HARLEY DAVIDSON VRSCF RIGID SADDLEBAGS INSTALLATION MANUAL

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

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Kit Contents See Figure 5 and Table 1. PREPARATION 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 follow the instructions given to remove the main fuse. 2. Remove the rider seat and passenger pillion per the instructions in the service manual. 3. See Figure 1. Remove the four rear fender mounting bolts (1) and washers (2), and the passenger grab strap (3). If necessary, move the ECM to better access the fender mounting bolts. 1 3 2 is05463a 1. Bolt (4) 2. Washer (4) 3. Grab strap Figure 1. Fender Mounting Bolts 4. Disconnect the six-way tail lamp socket housing and four- way turn signal lamp socket housing from the vehicle main harness following the instructions in the service manual. Disconnect the two-way license-plate illuminator socket housing from the tail lamp harness. 5. If a luggage rack, sissy bar upright or both have been mounted on the rear fender , remove the two screws and washers, and two carriage bolts and nuts that secure the luggage rack bracket to the seat pan. NOTE The rack and/or upright will remain attached to the rear fender when the fender is removed. 6. Remove the rear fender from the seat pan by lifting upward and sliding the fender back. 7. If a center-mounted license bracket is installed, it can remain attached to the seat pan. If a side-mounted license bracket is installed: a. Remove the license plate from the vehicle (if installed), and set aside for later installation. b. See Figure 2. Remove the two bolts (8) holding the side license-plate bracket (1) to the seat pan (9). c. Remove the license-plate adjuster bracket (2) carriage bolt (3), washer (4) and lock nut (5), and the license- plate illuminator (6) and screws (7) from the bracket. d. The original equipment (OE) license-plate bracket (1), screws (7) and bolts (8) can be discarded. Set the remaining items aside for installation to the new side license-plate bracket. 8. Remove and discard the rear side reflectors (10). If a center-mounted license bracket is installed, remove the reflectors from the license bracket sides. Remove any residual adhesive from the bracket. If a side-mounted license bracket is installed, remove the reflectors from the upper frame just forward of the shock absorbers. Remove any residual adhesive from the reflector mounting area on the frame. NOTE Access to the shock absorber adjustment collar is more difficult with the saddlebags in place. 9. Adjust the rear suspension preload, if desired, per the instructions in the service manual

HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required 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 Figure 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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HARLEY DAVIDSON BASEPLATE KIT INSTALLATION MANUAL

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

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51138-07 2007 VRSCAW, VRSCX, and VRSCDX 51220-07 2007 VRSCD 51120-07 Kit Contents See Figure 9 and Table 2. INSTALLATION 2 1 3 is02795 1. Seat tether 2. Hex nut 3. Seat post nut Figure 1. Remove Pillion 1. See Figure 1. Open rider’s seat and remove tether (1) from pillion base. 2. Remove and save seat post nut (3) and hex nut (2) from the pillion base for reinstallation. Lift pillion tabs off frame studs and push the pillion forward to release bottom of the pillion from pillion post on fender. Lift the pillion away from the motorcycle and temporarily set aside. 1 is02786 1. Electronics Caddy Figure 2. Remove Electronics Caddy 3. See Figure 2. Make note of electronics caddy location and wiring routes under pillion base. Press on the caddy’s retaining tabs and remove the caddy from the fender. Move the caddy and wiring to the side. 2 1 2 is02787 1. Pillion post 2. Screws and washers Figure 3. Remove Fender Support Screws and Washers 4. See Figure 3. Remove the four fender support screws and washers (2). Discard screws, but save three washers for re-installation. From under the fender use an allen wrench to hold the lower pillion screw while removing the upper pillion post (1). Save the pillion post and lower washer for reinstallation. 5. Thoroughly clean fender at pillion mounting area of all dirt and debris

HARLEY DAVIDSON SHORT CB ANTENNA MAST REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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Additional Parts Required 1998 through 2008 models require use of the original equipment (OE) load coil. 2009 and later models DO NOT require use of a load coil. Kit Contents There are no service parts available with this kit. INSTALLATION 1. 2008 and earlier models: Use a 2 mm hex key to loosen the bottom set screw of the antenna mast. ALL models: Unscrew the antenna mast from the antenna base. 2. Thread the new antenna mast onto the threads of the antenna base. IN SERVICE 2008 and earlier models: If a degradation of CB performance is detected: 1. Open the Tour-Pak. 2. Open the map pocket (if present), and remove the acorn nuts with flat washers. Remove the map pocket and molded liner from the Tour-Pak. 3. Check the routing of the load coil wiring (see Figure 2). Wire routing other than as shown can cause a degradation of the CB signal

HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.

HARLEY DAVIDSON FRONT AGITATOR WHEELS INSTALLATION MANUAL

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

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Recommended Additional Parts 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) Kit Contents See Figure 1 and the Service Parts Tables. INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. See the service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) 2. See Figure 1. Install valve stem assembly (D) on wheel. See the service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. See the service manual. 4. Install primary bearing with a Wheel Bearing Remover and Installer. See the service manual. The left side of the wheel has DOT cast in the wheel to indicate the primary side of the wheel. 5. Install wheel spacers (previously removed). 6. Install front wheel (1) and stock axle. See the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly so they 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

HARLEY DAVIDSON SOFTAIL DELUXE SEATS INSTALLATION MANUAL

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

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These kits fit 2005 and later FLSTN model motorcycles. Additional Parts Required NOTE A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 3 and Table 1. INSTALLATION 1. Remove existing seat according to Owner’s Manual Instructions. Save all attaching hardware. 2. See Figure 1. Install two flange nuts (1) from kit onto the seat mounting studs. Tighten flange nuts to 5-8 ft-lbs (7- 11 Nm) . 1 is03023 1. Install flange nuts Figure 1. Flange Nut Locations NOTE See Figure 3 for Steps 3-6. 3. Remove two screws (A) and rear mounting bracket (B) from stock seat. Save all hardware. 4. Install the rear mounting bracket (B) removed in Step 3 onto the new seat using the seat bracket screws (A). Tighten screws to 19 in-lbs (2.1 Nm) . 5. Install new seat (1) on the motorcycle by inserting the tab at the front of the seat into the slot at the rear of the fuel tank. 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) 6. Fasten rear seat bracket (B) to fender nut using stock mounting screw (C). 7. See Figure 2. To install grabstrap, remove front screw and washer from rear fender support. Install grabstrap with thick washers (1), thin washers (3) and screws (4) from kit. Tighten to 21-27 ft-lbs (28-37 Nm)

HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. 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 Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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HARLEY DAVIDSON CHROME INSTRUMENT BEZEL COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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This kit is designed for installation on voltmeter, fuel gauge, oil pressure and air temperature gauges used on 1986 and later FLT and FLHT models. Kit Contents Table 1. Kit Contents Description Quantity Chrome bezel cover 2 Adhesive tape, double-sided strip 1 There are no Service Parts available with this kit. INSTALLATION NOTE Using a 50:50 mixture of isopropyl alcohol and water, wipe dirt, oil and grease off of instrument bezel and bezel cover before applying double-sided tape or tape may not adhere well. 1. See Figure 1. Cut tape (1) into six equal pieces. 2. Remove paper liner from one side of tape and apply tape to front face of gauge pressing firmly into place. Space all three pieces equally. 3. Remove outer liner from tape. 4. Place bezel over gauge and press firmly into place