HARLEY DAVIDSON NOSTALGIC SADDLEBAG GUARD RAILS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL 1. If desired, remove the saddlebags. 2. Remove screws (C) and locknuts (D). Save for installation. 3. Remove reflectors with fishing line or dental floss. Use a sawing motion to remove the adhesive. Clean the surface thoroughly with an equal mixture of isopropyl alcohol and distilled water. Allow the surface to dry thoroughly. INSTALLATION 1. See Figure 1. Position the correct saddlebag guard rail (1 or 2) over the saddlebag guard and support assembly (A). Loosely install the screw (C) through the saddlebag-to- fender support bracket (B), through the saddlebag support (A) and through the inner hole of the saddlebag guard rail bracket. Install nut (D). Tighten finger-tight. NOTE Position the saddlebag guard rail as low as possible on the stock saddlebag guard and support assembly. 2. Install screws (6) and washers (5) through the clamp end of the saddlebag guard rail. Position clamp end around the upright of the saddlebag guard and install the clamp (3 or 4). Tighten screws finger-tight. 3. Align the saddlebag guard rail (1 or 2) parallel to the bottom of the saddlebag and muffler. Tighten the cap screw (C) and locknut (D) to 15-20 ft-lb (20-27 Nm) . 4. Tighten the clamp screws (6) to 22 in-lb (2.5 Nm) . NOTE The reflectors are location-specific. There are markings on the back of the reflector – “L BOTTOM” or “R BOTTOM”. 5. Peel the backing from the base of the new reflector (7 or 8). Without touching the reflector to the saddlebag guard, position the reflector and press the reflector to the saddlebag guard above the clamp (3 or 4) and press for 30 seconds. After releasing pressure, avoid direct contact with the reflector for at least 20 minutes. 6. Repeat all steps for the other side of the motorcycle. NOTE For ease of use, move the saddlebag buckles to the highest hole on the strap. 7. Install the saddlebags, if removed

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HARLEY DAVIDSON FXDWG ENGINE GUARD KIT INSTALLATION MANUAL

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

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FXDWG ENGINE GUARD KIT General This kit is designed for installation on 1993 and later FXDWG Dyna Wide Glide. QTY DESCRIPTION 1 Engine guard 2 U-Bolt 4 Locknut 1 Bolt, 3/8-16 x 7/8 in. 1 Lockwasher, 3/8 in. 1 WARNING This engine guard may provide limited leg and cosmetic vehicle protection under unique circumstances (fall over while stopped, very low speed slide). However, it is neither designed nor intended to provide protection from bodily injury in a collision with a vehicle or any other object. Installation 1. Lift engine guard into place. Align top center mount of guard with frame crosspiece member between frame downtubes. 2. Secure top center mount to frame crosspiece member using 3/8-16 x 7/8 in. bolt and lockwasher included in kit. Do not fully tighten at this time. 3. On right side of motorcycle, install U-bolt from kit around the frame member and into the holes in the lower mounting bracket. Secure loosely into place using two locknuts from kit. 1 CAUTION Left U-bolt must be installed between the frame and the clutch cable. Do not pinch clutch cable between the U- bolt and the frame. 4. On left side of motorcycle, install remaining U-bolt from kit around the left frame member and into holes in lower mounting bracket. Secure loosely into place using two locknuts from kit. 5. Tighten upper mounting bolt installed in step 2, to 30-33 ft-lbs. Alternately tighten U-bolt hardware to 25 ft-lbs. Tighten left and right side U-bolts evenly, so that approximately the same length of bolt protrudes from end of nut

HARLEY DAVIDSON FXSTD PASSENGER BACKREST AND LUGGAGE RACK INSTALLATION MANUAL

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

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Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) INSTALLATION Passenger Upright 1. Unscrew the captive screw fastening the seat rear bracket to the fender. 2. Remove the rubber plugs from the three holes in the rear fender where the passenger upright installs. 3. See Figure 2. Fasten the studplate (2) to the fender (A) with the backing plate (3) and three flange locknuts (4). 4. See Figure 1. Fasten the passenger upright (3) to the studplate (1) with three flange locknuts (2). 5. Insert the seat front bracket into the frame, then fasten the seat rear bracket to the fender. NOTE The seat must be temporarily bowed up in the center to fit the seat rear bracket through the slot in the passenger upright. 6. Kit 51144-02 only. See Figure 2. Carefully clean the lower hole (B) on the passenger upright (1) with isopropyl alcohol to remove any grease or dirt. Remove backing from adhesive emblem (5) and press the emblem firmly in to place. 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) 1 4 3 2 is03890 1. Stud plate 2. Locknut, flange (3) 3. Passenger upright 4. Backrest pad Figure 1. Passenger Upright, Backrest Pad and Luggage Rack Installation NOTE When temporarily removing the passenger upright, the mounting and backing plates may be left in place to simplify passenger-upright re-installation. Thread the flange nuts back onto studs to store the nuts. 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) Backrest Pad See Figure 2. Fasten the backrest pad (7) to the passenger upright (1) using the button-head screw (6) as shown. Luggage Rack NOTE See Figure 2. Fasten the luggage rack (8) to the backrest with the backrest pad (7) removed from the studplate (2). -Fasten the luggage rack (8) to the passenger upr ight (1) using the luggage-rack mounting plate (11), button-head screw (12)

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HARLEY DAVIDSON HEEL RAISER FOOTPEG KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. If the motorcycle is equipped with a pin and retaining ring, remove them and retain for future use. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs and the spring washers. Save the spring washers for installation. NOTE See Figure 1. When performing the next step, verify that the spring washer is positioned inside of the footpeg support with the square edge (2) towards the inside of the support. 1 3 2 is02094 1. Spring washer 2. Spring washer square edge 3. Footpeg support slot Figure 1. Footpeg Spring Washer Installation 3. See Figure 1. Install the new footpegs in the same manner as the old footpegs were installed. Insert a spring washer (1) and the mount end of the footpeg inside the slots (3) of the footpeg supports. 4. Secure each footpeg and spring washer to the footpeg support with the screw and locknuts or pin and retaining rings removed earlier. Tighten the locknuts to 19 ft-lb (26 Nm) . Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a)

HARLEY DAVIDSON SPORTSTER FORWARD FOOT CONTROLS

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

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LEFT (SHIFTER) SIDE 1. Remove stock footrest assembly and save footrest for reinstallation. Replace existing sockethead capscrews that attached footrest bracket to primary cover with washers (5) and shorter screws (21) from kit. 2. Remove stock shift lever and save shifter peg and mounting screw. 3. See Figure 1. Remove left side stock motor mount and save nuts, washers, and P-clamp for clutch cable. The bolts will be replaced. 4. Put Loctite 243 on threads of left side foot control support (15) and thread support into left side machine motor mount (11). Install C-clip (8) onto support where it exits the backside of machine motor mount to hold support in place. 5. Install left side motor mount assembly in place of stock motor mount using washers and nuts saved from step 3, and bolts (22 and 23) from kit. Tighten bolts to 25-30 ft-lbs (41-47 Nm). Make sure to reinstall the P-clamp and clutch cable in the same hole location they were removed from in step 3. 6. Install shift lever (14) from kit using stock fastener. 7. Put Loctite 243 on threads of clevis mounting screw (4) and install shift lever pedal (13), clevis (17), and footrest (stock), as shown. To install footrest, place a spring washer (19), along with the mount end of the footpeg, inside the slots of the clevis. Make sure the spring washer is positioned inside the clevis with the square edge towards the inside as shown in Figure 3. Secure footpeg and spring washer with bolt (2) and locknut (7). Tighten locknuts to 19 ft-lbs (26 Nm)

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HARLEY DAVIDSON STREET STALKER FRONT FENDER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL 1. If model has mechanical speedometer drive, remove cable from fender bracket. Disconnect speedometer cable from the speedometer head. 2. Remove front wheel according to the Service Manual. 3. Disconnect and remove fender tip light power wire. 4. Remove hardware that holds fender in place and remove fender. INSTALLATION 1. See Figure 1 and Table 1. For each support bracket (4), remove backing from one side of tape (3), and affix tape to support bracket, carefully matching the contours of the bracket and tape for proper fit. 2. Remove backing from tape and place support brackets into position on the inside of fender (one on each side), aligning the mounting holes in each bracket with the holes in the fender. The tape side will affix to the inside of the fender. 3. Carefully place fender in position and secure fender with screws and flanged locknuts in kit. Tighten hardware to 12 ft-lbs (16.27 Nm). 4. Install front wheel according to the Service Manual. 5. Install mechanical speedometer cable. Use tie wrap (10081) to secure

HARLEY DAVIDSON SISSY BAR SIDE PLATE KIT INSTALLATION MANUAL

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

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INSTALLATION NOTE When removing rear fender reflectors, be careful not to damage fender paint. 1. Carefully remove the rear reflector. Remove any remaining adhesive from the back side of the reflector and any adhesive from the side of the fender. 2. See Service Parts Illustration. Remove the screws, washers, locknuts and clipnuts that attach the fender support cover and fender support to fender. Discard the button head screws but retain the washers (A), locknuts (B,C) and clipnuts (D) for installation. NOTE Prior to performing the following step, obtain a little slack for the turn signal assembly by reaching under the fender and bending open the aluminum tab on the clip securing wiring to fender. 3. Remove the locknut (B) from the turn signal stud (E) and gently remove the turn signal assembly from fender support cover, fender support and fender. Save locknut for installation. The turn signal will remain loosely attached to motorcycle by rear directional wire. 4. Carefully position the side plate between fender support and fender. While holding sideplate in position, line up the screw mounting holes and make sure the turn signal wiring passes through the cutout (slot) in the side plate. Coat threads of screws (1 and 2) from kit with Loctite 243 (blue) (Harley-Davidson part number 99642-97) and install locknut and clipnut, however do not tighten completely. 5. Add Loctite 243 (blue) (Harley-Davidson part number 99642-97) to turn signal stud and install through fender support cover, fender support, side plate and fender. Install locknut and tighten to 8-13 ft-lbs (11-18 Nm). Making sure sideplate remains aligned, return to fender support screws and tighten to 8-13 ft-lbs (11-18 Nm). 6. Reach under fender and position turn signal wiring into tab on clipnut. 7. Obtain reflector (3) from kit. Peel off protective strip backing and firmly press reflector (3) to side plate (4), centering reflector horizontally and vertically. 8. Repeat steps 1 through 7 on opposite side of fender

HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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HARLEY DAVIDSON ADJUSTABLE MALE-MOUNT FOOTPEGS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. 3. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer, along with the mount end of the footpeg, inside the slots of the footpeg supports. Make sure the spring washer is positioned inside the footpeg support with the square edge towards the inside of support as shown at the bottom of Figure 1. 4. Secure each footpeg and spring washer with the screw and locknut removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm) . 5. For each footpeg, loosen the adjusting screw in the recessed hole until the footpeg rotates. Position the footpeg as desired, then tighten the adjusting screw as follows: For Kits 50133-95, 50134-95 or 50500-03: Tighten to 21 ft-lbs (29 Nm) . For Kit 50474-03: Tighten to 14-16 ft-lbs (19-22 Nm)

HARLEY DAVIDSON HERITAGE REAR FENDER RAIL DISASSEMBLY AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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DISASSEMBLY NOTE See Figure 1. Saddlebags must be removed to insert spacer (1). 1. Using a small flat head screw driver, remove rear fender tip light lens cover (A) by gently prying cover away from assembly. (There is a notch at top of cover to ease removal.) Remove and retain cover (A) and gasket (C). 2. Remove fender tip light assembly (B) by removing two screws, four star washers, and two nuts (not shown) using a #2 Phillips screw driver and a 3/8 inch wrench. Retain all hardware for reassembly. 3. Remove hole plugs from rearmost fender strut holes on both sides of fender. 4. Mark fender on both sides of bike using rear most fender strut hole as a template. 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) 5. Carefully remove fender strut and drill a 11/32 inch hole through each side of fender in locations marked in Step 4. 6. Loosely reinstall fender strut (D), allowing enough room to slip spacer (1) between fender (E) and strut. INSTALLATION 1. Align rear fender rail (2) from kit with rearmost fender strut (D) mounting holes, making sure lower mounting tab (3) is inside fender (E). Place large chrome washer (4) from kit next to head of button head socket bolts (5) from kit. Insert bolt through fender rail (2), fender strut (D), spacer (1) and fender (E), in that order. Install large unfinished washer (6) from kit onto end of bolt (5). Secure assembly into place by threading locknuts (7) from kit onto ends of bolts (5) from inside of fender (E). Tighten loosely at this time. 2. Install truss head screw (8) from kit through fender (E) and rear fender rail mounting tab (3). Secure into place using small washer (9) and locknut (10) from kit. Use #2 Phillips screwdriver and a 3/8 inch wrench to tighten rear mounting assembly securely. 3. Tighten fender strut bolts (5) to 21-27 ft-lbs.(28-37 Nm) 4. Reinstall fender tip light assembly (B), gasket (C) and lens (A) using original hardware (not shown)

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