but you should keep them for the future, in case you decide to uninstall the lowering kit. Slide over the main kit body and insert the provided hex head cap screw as shown Next, slide the provided hex head cap screw all the way through