HARLEY DAVIDSON ADJUSTABLE AIR DEFLECTOR KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 15-02-2011

download
INSTALLATION 1. See Figure 1. Models with NO air deflectors installed: Remove and discard the eight hole plugs (1) from the right and left edges of the inner fairing assembly. Models WITH air deflectors currently installed: Remove and discard the eight screws that retain the right and left air deflectors. Remove and discard the deflectors. 2. See Figure 2. Select a right-side (1) or left-side (2) air deflector, and four screws (3) from the kit. Determine the correct side by holding the mounting-hole side of the deflector against the fairing. 3. Place the deflector against the inner fairing, lining up the holes. Insert the screws through the deflector holes and into the fairing air deflector holes. Tighten the screws to 25-30 in-lbs (2.8-3.4 Nm) . 1 1 is04653a Figure 1. Remove Hole Plugs SERVICE PARTS 3 2 1 is04654 Figure 2. Service Parts: Adjustable Air Deflector Kit Table 1. Service Parts Table Part Number Description (Quantity) Item 58128-08A Air deflector, adjustable (right side) – Dark Smoke 1 57655-08A Air deflector, adjustable (right side) – Light Smoke 58129-08A Air deflector, adjustable (left side) – Dark Smoke 2 57657-08A Air deflector, adjustable (left side) – Light Smoke 2563 Screw (8

HARLEY DAVIDSON CHROME DISPLAY STAND INSTALLATION MANUAL

0

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

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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 disconnect the battery negative (-) cable or remove the main fuse. NOTE Make sure that the cutout (B) of the strap (3) is oriented to the rear of the motorcycle after installation. 2. See Figure 2. Install strap (3) and weld nut (4) to the frame in the locations shown. 3. Position the center display stand over the mounting holes under the frame, oriented so that the skid plate faces for- ward. 4. Apply a small amount of Loctite 271 – Red to the two long screws (1) and secure the rear of the display stand to the frame by installing the two screw to the strap. 5. Apply a small amount of Loctite 271 – Red to the short screw (2) and secure the front of the display stand to the frame by installing the screw to the weld nut. 6. Tighten screws to 60-96 in-lbs (7-11 Nm) . 7. Refer to the service manual and connect the battery cables or install the main fuse. 1 2 is05370 1. Flange side 2. Flat side Figure 1. Chrome Display Stand Foot Orientation ADJUSTING THE DISPLAY STAND The left and right feet of the display stand are independently adjustable to vertically level the vehicle with the display stand extended. To adjust the display stand: NOTE The display stand can be adjusted with rear tire to ground contact or with rear tire off the ground. With the rear tire to ground contact adjustment, the rear wheel is on the ground but enough weight is on the display stand legs to make the motorcycle stable from side-to-side and front-to-back. Using the display stand to center the motorcycle will require effort. With the rear tire off the ground adjustment, the rear tire clears the ground so tire can be rotated for cleaning or maintenance purposes. Using the display stand to lift rear tire off the ground will require more effort. Do not center the vehicle with someone on the vehicle. To reduce effort, remove stored items from saddlebags, if equipped

Incoming search terms:

HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 11-02-2011

download
Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

Incoming search terms:

HARLEY DAVIDSON TOURING DETACHABLE TOUR-PAK RACK INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 09-02-2011

download
INSTALLATION NOTE See Figure 3. When installing Tour-Pak to Rack in the following Steps, note that holes on Rack provide two positions for mounting Tour-Pak in desired location. 1. Place Tour-Pak on support tube and open lid. NOTE See Figure 3. In the following step, the longer bolts (6) are used for 2005 and earlier (King only) and Chopped Tour-Paks while the shorter bolts (5) are used for Leather Tour-Pak and 2006 and later King Tour-Paks. 2. See Figure 3. Obtain bolt (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align rear center hole in Tour-Pak with same hole in support tube (8). Slide bolt with flat washer through Tour-Pak, through support tube, then through concave spacer (with concave side facing support tube). At bottom of support tube, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. 3. Obtain bolts (5 or 6), two flat washers (3), concave spacer (4) and hex lock nut (2) from kit. Align top support tube (8) with detachable tour-pak rack holes (four). Slide bolts with flat washer through Tour-Pak, through support tube, through concave spacer (with concave side facing support tube) then through rack. At bottom of detachable tour-pak rack, install washer (3) and nylock cap nut (2). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. NOTE Always install the mounting bolts from inside the Tour-Pak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak. 4. Repeat Step 3 and install hardware to the remaining three holes in Tour-Pak and mounting rack. 5. In a crosswise pattern, alternately tighten the five bolts to 96-120 in-lbs (10.8-13.5 Nm) . Be sure that concavity on each spacer is inline with the rail and has not rotated out of position. INSTALLATION-TOUR-PAK AND RACK 1. Follow the instructions included in the docking point kit and install docking points. 2. See Figure 1. While standing behind the motorcycle, place the front Tour-Pak rack notches into the front docking points (1). Make sure the notches seat fully into the front docking points. 2 1 is04025 1. Front Docking Point 2. Rear Docking Point Figure 1. Docking Point Bracket 3. See Figure 1 and Figure 2. Position the latches over the rear docking points (2). Check to be sure the latches fit into the neck of the rear docking points as shown in figure 2. This may require some gentle squeezing or spreading of the rack

Incoming search terms:

All Harley Davidson Oil Recommendations

0

Filed Under (Harley Davidson) by admin on 06-02-2011

download
Harley Davidson has manufactured 9 types of engines from 1929 to the current model. Flathead (1929-1974), Knucklehead (1936-1947), Panhead (1948-1965), Shovelhead (1966-1984), Evolution (Blockhead) 1340 (1984-1999), Big Twins 1450 (2000 to current), Revolution/V-Rod (2001 to current) Ironhead Sport- sters (1957-1984) & Evolution Sportsters 1985 to current. Harley Davidson recommends SAE 50 or 60 for the engine oil in their Flathead, Knucklehead, Panhead, and Shovelhead. AMSOIL recommends AHR SAE 60 or MCV 20W-50 motorcycle oil for all these older models. Use AMSOIL SVG or SVO for the transmissions. Of these models only the Shovelhead has a chain case that is lubed, and is fed by the engine oil. In the Evolution 1340, Big Twins 1450, and V-Rods, AM- SOIL recommends MCV 20W-50 motorcycle oil in all 3 holes (engine, transmission, and primary chain case). AMSOIL recommends SVG as an alternative oil for the transmission, and SVO as an option for older transmissions. New seals are recommended where excessive leaking exists.

HARLEY DAVIDSON ENGINE GUARD KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 06-02-2011

download
This kit fits 1991 and later Dyna Glide models except Dyna models equipped with forward controls, 1993 and later FXDWG, 1994 and later FXDS Dyna Convertible models Installation The slider tubes on the front forks of some motorcycles may require adjustment to prevent the front fender from contacting the engine guard at full fork compression. 1. Check that the top of tube cap on each front-fork slider tube is positioned 0.42 – 0.50 in. (10.7 – 12.7 mm) above the top surface of the fork upper backet. Adjust slider tube position if necessary. See the FRONT FORKS section of your service manual. 2. Remove the highway footpegs and side plates. Retain the footpegs and mounting hardware, including footpeg supports. Discard the side plates and plate-mounting hardware. 3. See Figure 1. Position the engine-guard top mounting plate on the engine-side of the frame upper crossmember. Fasten the guard to the frame using the hardware from this kit as shown. Do not tighten at this time. 4. On each side of the engine guard, insert two socket- head tapping screws with lockwashers from this kit through the two lower mounting holes in the engine- guard lower side plates and into the threaded holes in the frame lower-side bracket. 5. Torque the mounting hardware in steps 2 and 3 to 33 ft- lbs (44.7 Nm).

HARLEY DAVIDSON CHROME PASSENGER FOOTBOARD SUPPORT KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 06-02-2011

download
Removing Passenger Footpegs 1. Remove and discard the socket screw and lock washer attaching the existing footpeg bracket to the rear swing arm bracket. Proceed to Step 5. Removing Passenger Footboard Supports 1. For standard footboard 50613-91: See the Service Parts illustration. Tilt the footboard to the “up” position. Remove the underside chrome footboard covers if so equipped. From the bottom of the footboard, use a small flat-blade screwdriver to push the rubber beads on the pad up through the holes in the footboard pan. Remove the pad. For swept-wing (FLHRS- and FLHTCSE-style) footboards: With the passenger footboard in the “down” position, carefully raise an outside “corner” of the stock footboard insert off the footboard pan with a suitable flat-bladed tool, taking care to avoid scratching the chrome footboard pan. Continue around the edge of the footboard, using a second flat-bladed tool if necessary to pry up and remove the old insert. 2. Using a brass drift and rubber mallet, tap one pivot pin (6) out of the pivot hole into the center pocket of the footboard pan, remove the pin and set it aside. Repeat for the second pin. 3. Remove the footboard from the support bracket (1). Remove and discard the steel ball (5) and spring (4) from the hole in the bracket. 4. Remove and discard the socket head screw (2) and lock washer (3) attaching the footboard support bracket to the rear swing arm bracket. Proceed to Step 5. Installing the New Footboard Supports NOTE Three holes are available in the rear fork brackets for footboard support mounting. Depending on model and year, the footboards can be installed in any of two or three positions for passenger comfort. A plastic plug, inserted in the upper hole at the factory, can be removed. 5. See the Service Parts illustration. Position a new chrome footboard support (1) against the swing arm bracket at the desired height. The left and right supports are identical. With the locating peg on the footboard support in the next lower hole, fasten the support with a hex socket screw (2) and lockwasher (3) from the kit. Tighten the screw to 15-18 ft-lbs (20-24 Nm). 6. Place the new spring (4) into the retaining hole in the footboard support. Rest the detent ball (5) on top of the spring

HARLEY DAVIDSON CHROME LOWER BELT GUARD INSTALLATION INTSRUCTIONS

0

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

download
INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the Maxi® Fuse. 2. See Figure 1. Remove the three screws with captive washers (3) securing the original equipment (O.E.) lower belt guard (debris deflector, Item 1) to the underside of the rear fork (2), and set them aside for re-use. Remove and discard the lower belt guard. 3. Position the new chrome lower belt guard in place on the underside of the rear fork, lining up the three holes in the belt guard with the mounting holes in the fork. Insert the three screws saved earlier through the holes in the belt guard, and thread them into the fork. Tighten the screws to 36-60 in-lbs (4.1-6.8 Nm) . 4. Verify that the Ignition/Light Key Switch is turned to the OFF position. Refer to the Owner’s Manual and follow the instructions given to re-install the Maxi® Fuse. 2 1 3 is04766 1. Lower belt guard (debris deflector) 2. Rear fork (swingarm) 3. Screw with washer (3) Figure 1. Lower Belt Guard Installation

HARLEY DAVIDSON STAINLESS STEEL SPLASHGUARD INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 30-01-2011

1. Refer to the appropriate Service Manual and remove the Maxi® fuse. 2. Refer to the applicable Service Manual and remove the rear wheel. 3. See Figure 1. Remove one screw (1) and stock splash- guard (2) from swingarm (3). 4. Remove the protective film from the new splashguard. 5. See Figure 4. Using two screws (4) and nuts (2), loosely install the H-clips to the back of the splash guard vertically as shown. 2 1 3 is04881 1. P-clamp 2. Splashguard 3. Raised bar of swingarm Figure 2. Install Splashguard -J04271 1 of 2 1 3 2 4 5 is04892 1. H-clip 2. Swingarm 3. Splashguard 4. Screw 5. Nut Figure 3. H-Clips Installed on Swingarm 6. See Figure 2. Slide two P-clamps (1) around the upper bar of the rear fork. The straight side of the clamp will face rearward, as shown in Figure 4. 7. See Figure 4. Orient the splashguard with the polished side facing the rear wheel. Align the upper two holes with the P-clamp holes. Secure splashguard to the P-clips with two screws (4) and locknuts (2). Do not tighten at this time. 8. See Figure 3. Turn H-clips (1) horizontal on the splash- guard. Press splashguard (3) into place. When the splashguard is in place, rotate the H-clips down over the raise bar of the swingarm (2). Tighten the screw (4) and nut (5) to secure the H-clips. NOTE If adequate clearance does not exist between the splashguard and rear brake line and drive belt, adjust fender extension by loosening hardware and centering the splashguard. 9. See Figure 4. Ensure the splashguard does not touch the drive belt on the left side and the rear brake line on the right side, then tighten P-clip mounting screws (4) and nuts (2) securely. 10. Refer to the applicable Service Manual and install the rear wheel. 11. Refer to the appropriate Service Manual and install the Maxi fuse

HARLEY DAVIDSON SOFTAIL BACKREST KIT Installation Instructions

0

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

download
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