HARLEY DAVIDSON TRUNK MOUNT FLAG KITS INSTALLATION MANUAL

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

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Installation Water may enter Tour-Paks/saddlebags with flag mast installed during inclement weather. Attaching a flag mast to a Tour-Pak or saddlebag without wear pads in place may result in damage to the Tour-Pak or saddlebag exterior. Periodically check to ensure the flag mast remains in contact with wear pads. 1. See Figure 1. Remove adhesive backing from wear pad and place on area where mast base will hit the painted portion of the Tour-Pak and/or saddlebag. Attach flag mast to Tour-Pak or saddlebag as shown. Attaching flag mast to Tour-Pak or saddlebag without rubber pads in place may result in damage to exterior of Tour-Pak or saddlebag. 2. Cut the self adhesive rubber pad in half. Remove the backing from the rubber pads and place on the inside of the Tour-Pak or saddlebags on each side of the flag mast as shown. CAUTION CAUTION CAUTION INSTRUCTIONS -J01143 REV. 11-20-01 TRUNK MOUNT FLAG KITS ® Kit Numbers 94612-98, 94617-98, 94618-98, 94626-98 Figure 1. Flag mast installed on Tour-Pak Place wear pad on area where mast base will hit the painted portion of the Tour-Pak and/or saddlebag i01121 Figure 2. Rubber pads installed on interior of Tour-Pak

HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY 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) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY 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) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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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 VRSC ACCESSORY SEATS AND PILLIONS INSTALLATION MANUAL

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

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INSTALLATION Installing Seat and Pillion Kits: 51584-01, 52028-02, 52036-01, 53432-02, or 52927-05 NOTE Proper installation of 53432-02 (Sundowner) and 52927-05 (Tallboy) requires installation of Fender Base Plate Kit 51120- 01 1. Refer to the appropriate Service Manual and remove the stock seat and pillion. 2. See Figure 2. Remove the two mounting bolts (2) from the passenger grabstrap (1). Save the bolts for re-installa- tion. NOTE The grabstrap must loop toward the rear. Check that the “Harley-Davidson” text on the grabstrap can be read from the front of the vehicle. 3. See Figure 2. Install stock grabstrap bolt, and one end of grabstrap as shown. While holding the grabstrap end parallel to the formed line of the fender, tighten the bolt to 8-12 Nm (71-106 in-lb ) . Repeat for opposite end of grabstrap. NOTES The new pillions included in Kits 52028-02 (Custom), 52036- 02 (Badlander) and 51584-01 (Leather Badlander) are installed from front-to-back. The pillion included in Kits 53432-02 (Sundowner) and 52927- 05 (Tallboy) must be installed through the grabstrap from back- to-front. To install the Sundowner or Tallboy Pillion on a motorcycle having a sissybar upright installed on Fender Base Plate Kit 51120-01, remove the upright before installing the pillion. Reinstall the upright after the Sundowner Pillion is installed. For kit numbers 52028-02 (Custom), 52036-01 (Vinyl Bad- lander) and 51584-01 (Leather Badlander) Seat Kits, be aware of the following: The 2003 Model Year 100th Anniversary VRSCA vehicle with two-tone sterling silver and vivid black paint has protective tape covering the rear under-the-seat area of the airbox cover. For the seats listed above, it will be necessary for cosmetic reasons, to carefully remove the protective tape and reapply it so it is in the correct position for these shorter-nose seats. Some trimming of the lower portion of the protective tape may be necessary to eliminate interference with the airbox cover latch. If necessary, reorder protective tape (48403-03). 4. Install new pillion into position through grabstrap. Prevent pinching TSSM control wiring by routing the cable through the channel on the underside of the pillion (see Figure 2) and away from the pillion mounting bolt. Pinched wiring may damage the TSSM system. 1 3 2 is00014 1. Pillion 2. Grabstrap 3. Pillion base mounting hole Figure 3. Pillion Base Mounting Hole 5. See Figure 3. Push the pillion (1) forward through the grabstrap (2) until the pillion mounting hole is approximately 25 mm (1 in.) forward of the hole (3) in the frame. 6. See Figure 2. Push down on the pillion and slide the pillion toward the rear to engage the pillion slot with the fender tongue (5). Push rearward until the pillion mounting holes align. After installing pillion, pull upward to be sure it is locked in position. While riding, a loose pillion can shift causing loss of control, which could result in death or serious injury. (00387a) 7. Install original pillion mounting bolt. Tighten bolt to 11-14 Nm (97-124 in-lb ) . 8. Re-install the sissybar upright, if removed earlier. 9. Position the seat (as if opened) onto the frame. Slide the seat forward to insert the seat-hinge pins into the bushings on the frame. 10. See Figure 1. Clip the plastic seat-hinge sleeve (2) over the seat hinge. 11. See Figure 1. Insert the seat tether (3) into the hole in the motorcycle frame. 12. Refer to the applicable Owner’s Manual and close the seat. Installing Seat Kits: 51595-05, 52024-01, or 51647-06 Kit 51595-05 requires the use of pillion kit 51594-05. Kit 51647-06 requires the use of pillion kit 51648-06. Kit 52024-01 requires the use of either the stock pillion or Touring Pillion 52023-01A. 1. Refer to the appropriate Service Manual and remove the stock seat.

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HARLEY DAVIDSON QUICK RELEASE DETACHABLE WINDSHIELD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation 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) NOTE Cover the front fender, headlamp and the front of the fuel tank with clean shop towels to prevent scratching. Make sure the windshield assembly does not contact chrome or painted parts. Damage to the finish could result. Turn Signal Relocation Relocate the turn signals according to instructions included in the Turn Signal Relocation Kit, item 20. Assemble the Clamps to the Windshield 1. See Figure 1. Remove the windshield sub-assembly from the packaging and place face down on a clean, soft surface with the mount brackets facing upward. 2. See the Service Parts illustration. Remove both the clamp and hardware kits from the packaging, and separate similar parts in preparation for assembly. Note that upper and lower clamps are exactly alike. 3. See Figure 2. Assemble the clamp assemblies and hardware stacks. The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce the windshield’s ability to break away in a collision, which could result in death or serious injury. 4. See Figure 2. One clamp at a time, with the clamp facing upward and inboard of the windshield bracket (2), tighten the shoulder bolts (1) enough to hold the clamp orientation to the windshield during mounting of the windshield to the bike. The bolts will be fully tightened later. Install the Windshield NOTE Keep front wheel straight to prevent brackets from scratching fuel tank. 1. Make sure all four clamps are in the “open” position, then bring the windshield (with the clamp side away from you) to the front of the bike. 1 WARNING 1 WARNING ® Kit Numbers 58779-05, 57160-05 1 of 3 Figure 1. Windshield Mounting Brackets i07503 Figure 2. Windshield MountingClamp i07504 1 Shoulder bolt 2 Right windshield bracket 3 Cup washer 4 Belleville washers (cupped sides face each other with windshield bracket between)

HARLEY DAVIDSON CHROME REAR WHEEL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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Kits 41017-00, 41026-00 and 41262-03 are designed for installation on 2000 and later XL, FXD and 2000-2002 Softail Model Motorcycles (except FXSTD and FLSTS). Kits 41260-03, 41261-03 and 41265-03 are designed for installation on 2003 and later Softail Model Motorcycles (except FXSTD and FLSTS). Kit Numbers 41017-00 and 41261-03 contain a16 inch chrome slotted rear wheel. Kit Numbers 41026-00 and 41260-03 contain a 16 inch chrome fatboy rear wheel. Kit Numbers 41262-03 and 41265-03 contain a 16 inch mirror chrome disc rear wheel. See Service Parts Illustration for kit contents. nstallation Do not re-use brake disc screws. New screws are provided for disc installation. Re-using original disc screws can result in torque loss and damage to rotor and/ or brake assembly. (00319a) Refer to the appropriate Service Manual for wheel removal and installation procedures. See Service Parts Illustration. This kit contains the necessary parts for wheel installation, however you will need to save the Axle, Axle Nut, Brake Disc, and the Drive Pulley with related hardware for reinstallation. NOTE The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Apply two drops of LOCTITE THREADLOCKER 262 (red) to each of the five sprocket mounting screws. Follow the bolt torque procedure in your service manual or, if installing an accessory hardware kit, in the I-sheet included with the hardware kit. Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel & Tire Cleaner Part Number 94658-98 applied with Harley Wheel & Spoke Brush Part Number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner Part Number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, Part Number 99701-84

HARLEY DAVIDSON CLEAR/SMOKED BULLET STYLE OR VRSC TURN SIGNAL LENS KITS INSTALLATION MANUAL

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

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Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson Dealer. 1. See Figure 1. Locate the removal notch on the turn signal lens and carefully pry from housing. Discard lens. Repeat for remaining lenses. 2. Remove bulbs from turn signal assemblies. 3. Obtain new amber bulbs from kit. Install the bulbs marked 1157A (Dual Filament) to the front turn signal assemblies. Install the bulbs marked 1156 (Single Filament) to the rear turn signal assemblies. NOTE See Figure 1. VRSC (V-Rod) Models have unique rear turn signal lenses. The rear lens is identified with a dimple mark in the center of lens. The front has no dimple. 4. Obtain new lens from kit and install by snapping into place. Check turn signals for proper operation. ® Figure 1. “Bullet” and VRSC Turn Signal Lenses Kit Numbers 69303-02, 69304-02, 69309-02 and 69315-02 Service Parts Clear/Smoked “Bullet” and VRSC Lens Kits Date 5/02 Part No. 69303-02 and Others Item Description Part Number Kit Number 69303-02 1 Clear lens, bullet, front and rear (4) 69324-02 Kit Number 69304-02 2 Smoked lens, bullet, front and rear (4) 69325-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear) 69330-02 Item Description Part Number Kit Number 69309-02 1 Clear lens, VRSC, front (2) 69324-02 5 Clear lens, VRSC, rear (2) 69322-02 Kit Number 69315-02 2 Smoked lens, VRSC, front (2) 69325-02 6 Smoked lens, VRSC, rear (2) 69323-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear

HARLEY DAVIDSON BILLET-STYLE FOOTBOARD INSERTS INSTALLATION INSTRUCTIONS

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

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Kit numbers 51010-01 and 51011-01 fit 1980 and later FLT, FLHT, FLHR, FLHS, and FLTR models; and 1986 and later FLSTC, FLSTN, FLSTF, and FLSTS models. Kit numbers 51016-01 and 51017-01 fit 1986 and later Softail models equipped with footboard kit part number 50602-89A, 50955-97A, 50602-00, or 50955-00; and 1986 and later FLHT, FLT, FLHR, FLTR, and FLHS models. These inserts are compatible with passenger chrome- footboard covers. Installation REMOVE EXISTING FOOTBOARD INSERTS 1. Apply liquid dishwashing soap to the footboard-insert rubber beads protruding through the bottom of the footboard. 2. Pry the footboard insert out from the top of the footboard to remove the insert. INSTALL NEW FOOTBOARD INSERTS 1. Apply liquid dishwashing soap to the new footboard- insert rubber beads. 2. Place the footboard insert into position on the footboard. Use a pliers to pull each rubber bead into its footboard hole until the beads protrude through the footboard. 3. Repeat the above steps for the remaining footboard insert.