HARLEY DAVIDSON FLHTCUTG MUDFLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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INSTALLATION 1. See Figure 1. Center drilling template on the rear fender. Adjust template to the bottom edge of the fender and tape template to fender. 2. Center punch the two template drilling locations. NOTE Use caution to prevent damage to the tire when drilling the attachment holes for the mudflaps. 3. Use a 5/16 inch bit to drill the template holes. 4. See Figure 2. Install the mudflap using one stud, washer and nut in each fastening hole. Tighten to 5-10 ft-lbs (6.8- 13.6 Nm) . 5. Repeat Steps 1-4 for the opposite fender.

HARLEY DAVIDSON FXDWG ENGINE GUARD KIT INSTALLATION MANUAL

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

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FXDWG ENGINE GUARD KIT General This kit is designed for installation on 1993 and later FXDWG Dyna Wide Glide. QTY DESCRIPTION 1 Engine guard 2 U-Bolt 4 Locknut 1 Bolt, 3/8-16 x 7/8 in. 1 Lockwasher, 3/8 in. 1 WARNING This engine guard may provide limited leg and cosmetic vehicle protection under unique circumstances (fall over while stopped, very low speed slide). However, it is neither designed nor intended to provide protection from bodily injury in a collision with a vehicle or any other object. Installation 1. Lift engine guard into place. Align top center mount of guard with frame crosspiece member between frame downtubes. 2. Secure top center mount to frame crosspiece member using 3/8-16 x 7/8 in. bolt and lockwasher included in kit. Do not fully tighten at this time. 3. On right side of motorcycle, install U-bolt from kit around the frame member and into the holes in the lower mounting bracket. Secure loosely into place using two locknuts from kit. 1 CAUTION Left U-bolt must be installed between the frame and the clutch cable. Do not pinch clutch cable between the U- bolt and the frame. 4. On left side of motorcycle, install remaining U-bolt from kit around the left frame member and into holes in lower mounting bracket. Secure loosely into place using two locknuts from kit. 5. Tighten upper mounting bolt installed in step 2, to 30-33 ft-lbs. Alternately tighten U-bolt hardware to 25 ft-lbs. Tighten left and right side U-bolts evenly, so that approximately the same length of bolt protrudes from end of nut

HARLEY DAVIDSON FXSTD PASSENGER BACKREST AND LUGGAGE RACK INSTALLATION MANUAL

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

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Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) INSTALLATION Passenger Upright 1. Unscrew the captive screw fastening the seat rear bracket to the fender. 2. Remove the rubber plugs from the three holes in the rear fender where the passenger upright installs. 3. See Figure 2. Fasten the studplate (2) to the fender (A) with the backing plate (3) and three flange locknuts (4). 4. See Figure 1. Fasten the passenger upright (3) to the studplate (1) with three flange locknuts (2). 5. Insert the seat front bracket into the frame, then fasten the seat rear bracket to the fender. NOTE The seat must be temporarily bowed up in the center to fit the seat rear bracket through the slot in the passenger upright. 6. Kit 51144-02 only. See Figure 2. Carefully clean the lower hole (B) on the passenger upright (1) with isopropyl alcohol to remove any grease or dirt. Remove backing from adhesive emblem (5) and press the emblem firmly in to place. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1 4 3 2 is03890 1. Stud plate 2. Locknut, flange (3) 3. Passenger upright 4. Backrest pad Figure 1. Passenger Upright, Backrest Pad and Luggage Rack Installation NOTE When temporarily removing the passenger upright, the mounting and backing plates may be left in place to simplify passenger-upright re-installation. Thread the flange nuts back onto studs to store the nuts. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) Backrest Pad See Figure 2. Fasten the backrest pad (7) to the passenger upright (1) using the button-head screw (6) as shown. Luggage Rack NOTE See Figure 2. Fasten the luggage rack (8) to the backrest with the backrest pad (7) removed from the studplate (2). -Fasten the luggage rack (8) to the passenger upr ight (1) using the luggage-rack mounting plate (11), button-head screw (12)

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HARLEY DAVIDSON DYNA CHROME COIL COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Installation 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Note the position of each spark plug wire in the ignition coil, then disconnect the two wires. 3. If there is an existing coil cover: Remove and discard the coil-cover mounting screws and spacers. Remove and discard the coil cover. If there is not an existing coil cover: Remove and discard the two coil mounting screws. 4. See the Service Parts illustration. Obtain the coil cover bracket (3), two long screws (4) and two spacers (2) from the kit. 5. Insert the screw into one of the holes in the bracket as shown, through a spacer, and into a coil mounting hole. Repeat with the second screw and spacer. 6. Assemble the coil to the electrical caddy with the two screws. Tighten the screws to 50 in-lbs (5.6 Nm). 7. Obtain the new chrome coil cover (1) from the kit. Position the cover over the coil, and fasten to the coil cover bracket with the three chrome screws (6) and washers (7) from the kit. Do not fully tighten the screws at this time. 8. Connect the spark plug wires through the holes in the side of the coil cover onto the correct coil terminals. 9. Adjust the cover to center the spark-plug wire boots in the coil cover holes for best appearance. Tighten the three chrome screws securely 10. Refer to the Service Manual and follow the instructions given to install the maxi-fuse

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HONDA GL1100 Manifold Cover Installation Manual

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Filed Under (Honda) by admin on 04-03-2011

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Note: Read instructions carefully before installing. 1. Start with right side. Remove (2) screws and washers from each manifold tube base. NOTE: Save this hardware it will be reused. 2. Remove (4) screws and washers that hold chrome wire guide to carbs. 3. Apply a small amount of grease to the No. 10 washers (4). This will help to hold them in place on installation. 4. Place the No. 10 washers over the threaded holes in the carb base. 5. Reinstall the OEM wire guide and carefully insert 20 mm screws and lock washers. NOTE: The screws DO NOT go through the tube on the manifold covers. 6. Sandwich the tabs on the manifold cover between the carb top and the wire guide. Finger tight the screws. NOTE: Route spark plug wires OVER THE TOP of the wire guide. 7. Lift bottom of manifold cover and insert aluminum washers removed in step 1. Put smooth of washers toward manifold. You may have to use small amount of grease on these washers also to position them. 8. Position manifold cover and reinstall (2) OEM screws removed in step 1 9. REPEAT STEPS FOR THE OTHER SIDE.

HARLEY DAVIDSON STREET STALKER FRONT FENDER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL 1. If model has mechanical speedometer drive, remove cable from fender bracket. Disconnect speedometer cable from the speedometer head. 2. Remove front wheel according to the Service Manual. 3. Disconnect and remove fender tip light power wire. 4. Remove hardware that holds fender in place and remove fender. INSTALLATION 1. See Figure 1 and Table 1. For each support bracket (4), remove backing from one side of tape (3), and affix tape to support bracket, carefully matching the contours of the bracket and tape for proper fit. 2. Remove backing from tape and place support brackets into position on the inside of fender (one on each side), aligning the mounting holes in each bracket with the holes in the fender. The tape side will affix to the inside of the fender. 3. Carefully place fender in position and secure fender with screws and flanged locknuts in kit. Tighten hardware to 12 ft-lbs (16.27 Nm). 4. Install front wheel according to the Service Manual. 5. Install mechanical speedometer cable. Use tie wrap (10081) to secure

HONDA GL1500 FRONT WHEEL INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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1. Rotor Covers. Tri-chromed ABS rotor covers replace the painted ones. Light weight, beautiful and functional. Include a rear strap and sold in pairs. Also, available are chrome rotor covers with amber strip lights installed. Fits 1988 to 2000. 2. Fork Light Mounts . Specially designed mounts are tri-chromed metal and hold a total of 6 lights. Lights not included. Sold in pairs 3. LED Lighted Rotor Cover Trim Rings . NEW Update your bike with LED lights. Tri-chromed ABS rings include amber or red, blue and amber LED lights. Sold in Pairs 5. 252-216 Rotor cover Plugs. TheseĀ¾” chromed steel plugs fill the holes on the GL1500 rotor covers. Sold in a 4 pack

HARLEY DAVIDSON PASSENGER HANDRAIL GRIP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits all 1999 through 2005 Electra Glide model motorcycles with passenger handrail. Kit Contents See Figure 1 for a list of the kit contents. No Service Parts are available for this kit. INSTALLATION NOTE The passenger handrail grips are side-specific. Install the grips so that the Bar-and-Shield logo is oriented properly. 1. See Figure 1. Obtain a rubber grip insert (4) from the kit. 2. Open up the rubber insert along the horizontal split (A), and fit it over the forward curve of the handrail. Ensure that the insert is positioned to fit the curve properly, with no kinks or gaps. 3. Obtain an inner grip (1), the correct-side outer grip (2 or 3), and six screws (5) from the kit. 4. Position the inner and outer grips over the insert, pressing them firmly together and lining up the holes. 5. Insert a screw through one of the holes in the inner grip, and carefully thread part way into the mating hole in the outer grip. Repeat for the remaining five screws. 6. Use the hex socket wrench (6) provided to tighten all six screws securely. 7. Repeat Steps 1 through 6 for the opposite side

HARLEY DAVIDSON FLSTF TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL 1. Remove seat according to the instructions in the Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 2. See Figure 1. Disconnect battery cables, negative (-) cable first. 2 1 is03242 1. Negative (-) cable 2. Tail lamp connector Figure 1. Negative Battery Cable and Tail Lamp Connector 3. See Figure 2. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 2. Remove Tail Lamp Lens 4. See Figure 3. Using a Terminal Pick Tool (1), depress locking tabs and disconnect turn signal connectors (2- place) (2, 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. 6. See Figure 4. Remove turn signal wiring (1, 2) from clips (3) under rear of fender INSTALLATION NOTE Proper installation of kit requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Route Turn Signal Wiring Through Rear Fender and Support 1. See Figure 5. Remove three rear screws (1) from fender support (2). 2. Loosen, but do not remove two front screws (3) from fender support. 1 3 2 is03285 1. Screw, rear (3) 2. Fender support 3. Screw, front (2) Figure 5. Fender Support Screws and Fender Support 3. Pull fender support away from rear fender to gain access to turn signal mount. 4. Remove stock screw and washer from turn signal mount. 5. See Figure 7. Pull turn signal (B) and turn signal mount (A) away from fender support. 6. Remove turn signal and wires from vehicle by routing turn signal wiring and connector through holes in rear fender and fender support. Gently guide wires through holes to ensure they do not get damaged. Feed Wiring and Install Relocation Bracket 1. See Figure 6. Feed turn signal wiring and connector through middle hole in turn signal relocation bracket and under rear of fender support. 1 is04635 1. Wire harness Figure 6. Wire Harness Routing 2. See Figure 7. Insert stock screw and washer through rear hole of relocation bracket (1) and turn signal mount (A). 3. Thread screw into turn signal (B). Tighten to 12-16 ft-lbs (16.3-21.7 Nm). 4. Align relocation bracket (1) with rear of fender support and install with screw (2) and nut (3) from kit. Tighten nut to 12-16 ft-lbs (16.3-21.7 Nm). Complete Turn Signal Relocation Wiring 1. See Figure 5. Install one rear screw (1) to hold fender support in place while routing wiring. Install screw snugly but do not fully tighten

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HARLEY DAVIDSON ULTRA TOUR-PAK BRAKE LAMP CHROME ACCENT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation- Corner Brake Lamp Trim 1. Carefully cut out brake lamp trim template (1) attached to this instruction sheet. 2. Position template (1) on plastic brake housing (2) as shown in Figure 2. 3. Using a punch, score two points indicated on template to mark mounting hole locations (3) on plastic brake housing (2). 4. Using a 1/8 in. drill bit, drill a pilot hole in plastic housing. 5. Use a 7/32 in. drill bit to drill through housing and fiberglass Tour-Pak. 6. See Figure 3. Insert studs on chrome brake lamp trim piece through holes drilled in plastic housing and Tour- Pak. Using two flatwashers (1), two lockwashers (2) and two acorn nuts (3) from kit, secure trim piece to Tour- Pak. Tighten finger tight. 7. See Figure 3. Locate brake lamp retaining clip (4) on inside of Tour-Pak and remove. Save clip (4) for later reinstallation. 8. Form chrome trim around corner of Tour-Pak, so that it is positioned around plastic housing evenly. While holding chrome trim in position, mark forward mounting hole position on Tour-Pak using a punch