HARLEY DAVIDSON FLHT (Electra Glide Standard) FAIRING COMPARTMENT POUCH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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General This kit is designed for 1996 and later FLHT, Electra Glide Standard, model motorcycles Kit contents: QTY DESCRIPTION 1 Pouch 4 Velcro™strip Installation 1. Wash inside of fairing compartment with a clean, soft, nonabrasive cloth, water and mild soap. 1 CAUTION DO NOT use benzine, paint thinner, gasoline, powdered abrasives, alkaline cleansers, or any other harsh cleansers to clean the fairing compartment. They will damage the surface. Never scrape fairing surfaces with a razor blade or other sharp instrument because permanent damage will result. 2. Arrange pouch in compartment. 3. Align and attach velcro strips from kit to top, bottom and sides of compartment so they match the placement of velcro strips on pouch. 4. To secure pouch to fairing compartment, press pouch velcro strips against compartment velcro strips. Care of Pouch 1. When necessary, remove and wash pouch with mild soap and warm water

HARLEY DAVIDSON 80-SPOKE REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Additional Parts Required This kit includes the custom wheel only. Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley-Davidson dealer: •Wheel Bearing Remover and Installer (HD-44060) •Wheel Installation Kit (See Service Parts Tables for part number) The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning: •Harley® Bright™ Chrome Cleaner (94683-99) •Harley® Glaze™ Polish and Sealant (99701-84) •Harley®Wheel and Spoke Brush (43078-99) •Harley-Davidson®Wheel and Tire Cleaner (94658-98) The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See the Service Parts section for kit contents. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. NOTE Remove the rear brake caliper before removing the wheel. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. Install the tube and tire on wheel. Refer to REAR WHEEL in the Service manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. 4. Install rear wheel (1), stock axle and stock axle nut. Refer to REAR WHEEL in Service Manual

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HARLEY DAVIDSON XR1200 LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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Kit 53976-08 (XR1200 Passenger Upright Kit) is available for separate purchase. Contact your Harley-Davidson dealer for more information. Kit Contents See Figure 2 and Table 1. REMOVAL 1. Remove pillion and seat following the instructions in the appropriate Service Manual. 2. Remove the seat base following the instructions in the appropriate Service Manual. 3. See Figure 1. Remove the turn signal mounting screws (3) and discard. Allow the turn signal to hang by the harness until lower bracket installation. 4. Remove the rear fender support strut screws (6) and dis- card. INSTALLATION 1. See Figure 2. Install lower luggage rack mount bracket with screws (9), flat washers (10) and nuts (8). Bracket will mount around nut (Item 2 in Figure 1). Tighten to 19 ft-lbs (26 Nm) . 2. Install screws (7) and nuts (8) through the rear fender support strut and the lower luggage rack mount bracket. Tighten to 19 ft-lbs (26 Nm) . 3. Route the turn signal wire harnesses through the groove in the bracket. Install new turn signal mounting screws (11). Tighten screws to 3-5 ft-lbs (4-7 Nm) . 4. Install seat base following the instructions in the appropriate Service Manual. 5. Install upper luggage rack mount bracket (4) with original equipment seat base screws in the lower holes (A). Do not tighten at this time. 6. Install screws (3) into slotted holes in the upper luggage rack mount bracket (4) and flange nuts (6). Slide the upper bracket as far back in the slots as possible. Tighten screws (3) to 10 ft-lbs (13.5 Nm) 4 1 1 2 5 6 3 is05250 1. Lower luggage rack mount bracket screw (4) 2. Nut (2) 3. Turn signal mounting screw (4) 4. Upper luggage rack mount bracket 5. Luggage rack 6. Rear fender support strut screw (2) Figure 1. Luggage Rack Installation NOTE If installing the Passenger Upright Kit (part number 53976-08) (available separately), do not install spacers (2) and screws (3) in front holes. 7. Install luggage rack (1) aligning the holes with the holes in the upper luggage rack mount bracket. Install spacers (2) and screws (3) in holes. Tighten to 6-10 ft-lbs (8-13.5 Nm) . 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) 8. Install pillion and seat following the instructions in the appropriate Service Manual. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a

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HARLEY DAVIDSON DYNA REAR AXLE COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-03-2011

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Models This kit fits 2006 Dyna models. This kit does not fit on motorcycles equipped with saddlebags. Kit Contents See Figure 1 and Table 1. INSTALLATION 1. Place axle covers in position over ends of swingarm with the deeper cover on the left side (covering the axle nut). 2. Fasten the clamping bars (3) to the backs of the covers using hex-head screws (5) and Belleville washers (4), securing the covers to the swingarm. Tighten the hex-head screws to 21-27 in-lbs (2.4-3.0 Nm) . Do not overtighten SERVICE PARTS 4 1 3 4 5 2 3 5 is00709 Figure 1. Service Parts: Dyna Swingarm Axle Cover Table 1. Service Parts Table Part Number Description (Quantity) Item Part Number Description (Quantity) Item 45159-97 Washer, Bellville (4) 4 Not Sold Separately Axle cover, left side 1 3644 Screw, #10-24 x 1/2 inch (4) 5 Not Sold Separately Axle cover, right side 2 Not Sold Separately Clamping bar (2) 3

HARLEY DAVIDSON FRONT FENDER SKIRT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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1980 and later Touring •1986 and later FLSTC •1993-1996 FLSTN •2006 and later FLST This kit is not designed for FLSTF model vehicles. Kit Contents Table 1. Kit Contents Quantity Description 1 Fender skirt 6 Screw, pan head 6 Locknut, hex 6 Washer, flat 1 Adhesive foam strip (Heritage models only) INSTALLATION 1. See Figure 1. Remove fasteners (2) from stock fender skirt. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) NOTE Some early models have rivets for fasteners. These rivets will need to be drilled out. Drill the rivet heads to a sufficient depth to remove the head from the rivet shaft. Do not attempt to drill the rivet all the way through. This may scratch the fender?s painted surface. 1 5 3 2 4 is 01097 1. Fender skirt 2. Screw, panhead 3. Locknut, hex 4. Flatwasher 5. Adhesive foam strip (Heritage models only) Figure 1. Front Fender Skirt and Assembling Hardware 2. Remove stock fender skirt (1). 3. Thoroughly clean the fender under the skirt. At this point it may be a good idea to wax this portion of the fender to prevent rust in the future. 4. For Concho style and Bar and Shield style fender skirts, cut the adhesive foam strip (5) into three equal parts. Remove the backing from the adhesive strips and apply adhesive on middle and two sides at the inside/bottom of the skirt. The foam strips will prevent rattling and unwanted noise. For V-Logo style skirts, cut foam strip into three pieces; however make two slightly larger to cover the heads of the screws that hold the V-Logos in place. Use the remaining smaller piece on the middle, inside/bottom of the skirt. NOTE On some FLT models, there may not be enough fender skirt support to allow the application of adhesive strips. If this is true for your motorcycle, you may install this kit without the adhesive strips. 5. Place the fender skirt in position, aligning fastener holes. 6. Install the screws (2) from the outside of the fender. Install the washers (4) and nuts (3) inside the fender

HARLEY DAVIDSON VRSC REAR AXLE COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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This kit fits 2002 and later VRSC model motorcycles. Kit Contents There are no Service Parts available with this kit. INSTALLATION 1. Using a suitable lift, support the vehicle beneath the frame until the rear tire is just slightly off the ground. 2. See Figure 1. Remove the right side upper shock mounting bolt (2) and spacer (4). Retain the shock mounting nut (not shown) which passes through the fender support and side rail assembly. 3. Pivot the shock towards the vertical position. 4. Remove the left side lower shock mounting bolt (1) and washer (5). 5. Pivot the shock towards the horizontal position. 6. Insure that the shocks are clear of all components and carefully lower the vehicle to provide access to the right side lower shock bolt. 7. Support the right shock and remove the lower shock mounting bolt (1), washer (5) and nut (6). 8. Position the right side cover provided in the kit over the swingarm 9. Reposition the right side shock and re-install the lower shock mounting bolt (1) and washer (5) by inserting through the shock, cover and swingarm. Thread into nut (6) and tighten to 41-68 Nm (30-50 ft-lbs)

HARLEY DAVIDSON SOFTAIL CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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Kit Contents See Figure 3 and Table 2 for complete kit contents. See Table 1 for the grab strap part number associated with each seat kit. Table 1. Kit Numbers and Grab Strap Usage Grab Strap Kit Number 51332-07 51310-07 51910-08 51936-08 51701-06 51308-07 51365-07 51367-07 51387-06A 51388-06 51389-06 51390-06 51391-06 51392-06 51398-07 51365-07 51410-08 51411-08 51412-08 51414-08 51415-08 51416-08 51407-08 The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley- Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) INSTALLATION NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. FXST, FXSTB and FXSTS Models 1. See Figure 3 and Table 2. Unscrew the captive thumbscrew fastening the back of the original equipment (OE) seat to the vehicle. 2. Pull the seat slightly to the rear to disengage the tang at the front of the seat from the motorcycle frame. 3. Lift the front of the seat while pulling the seat carefully forward to remove the seat from the vehicle. 4. Remove the OE grab strap and attaching hardware. Save the hardware for later use. 5. Install the grab strap. See either “For Kit 51936-08″ or “For All Other Kits” to install the grab strap. 2007 and Later FLSTF Models 1. Remove original equipment (OE) seat and mounting hardware following the instructions in the Owner’s Manual. 2. Remove and discard the OE grab strap and attaching hardware. 3. See Figure 3. Install two flange nuts (9) from the kit onto the OE grab strap mounting studs (as shown in Figure 1, Item 1). 4. Install the grab strap. See either “For Kit 51936-08″ or “For All Other Kits” to install the grab strap.

HARLEY DAVIDSON SOFTAIL DETACHABLE SIDEPLATE KIT INSTALLATION MANUAL

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

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Kit Contents See Figure 5 and Table 1. INSTALLATION Sissy Bar Installation to Sideplates 1. See Figure 5. Insert the legs of the sissy bar upright (A) all the way into the channels (B) of the sideplates (1 and 2) as shown. 2. Apply a few drops of Loctite 262 – Red to the threads of the button head screws (4). Thread the screws into the holes in the sideplate channels, and tighten to 96-120 in-lbs (11-14 N-m) . Sissy Bar and Sideplate Installation to Docking Points 3. See Figure 1. While standing behind the motorcycle, place the left-side and right-side front sideplate notches (2) into the front docking points (4) on the fender supports (3). See Figure 2 for views of correct and incorrect sideplate engagement. NOTE Failure to properly align the front docking points and sideplates may result in damage to the rear docking points. 1 3 2 4 is05682 1. Sissy bar and sideplate assembly 2. Front notch 3. Right side fender support 4. Front docking point Figure 1. Place Front Notches into Front Docking Points 4 4 3 2 2 1 1 1 2 is00963 1. Sideplate (right side) 2. Right front docking point 3. Correct: sideplate fully engaged in docking point 4. Incorrect: sideplate NOT fully engaged in docking point Figure 2. Sideplate Fit to Front Docking Points

HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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

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This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON STAMPED MINI AND SHORT BACKREST KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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These Stamped Backrest kits are designed for installation on all vehicles with Mini and Short sissy bar uprights. Kit Number 52527-01 is only for models equipped with a Mini sissy bar upright. Kit Number 52531-01 is only for models equipped with a Short sissy bar upright. See Service Parts illustration for kit contents. Installation 1. Remove stock chrome backrest bracket. Discard hardware. 2 Install backing plate (2) with 1/4 inch x .50 long screws (4) supplied with kit through mounting bracket and into backrest. Tighten screws to 7 ft-lbs (9.5 Nm). 3. Position stamped cover (1) so tabs and cover are slightly below notches in backing plate. Slide stamped cover (1) into position by sliding upwards until cover locks in position. 4. Install two #8 screws (3) through bottom of stamped cover (1) and then into backing plate (2). Tighten screws to 18-24 in-lbs (2.0 to 2.7 Nm)