HARLEY DAVIDSON FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION Removing Outer Fairing 1. Standing at the front of the vehicle, use a T-27 TORX® drive head to remove the three outer fairing screws (with flat washers) just below the windshield. 2. Moving to the inner fairing side, use a T-27 TORX drive head to remove the two fairing screws just above the wind deflectors on the left and right side. 3. Turn the handlebar to the right and remove the outer fairing screw (reach in below the fairing cap). Turn the handlebar to the left and remove the fairing screw on the opposite side. 4. Tilting the outer fairing toward the front, squeeze the two external tabs to remove the wire connector at the back of the headlamp assembly. 5. Lift the fairing (with headlamp assembly) off the motor- cycle. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 6. Remove the Windshield. Installing Mirrors 1. See Figure 1. Place template on inside of fairing as shown to locate mounting holes for mirror. 2. Begin by drilling a 1/8 inch pilot hole at each location marked on the template. For the center hole (2) where the 3/8 inch threaded stud passes through the fairing use a 13/32 inch diameter twist drill to drill the hole to its final size. For the alignment hole (1), use a 7/32 inch diameter twist drill to drill the hole to the final size. 2 1 is 02115 1.7/32 inch hole location 2.13/32 inch hole location Figure 1. Positioning Template 1 is06315 1. Auxiliary mirror Figure 2. Orientation of Auxiliary Mirror NOTE The flange nut is a self locking nut and must not be tightened more than 30 in-lbs (3.4 Nm). 3. See Figure 3. Place mirror (2) in position and install backing plate (4) with the raised post (B) (with the L and R marking) toward the nut surface. Install the flange nut (6) and tighten nut to 20-30 in-lbs (2.3-3.4 Nm). 4. See Figure 2. Position the mirror so the round auxiliary mirror is in the upper inside corner position. 5. Repeat for right side

HARLEY DAVIDSON SOFTAIL REAR SADDLEBAG GUARDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION 1. Remove saddlebag, if equipped, from motorcycle. 2. Remove passenger footpeg or passenger footboard assembly (including footboard mount) from vehicle. 3. See Figure 1. Remove nut (1), seat strap bracket (if equipped) and 3/8 inch diameter bolt (2) from indicated position on rear fender support (immediately to the rear of the front seat) Discard the bolt, but save the nut for reinstallation. This location is where the upper part of the saddlebag guard will mount. 2 1 is03883 1. Rear fender support nut 2. Rear fender support screw Figure 1. Hardware Removal 4. See Figure 2. Install saddlebag guard (4) top flange (5) against fender support (3). Install 3/8-16 x 1-3/4 inch button head bolt with the seat strap bracket (if equipped) and hardware removed in Step 3 (if equipped) and nut in same direction as bolt removed in Step 3. Finger tighten only. 5. Position bottom flange (6) of saddlebag guard (4) against inboard surface of motorcycle frame (7) at location where passenger footpeg (2) (or passenger footboard bolt) attaches. If Heritage-Style Saddlebag relocation kit, Part Number 90238-00 is to be installed, the bracket should be positioned between the saddlebag guard flange and the motorcycle frame member. Follow installation instructions included with that kit. 6. See Figure 3. Determine your model application and follow the applicable installation procedure below: On models with passenger footpeg, but without saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support (B). Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Install lower saddlebag guard flange over bolt protruding from inboard surface of frame member. Install 3/8-16 lock nut to end of bolt. Tighten to 35-45 ft-lbs (47-61 Nm). Install footpeg (C) according to Service Manual instructions. On models with passenger footpeg and saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support. Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Position saddlebag relocation

HARLEY DAVIDSON SCREAMIN' EAGLE MECHANICAL COMPRESSION RELEASE FIX- TURE

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Filed Under (Harley Davidson) by admin on 04-02-2011

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DRILLING AND TAPPING PROCEDURE Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) NOTE Perform the following procedure on both the front and rear cylinder heads. Tool Setup NOTE Due to slight manufacturing differences, it may be necessary to tap the fixture into place with a rubber mallet. Do NOT use excessive force. 1. Align the fixture’s locating pins with the 3/8 inch tooling holes in the head and install the fixture on the head. 2. See Figure 1 and Figure 6. Secure the fixture (1) to the head with two 5/16-18 socket head cap screws (2) and washers (9) included in the kit. Install the screws in the holes marked “F” when modifying the front head or in the holes marked “R” when modifying the rear head. Tighten screws to 80 in-lbs (9 Nm) . 3. See Figure 3 and Figure 6. Install the drill bushing (3) in the bore marked “FRONT” when modifying the front head or in the bore marked “REAR” when modifying the rear head. 4. Tighten drill bushing set screw to 50 in-lbs (5.6 Nm) . 5. See Figure 2 and Figure 6. Install collar stop (4) onto the 1/2 inch diameter shank of the step drill bit (5). Secure the collar stop with the set screw 3.900 inches (9.90 cm) from the beginning of the 3/4 inch diameter step of the drill bi

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HARLEY DAVIDSON HIGH PERFORMANCE CYLINDER STUD KIT INSTALLATION INSTRUCTIONS

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

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This kit is designed for installation on 1986 and later XL model motorcycles. This kit is required on engines with compression ratios of 10:1 and higher. For XL 1200 engines with higher compression ratios, Screamin’ Eagle gasket kit part number 17046-98 is also recommended. Installation To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect the battery, negative cable first. 2. Remove top end heads and cylinders according to Service Manual instructions. Cylinder studs that are bent, scratched or broken must be replaced. Broken and bent studs distort clamp load, while scratches produce stress risers that may eventually lead to broken studs. Distorted clamp load causes head gasket leakage that may result in engine damage. Do not use a ratchet or breaker bar to install cylinder studs because they will bend the studs. 3. Remove existing cylinder studs according to Service Manual instructions. 4. Install new studs, Loctite end first. • Place a 0.313 inch DIAMETER BALL, HD Part Number 8860 (or from the XL clutch release mechanism) into the head bolt recess. Thread the stud into the head bolt until the stud bottoms on the ball. NOTE Pack clean shop towels into the crankcase openings to prevent the ball from falling into the flywheel compartment when removing the head bolt. • Clean the threads in the crankcase. • The studs have a Loctite patch on the crankcase end threads.Install the studs in the crankcase with the Loctite patch side down. • Use a T-handle to install the studs. Install studs until the free length is 4.84 ±.05 inches. See Service Manual for more detailed information. 5. Check all studs for proper height. 6. Reinstall the top end heads and cylinders according to the Service Manual Instructions

Motorcycle Engine Guard Adjustable Light Housing

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Filed Under (Kawasaki) by admin on 05-11-2010

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ADJUSTABLE HOUSING This highly polished, adjustable aluminum housing provides a very attractive means of adding the safety of Cuda TriOptic LED lighting to the engine guards on your Police Motorcycle. This newly developed 2.5 X 5.5 inch housing comes mounted on a ball swivel and can be adjusted and tightened to point LED lighting in any desired direction. This compact housing fits conveniently into position on the engine guard and is available with an engine guard clamp in a 1.00 inch or 1.25 inch diameter, which fits the engine guards of most popular motorcycles. The entire assembly is constructed of a highly polished aluminum alloy which blends very nicely with the chrome trim and accessories that are common on most motorcycles. COMPACT , LOW PROFILE CUDA LIGHT Our Engine Guard housing contains a newly developed model of the popular Cuda TriOptic light series with six LEDs positioned in a low profile format. This light housing provides a more compact but equally penetrating light source as the larger Cuda models. BUILT IN FLASHER As is Standard with all Cuda TriOptic products, this model can be programmed, prior to installation, to flash any one of eight selectable flash patterns; making the need for an external flasher unnecessary. EFFECTIVE LIGHT OUTPUT Cuda TriOptic lighting incorporates third generation, high intensity LEDs for dramatically bright light output. This high output light power is further enhanced by specially shaped lenses to ensure superior on and off-axis light distribution for maximum visibility. LOW AMP DRAW In addition to being extremely bright, the LEDs significantly reduce power consumption – a critical concern for fully equipped motorcycles. The 351011 (2-up) model, that is contained in this light housing, draws 0.7 amps per unit. RELIABILITY Cuda TriOptic LEDs are rated for over 100,000 hours of useful life – compared to 2500-5000 hours for a typical halogen bulb. Plus, Federal Signal LED products come with a 5- year warranty, and meet SAE and CAC standards for radio frequency interference. See the back of this page for technical specifications and ordering information so you can start specifying Cuda TriOptic LEDs for your motorcycles today!