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.

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HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. 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 your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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HARLEY DAVIDSON CHROME BILLET LIFTER-COVER KIT REMOVAL AND INSTALLATION MANUAL

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

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Installation with Stock Pushrods Refer to the service manual for your motorcycle model. Installation with Adjustable Pushrods Lifter-Cover Removal Installing or removing the pushrods with the valve train loaded can result in engine damage. On the cylinder being serviced, always set the lifters to the base circle on the cam before servicing pushrods, lifters, rocker arms, and valves. 1. Set the lifters of the rear cylinder to their lowest point, or base circle, on the cam. Refer to Setting the Lifters to the Base Circle in this instruction sheet. 2. See Figure 1. Insert a screwdriver into the slot on the side of the spring-cap retainer on the pushrod cover. 3. Press the spring-cap and retainer down while pulling outward to remove the spring-cap retainer. 4. See Figure 2. Lift the lower pushrod cover to reveal the lower third of the pushrod. 5. If the engine has stock pushrods installed and you are installing adjustable pushrods with this lifter-cover installation, go to step 6. If the engine already has adjustable pushrods installed and you are installing adjustable pushrods with this lifter-cover installation, go to step 7 6. Use a bolt cutter or similar tool to cut the stock pushrod. Avoid cutting the pushrods with a saw, grinder, or other method that may allow metal debris into the engine. Go to step 8. 7. Loosen the jam nut on each adjustable pushrod and resize each rod to its shortest length. 8. Remove the pushrod covers and pushrods from the engine. 9. Remove the O-rings from the seats in the engine at the top and bottom of the pushrod cover. 10. Remove the four screws fastening the lifter cover to the engine to remove the cover and gasket. 11. Remove old lifter-cover gasket material from the engine, taking care not to allow material to fall into the engine. Continue to Lifter-Cover Installation in this I-Sheet. Lifter-Cover Installation 1. See Figure 3. Verify that the lifter anti-rotation pin is in position. Installing or removing the pushrods with the valve train loaded can result in engine damage. On the cylinder being serviced, always set the lifters to the base circle on the cam before servicing pushrods, lifters, rocker arms, and valves. 2. Verify that the cylinder lifters are set to their lowest point, or base circle, on the cam. Refer to Setting the Lifters to the Base Circle in this instruction sheet. 3. Fasten the new lifter-cover gasket and chrome billet lifter cover to the engine using the chrome screws from this kit. In a cross pattern, torque the lifter-cover screws to 90 – 120 in-lbs (10.2 – 13.6 Nm). 4. See Figure 4. Loosen the jam nut on all of the pushrods and adjust the pushrods to their shortest length. NOTE See Figures 4 and 5. Install the narrow-band pushrods in the cylinder-intake location. Install the wide-band pushrods in the cylinder-exhaust location. 5. Assemble the O-rings (purchased separately) and pushrod covers. 6. Install the pushrods with the pushrod covers. The adjustment-end of the pushrod must be on the lifter

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HARLEY DAVIDSON SISSY BAR LUGGAGE INSTALLATION MANUAL

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

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INSTALLATION Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00095a) Harley-Davidson cannot test and make specific recommendations regarding every accessory or combination of accessories sold, the rider must assume responsibility for safe operation of the motorcycle when installing accessories or carrying additional weight. Use the following guidelines when equipping a motorcycle or carrying passengers and cargo. •The Gross Vehicle Weight Rating (GVWR) is shown on the information plate located on the frame steering head. GVWR is the sum of the weight of the motorcycle and accessories and the maximum weight of the rider and cargo that may be carried safely. Do not pull a trailer with this motorcycle. Do not exceed the GVWR as indicated on the frame label. •Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle’s center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. •Do not exceed the maximum load (indicated on the label inside) in the bag. Do not exceed the capacity of the luggage rack. •Be sure cargo is secure and will not shift while riding. Periodically recheck the load. •Ensure that the bag strap buckles are secure •Large surfaces, such as fairings, windshields, backrests and luggage racks, can affect handling. These items should be designed and approved by Harley-Davidson specifically for the motorcycle model and be properly installed. 1. Disconnect the quick-disconnect buckle on the bottom mounting strap, and undo the D-ring fasteners on the back straps. Add enough slack to the straps to wrap around the luggage rack and backrest pad. 2. See Figure 1. Center the bag on the luggage rack with the closure buckles facing the back of the motorcycle. Bring the mounting strap on the bottom of the bag around the underside of the luggage rack

HARLEY-DAVIDSON BACKPACK INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00095a) Harley-Davidson cannot test and make specific recommendations regarding every accessory or combination of accessories sold, the rider must assume responsibility for safe operation of the motorcycle when installing accessories or carrying additional weight. Use the following guidelines when equipping a motorcycle or carrying passengers and cargo. •The gross Vehicle Weight Rating (GVWR) is shown on the information plate located on the frame steering head. GVWR is the sum of the weight of the motorcycle and accessories and the maximum weight of the rider and cargo that may be carried safely. Do not pull a trailer with this motorcycle. Do not exceed the GVWR as indicated on the frame label. •Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in the motorcycle’s center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. Do not exceed 25 pounds (11 kilograms) maximum load in the backpack. •If attaching to a luggage rack, do not exceed the capacity of the rack. •Be sure cargo is secure and will not shift while riding. Periodically recheck load. •Ensure that the bag strap buckles are secure. •Secure backpack straps inside top pocket, keep away from rear wheel. •See Accessories and Cargo section of Owner’s Manual for more information. •Large surfaces, such as fairings, windshields, backrests and luggage racks, can affect handling. These items should be designed and approved by Harley-Davidson specifically for the motorcycle model and be properly installed.

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