HARLEY DAVIDSON SCREAMIN' EAGLE FORK BRACE KITS INSTALLATION MANUAL

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

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installation 1. See Service Parts illustration on page 2. On all models except those equipped with 39mm forks, push the dust covers off of the sliders and up the fork tubes until out of the way. On models equipped with 39mm forks, the fork brace fits over the dust cover. 2. Using allen wrenches, remove screws (1) and end caps (5 and 6) from brace halves (3 and 4). 3. Loosen screws (2), push brace halves together and insert between fork tubes. Heads of screws (2) must face towards the engine. 4. Make sure brace is down tight on fork sliders (dust covers on 39mm fork equipped models) and install end caps (5 and 6). Lightly secure end caps with screws (1). 5. Align brace halves (3 and 4) tighten screws (2) finger tight. 6. Push down on front forks several times to seat fork brace and allow it to self-align. It is very important to tighten all screws evenly and carefully to prevent binding. 7. Tighten end cap screws (1) and brace screws (2). 8. Slide dust covers down onto fork brace (except 39mm fork equipped models).

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HARLEY DAVIDSON 5-3/4 INCH HEADLAMP TRIM RING INSTALLATION MANUAL

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

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles. KIT CONTENTS See Figure 2 and Table 1. INSTALLATION 1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely

HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. 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) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

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HARLEY DAVIDSON DYNA GLIDE CUSTOM SEAT KIT Installation Instructions

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Filed Under (Harley Davidson) by admin on 05-02-2011

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Installation When performing the following procedures, be careful not to scratch painted surfaces (fender, tank, etc.) with metal tabs on seat. 1. Remove existing seat from motorcycle. Keep lockwasher and screw. 2. Remove existing grab strap and all attaching hardware. 3. Install new grab strap onto motorcycle at same location old grab strap was removed (re-use existing hardware). 4. On all models, except FXDWG , install existing stock rear bracket onto seat using stock hardware. On FXDWG models, install the new rear bracket, 52152- 97 onto the seat using the stock hardware. 5. Position new seat on motorcycle. Be sure bracket on front of seat fully engages seat mounting tab on frame. NOTE On rear fenders of 1997 -2003 models, a captive nut secured with a plastic retention washer has replaced the previously used weld nut. Do not remove the plastic retention washer unless the captive nut is damaged and must be replaced. The plastic retention washer also prevents seat bracket from contacting paint on fender. Therefore, no nylon washer is required between bracket and fender on 1997 – 2003 models. 1996 DYNA MODELS ONLY Secure seat with stock screw, stock lockwasher and place stock nylon washer between seat bracket and fender. 1997 – 2003 DYNA MODELS Secure seat with stock screw and stock lockwasher.

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HARLEY DAVIDSON WINDSHIELD KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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and later FLTR Black wind deflector 57957-98 Fits 1998-2003 FLTR (Domestic) Standard height clear 57958-98A Fits 1998-2003 FLTR Plus 3″ taller, clear 58009-98A Fits 1998-2003 FLTR (International) Standard height, clear 58246-99A Fits 1998-2003 FLTR Low profile smoked 58453-98A Fits 1998 and later FLTR Smoked and contoured low profile 58753-01A Kit Contents Table 2. Kit Contents Part Number Description Quantity Not Sold Separately Windshield 1 There are no Service Parts available with this kit. REMOVAL 1. Remove all hardware securing windshield. 2. Remove windshield. INSTALLATION 1. See Figure 1. Remove rubber trim strip from the original windshield and install on the replacement windshield. 2. Put the windshield into position. At each wellnut location use a scribe, or similar pointed tool, to make a pilot hole through the windshield tape where the mounting screw (4) goes into the wellnut (3). Install the mounting screws (4), with the nylon washers (5) and on 2004 models, the rubber washers (6) positioned as shown into the wellnuts (3). 3. Tighten mounting screws from the center to the outside edge on both sides. Tighten screws to 6-13 in-lbs (0.7- 1.5 Nm) . Well-nuts will expand to grip fairing.

HARLEY DAVIDSON AXLE CAP NUT KIT (CHROME) INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Secure the front wheel of the motorcycle. 2. Remove one hex nut, lockwasher and flat washer attaching the axle holder to the right-side fork damper tube. 3. Assemble a chrome flat washer, split lockwasher and cap nut from the kit to the fork damper stud, but do not fully tighten at this time. 4. Repeat with the remaining nut, lockwasher and flat washer on the other stud. 5. For 2000 and later models: See Figure 1. Insert a 7/16 inch drill bit (3) into the hole in the front axle (2). Pull the right-side fork leg (1) so that it just contacts the drill bit. 1 4 2 3 is04467 1. Fork leg 2. Front axle 3. Drill bit 4. Chrome cap nut, lockwasher and flat washer (2) Figure 1. Align the Front Wheel 6. Tighten the new chrome cap nuts (4) to 9-13 ft-lbs (12-18 Nm)

HARLEY DAVIDSON BADLANDER XL CUSTOM SEAT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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Removal of Stock Seat 1. Remove screw (8) to detach rear seat mounting bracket from fender. 2. Slide seat rearward to unhook front of seat from frame, then remove seat. 3. If equipped with a grab strap, remove hardware that holds it in place and remove strap. Installation of Kit Seat For 1996 and earlier models: Make certain you select the correct kit screw in step 1. Attempting to install a coarse threaded screw in a fine threaded hole, or vice versa, will damage threads. 1. Secure grab strap (2) to fender using washer (7) and appropriate screw (6) below: On 1995 and earlier models use 1/4-28 (fine) screw. On 1996 – 2003 models use 1/4-20 (coarse) screw. 2. Slide seat into position until front of seat engages frame, then secure bracket to fender with screw (8) using guide washer (3) between bracket and fender with the small washer diameter facing upwards. The guide washer will center the screw in the bracket hole and serve as a washer to protect the fender. NOTE For 1997 883 models, a retention nut and washer must be installed into the fender hole, covered with a plastic cap, where the rear seat bracket will be attached. A cable strap is included to aid in this installation. For 1997 – 2003 models: 1. Install grab strap (see step 1 for 1996 and earlier models). 2. Remove plastic cap from hole in fender where the rear seat bracket will be attached. 3. Place retention nut (5) over cable strap (9) so wide end of nut rests on eye of cable strap. Thread cable strap up under fender and through fender hole. Pull up on cable strap to hold nut snug against underside of fender. 4. With rib on retention nut seated into notch in fender hole, slide retention washer (4) into place from the rear. This will lock the retention nut in place. 5. Slide seat into position untilang=en

HARLEY DAVIDSON REAR FLOATING BRAKE DISC KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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This kit is designed to fit all late 1987 through 1999 XLH, FXR, Dyna and Softail models. Installation 1. See the appropriate Service Manual for all removal, assembly and disassembly procedures. NOTE A Service Manual for your vehicle is available from your Harley-Davidson dealer. NOTE The floating disc screw holes are countersunk to accept the retaining screw heads. Be sure you install the screws prop- erly. 2. Assemble brake disc and pads as described in appropriate Service Manual. 3. See Service Parts Illustration. Install new pan head screws. Tighten screws to torque values given in Service Manual.

HARLEY DAVIDSON ADVANCED AUDIO XM SATELLITE RADIO KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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this kit fits 2006 and later FLHT (Electra Glide®), FLHTC (Electra Glide Classic), FLHTCU (Ultra Classic® Electra Glide), FLHX (Street GlideTM) and FLTR (Road Glide®) model motor- cycles. XM satellite radio is available within the continental United States. It is not available in Alaska or Hawaii. Additional Parts Required FLHT models will require prior installation of an Advanced Audio AM/ FM/ CD Radio Kit (Part Number 76412-06) and an AM/ FM Antenna Kit (Part Number 76325-06 or 76317-06). Unless one has already been fitted as part of another Advanced Audio kit installation: FLHT, FLHTC, and FLHX models will require the additional purchase of a Non-Ultra Overlay Harness (Part Number 70169- 06) and a left-hand Antenna Bracket (Part Number 76456-06). FLHTCU models will require the additional purchase of an Ultra Overlay Harness (Part Number 70164-06) and a left-hand Antenna Bracket (Part Number 76456-06). FLTR models will require the additional purchase of a Non- Ultra Overlay Harness (Part Number 70169-06) and an Antenna Bracket (Part Number 76316-06). If two modules are already installed on top of the radio, two Dual-LockTM mounts, Part Number 76434-06, will be needed. These items are available from a Harley-Davidson Dealer INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. NOTE If another module has been installed in the location reserved for the XM radio module, relocate that module per the instructions supplied with that kit

HARlEY DAVIDSON AUTOMATIC PRIMARY CHAIN TENSIONER INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Refer to the appropriate Service Manual and remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect negative (-) battery cable. 3. Refer to the appropriate Service Manual and remove primary cover. 3 1 2 5 4 is00561 1. Screw (2) 2. Anchor plate 3. Nut and washer 4. Manual tensioner 5. Screw (2) Figure 1. Manual Tensioner: 1985-2000 Models 4. For 1985-2000 model motorcycles, remove manual tensioner and replace the carriage bolt as follows: a. See Figure 1. Remove two screws (5) and nut and washer (3), and remove chain tensioner (4). b. Remove two screws (1) and anchor plate (2). c. Replace the carriage bolt in the anchor plate with the carriage bolt from the kit. d. Apply 2-3 drops of Loctite 262 (red) to the threads of the anchor plate mounting screws (1), then install anchor plate and two screws. Tighten screws to 12- 14 ft-lbs (16-19 Nm) . For 2001 and later model motorcycles, remove manual tensioner as follows: a. See Figure 2. Remove nut and washer (1) and remove chain tensioner (2) Removing the Autotensioner for Service 1. Use a tie wrap and secure the shoe to the base of the autotensioner, without securing it to the autotensioner bracket. This will retain the autotensioner adjustment for reinstallation during service. 2. Remove two autotensioner hex screws, and autotensioner. Resetting the Autotensioner 1. See Figure 5. Compress autotensioner wedge (1) and spring back to the base. 2. Hold wedge in position by inserting a hex wrench or pick tool through the hole in the base of the autotensioner. 3. See Figure 6. Move plastic autotensioner shoe (1) into place as shown. 4. If available, install shipping plate (2) to secure the shoe to the base. If it is not available, secure the shoe to the base with a tie wrap

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