Harley-Davidson 39mm Fork FXR, FXD, XL from 87 to Current, Light Bar N935 & N935E INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Remove Headlight from Headlight Shell (Screwdriver) set aside. 2. Disconnect Turnsignal wires behind or inside Headlight Shell. 3. Unbolt Headlight Shell from Eyebrow (3/4″ Socket & Wrench). Let hang from wires. 4. Remove front Turnsignal Assemblies from motorcycle. 4a. If Turnsignals are mounted to the Handlebar use the 1/2″ Wrench. 4b. For fork mounted Turnsignals, 1996 to current, use the Torx Wrench 4c. For fork mounted Turnsignals 1987-92 use the 5/16 Hex Key Set turnsignals aside, they will not be reused. 5. Remove screw from Brake Hose Clamp and Clutch Cable Guide (Hex Key Wrench, 3/16″) located on the bottom of the lower Triple Clamp. Set aside, it will not be reused. 6 . Remove the Pinch Bolts from the lower Triple Clamp (Torx Wrench, 1993 to Current, or 5/16 Hex Key, 1987 to 92). Set aside, they will not be reused. INSTALLATION 1. Mount the Light Bar Assembly: A. Hold the Light Bar assembly up to the lower Triple Clamp, the center bracket will be below the Triple Clamp. B. Start the 1/4-20 x 3/4 Screw, with Washer, through the Brake Hose Clamp, clutch cable guide then the center bracket and into the threaded hole previously used for the Brake Hose Clamp. C. Position a Spacer between the Outer Brackets and the Triple Clamp and start the 3/8-16 x 2″ Hex Bolts through the Outer Bracket, then the Spacer and into the Pinch bolt location on the lower Triple Clamp. Do this on both sides of the lower Triple Clamp.

HARLEY DAVIDSON SPORT WIND DEFLECTOR AND WINDSHIELD KITS INSTALLATION MANUAL

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

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HEADLAMP VISOR INSTALLATION (2004 ONLY) 1 2 is 01467 1. Headlamp 2. Headlamp bracket mounting screws Figure 1. Remove Headlamp Mounting Screws (Left Side Shown) 1. See Figure 1. While holding the headlamp (1), remove the left and right headlamp bracket mounting screws (2). 2. See Figure 5. Obtain the headlamp visor (2) from the kit. 3. See Figure 2. Orient the headlamp visor (1) between the headlamp and headlamp mounting bracket (2) and reinstall the headlamp bracket mounting screws (3) securing the visor and headlamp to the headlamp mounting bracket. 4. Refer to the Service Manual and adjust the headlamp for the correct angle. 2 1 3 is01468 1. Headlamp visor 2. Headlamp mounting bracket 3. Headlamp mounting bracket screw Figure 2. Install Visor Between Headlamp and Mounting Bracket (Left Side Shown) 1 2 3 is03212 1. “RT” or “LFT” marking 2. Hinge-pin head faces up 3. Clamp post socket faces outward Figure 3. Fork Tube Clamp and Post Identification (Right-Side Clamp Shown) WINDSHIELD INSTALLATION 1. See Figure 5. Obtain one of the lower mount kits from the windshield kit carton. Identify the fork tube clamp for right- side (RT) or left-side (LFT) installation as indicated in Figure 3. NOTE The lower grommets (4) have been pre-installed into the Lexan® windshield. 2. Insert the rounded end of the post into the socket in the fork-tube clamp, oriented as shown in Figure 5. Lining up the hole in the end of the post with the hole in the clamp. With a 3 mm hex key, fasten the post to the clamp with the flat-head screw (16) from the kit, and tighten to 6.8 Nm (60 in-lbs ). 3. Place the clamp around the correct-side fork tube with the hinge-pin head facing up. Insert the two longer screws (15) from the lower mount kit through the counterbored holes in the outboard side of the clamp, and thread the screws part-way into the tapped holes in the inboard half. 4. Position the clamp so the top surface is approximately 6 to 13 mm (1/4 to 1/2 inch) below the upper triple-tree, and the hinge pin is straight forward. With a 4 mm hex key, tighten the screws just enough to hold the clamp in posi- tion. 5. Obtain the remaining lower mount kit and repeat Steps 2 through 4 to install the clamp to the opposite fork tube. 6. Obtain the upper mount kit from the windshield kit carton. NOTE The upper grommets (4), socket assemblies (3), windshield mount caps (6) and 5 mm screws (9) have been pre-installed into the windshield. 7. Place one of the handlebar clamps (5) onto one side of the handlebar, in the straight section between the riser and the handlebar controls, oriented as shown in Figure 4. NOTE Temporarily disengage the switch harness retainer from the handlebar to allow installation of the clamp.

HARLEY DAVIDSON TOURING LAYBACK LICENSE PLATE MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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This kit fits all 1999 and later FLHR (Road King®) models, FLTR (Road Glide®) and FLHT (Electra Glide® standard) models having license plates measuring a maximum of 7-1/4 x 4-1/4 inches (184 x 108 mm). Also fits 2003 FLHRSEI2 (Screamin’ Eagle® Road King). Does not fit with Detachable Tour-Pak Rack, part number 53276-04. Does not fit 2002 FLHRSEI (Screamin’ Eagle Road King). Kit Contents See Figure 1. INSTALLATION 1. Remove the license plate from the vehicle (if installed). Remove the two hex head bolts holding the original equipment (O.E.) license-plate bracket in place. The bolts and license-plate bracket can be discarded. 2. See Figure 1. Install the new layback license plate holder (1) using the button-head hex socket screws (3) from the kit. Tighten the screws to 19 ft-lbs (25.8 Nm) . 4 1 3 7 5 2 6 is02737 1. License plate holder, layback 2. Foam pad (6) 3. Screw, button head, hex socket (2) 4. License plate frame 5. Set screw, socket head (2) 6. Hex key 7. Reflector assembly, Part Number 59365-07 Figure 1. Layback License Plate Mount Components 3. Position the license plate onto the foam pads (2) of the license plate holder, centering and aligning the plate parallel to the holder edges for best appearance. NOTE Slots in the inside top edge of the license plate frame (4) fit over the two tabs on the top edge of the license plate holder. 4. Hook the top of the license plate frame over the top edge of the holder. Swing the bottom edge of the frame inward, holding the license plate in position against the pads. 5. Use the hex key (6) from the kit to securely fasten the license plate frame to the holder with the two socket head set screws (5)

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HARLEY DAVIDSON BILLET CLOCK, FRONT BRAKE MASTER CYLINDER MOUNT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. See Figure 1. Clean the face of the front master cylinder reservoir with denatured alcohol and a paper towel. 2. Remove the paper backing from the adhesive strip, and line the clock up squarely to the master cylinder reservoir as shown. Press firmly into place and hold for a few seconds. 3. Let the adhesive set for a while before setting the time. SETTING THE TIME ON THE CLOCK 1. Using the hex key included in the kit, remove the two screws securing the faceplate to the clock housing 2. Lift off the faceplate and “O”-ring, and set aside. Lift the clock face and movement assembly out of the housing. 3. Pull out the stem carefully, and turn it until the hands indicate the correct time. Carefully push the stem back in to start the clock. 4. Check that the “O”-ring is in place in the faceplate, and re-install the faceplate to the clock housing. Do not over- tighten. REPLACING THE CLOCK BATTERY The clock battery (Type SR626SW) is a common type, available wherever watch batteries are sold. When storing the motorcycle for a long period, pull out the stem carefully to stop the clock and save battery life