HARLEY DAVIDSON HALF HELMET STEREO HEADSET KIT/ AUDIO CABLE CONNECTION OPERATION MANUAL

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

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AUDIO CABLE CONNECTION 1. See Figure 3. Obtain the larger clip (4) and the coiled headset audio cable (2) from the kit. Install the 3.5 mm stereo jack end of the cable into the clip. 2. Connect the 3.5 mm stereo jack from the headset audio cable to the audio output socket on the Road Tech riser radio, satellite radio or other audio device. Position the clip in the area indicated in Figure 1, and rotate as needed to allow easy insertion and removal of the cable jack and audio output socket. 2 1 is04347 1. For FLHT models 2. For FXD, FXST, FLST, FLHR and FLTR models Figure 1. Clip Location NOTE Ambient temperature should be at least 60 °F (16 °C) for proper adhesion of the clip to the mounting surface. 3. Clean the clip mounting area with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Peel the liner from the adhesive backing of the clip. Carefully position the clip to the mounting surface, and press firmly into place. Hold the clip in position with steady pressure for 30 seconds. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) •Be sure audio connection harness or headset audio cable do not pinch, bind or interfere when handlebars are turned fully to left or right fork stops. 5. See Figure 3. Use the small clip (5) from the kit to retain any excess headset cable to the side of the console. Attach per Step 4. NOTES Allow AT LEAST 24 hours after applying the clip before exposing the area to vigorous washing, strong water spray or extreme weather. -J04930 1 of 2 PERATION 1. Plug in the coiled audio cable at the headset and audio source. 2. See Figure 2. Put the headset on as shown, with the headband across the back of the head, above the neck. Put the helmet on, and fasten securely

HARLEY DAVIDSON FRONT FENDER MEDALLION INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Locate the Medallion For XL, Dyna, and FX Softail (includingFXSTDSE): Front Fender Medallion (Kit No. 91194-04) 1. Center medallion on the fender laterally (side to side). 2. Locate the front tip of the medallion 1 3/8 in. (34.9 mm) back from the fender edge, the pin stripe, or two-tone paint line depending on the paint scheme. For Touring and FL Softail: Front Fender Medallion (Kit No. 91195-04) 1. Center medallion on the fender laterally (side to side). 2. Locate the front tip of the medallion 1 3/4 in. (44.5 mm) back from the fender edge, tip trim, tip light, the pin stripe, or two-tone line depending on accessories, trim and paint scheme. Prepare the Fender NOTE For maximum adhesive bond, the fender under and immediately surrounding the medallion must be clean and dry. 1. Clean the surface with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. 2. Allow fender to dry thoroughly. NOTE To prevent contamination, apply medallion within minutes. Apply the Medallion 1. With the protective film still in place, trial fit the medallion to the fender and adjust location to accommodate pin striping, two-tone paint, fender tips or lights. NOTE Ambient temperature should be 70 to 100°F (21 to 38°C). 2. Remove the protective film. 3. Carefully locate and center the medallion on the fender. 4. Press the medallion firmly into position. Without shifting the medallion on the fender, push hard with thumbs for about five seconds. 5. After releasing pressure, avoid direct contact with the medallion for at least 20 minutes. NOTE Allow ATLEAST 24 hours before exposing the fender to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperatures.

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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HARLEY DAVIDSON LOCKING GLOVE BOX DOOR KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Unsnap the original equipment (O.E.) left-side glove box door, and unfasten the tether by bringing the aglet end (see Figure 1, B) out through the retaining hole. Always wear proper eye protection when drilling or grinding. Flying debris could cause serious eye injury. (00402e) 2. Using an 3/16 inch (5 mm) bit positioned in the center of each snap, drill out the four plastic snaps surrounding the glove box opening. NOTE The glove box door, hinge and frame assemblies are side- specific. The assemblies install so that the tether retaining hole (C) in the door frame is to the inboard side. 3. Obtain the new left-side glove box door, hinge and frame assembly (1), a lock (2) and a tether assembly (8) from the kit. Remove the nut (3) from the lock. 4. Insert the lock through the hole in the glove box door as shown. Assemble the tether over the lock threads with the tab (A) on the inboard side of the lock, same as the retaining hole in the door frame. Tighten securely. 5. Open the left-side door, and position the door assembly at the glove box opening, lining up the holes. 6. Insert a screw (9) through each of the holes in the door frame and glove box. Install a hex nut with washer (10) onto the threads of each screw. Tighten finger-tight. NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the gaskets to the glove box door frame. 7. Clean the glove box door frame with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. NOTE The glove box gaskets are side-specific. With the paper backing facing the door frame, the oblong hole at the top of the gasket is to the outboard side. 8. Obtain the left-side gasket (6) and a hinge gasket (7) from the kit. Install the gaskets to the glove box door frame. a. The gasket liner on the large gasket is split to aid alignment. Peel one half of the liner from the adhesive backing of the left-side gasket. b. Using the frame edges and screw heads as a guide, carefully position the gasket to the glove box door frame and press firmly into place. c. Peel the remaining half of the liner from the gasket backing, and carefully position the rest of the gasket to the door frame. Press firmly into place. d. Apply steady pressure for a few seconds at all areas of the gasket to verify proper adhesion. e. Peel the liner from the hinge gasket. f. Carefully position the gasket to the door frame above the hinge, and press firmly into place.

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