HARLEY DAVIDSON CHROME LIFTER BLOCK COVER INSTALLATION MANUAL

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

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INSTALLATION 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 A Service Manual for your motorcycle is available at any Harley- Davidson Dealer. NOTE Removal of the air cleaner assembly and, in cases where the bike has forward controls, shifter linkage will aid in installation of this kit. Remove the air cleaner and, if necessary, shifter linkage by following procedures in the appropriate Service Manual. 1. Remove the two rear most screws on the rear lifter cover. 2. See Figure 1. Install rear lifter cover bracket (1) assembly using screws (2) removed in step 1. Torque screws to 90- 120 in-lbs (10.0 – 13.5 Nm). 3. Remove the two screws most forward on the front lifter cover. 4. See Figure 2. Install front lifter cover bracket (1) assembly using screws (2) removed in step 3. Torque screws to 90- 120 in-lbs (10.0 – 13.5 Nm)

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)

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HARLEY DAVIDSON DYNA PASSENGER PILLION SEAT INSTALLATION MANUAL

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

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REMOVE SEAT NOTE When performing the following installation procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove screw to detach rear seat mounting bracket from fender. 2. Remove two capscrews that attach seat mounting bracket to bottom of stock seat. 3. Remove the existing seat from the motorcycle. Save the seat bracket and mounting screws for installation of the new seat. 4. If motorcycle has a grabstrap installed, remove nut and washer that holds passenger strap in place and remove strap. 5. See Figure 1. Remove the plastic cap from rearmost fender hole (3). 6. Remove the seat retention nut and washer from the solo seat mounting hole. 7. See Figure 2. A cable strap may be used as an installation aid to remove and reinstall the retention nut and washer. Place the retention nut (1) over the cable strap (3) so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the rearmost fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. 8. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear. This will lock the retention nut in place. Remove the cable strap. 2 5 1 2 1 3 6 7 4 is00363 1. Retention nut and washer (2-up seat positon) 2. Retention nut and washer (solo seat position) 3. Rear-most fender hole 4. Middle fender hole 5. Grabstrap mounting hole 6. Flange screw 7. Plastic retention nut

HONDA GL1800 BACKREST (INSERT) INSTALLATION MANUAL

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Filed Under (Honda) by admin on 04-03-2011

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1. Place motorcycle on center stand. 2. Remove the two passenger handles and seat. 3. Install the base mount between the seat mounts (picture 1) and mark the two holes on seat base. 4. Drill two 9/32″ holes in the seat base. 5. In the middle of the two seams and in the center of the seat, install the boot (picture 2). 6. With a long serrated knife cut a hole in the seat inside the boot opening. You must clear a path in the foam from the cut to the two 9/32″ holes. 7. Insert the long bar through the hole into the seat from the outside with the hole tube facing forward (picture 3). 8. Bolt the base mount to the long bar using bolts and lock washers. 9. Attach the chrome pad mount to the long bar protruding through seat (picture 4). 10. Attach the pad to the pad mount with the mounting bracket (picture 5). 11. Reinstall the seat and adjust the pad angle (picture 6). Reattach passenger handles

HARLEY DAVIDSON FRONT FENDER RAILS AND STANCHIONS INSTALLATION MANUAL

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

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INSTALLATION 1. Carefully cut out appropriate template from sheet included in kit. One side is for FLSTS style fenders (with elliptical hole for front fender lamp), and the other side is for FLT style fenders (with rectangular front fender lamp). 2. Lay template on front fender (align around front fender lamp). 3. Underneath four holes marked on template, place high quality masking tape on fender. 4. Using a tape measure, measure from the top of the striping on the sides of each side of the fender, to the centerline of the each of the holes on the template (on some FLT models, with chrome fender trim, measure from the chrome fender trim at the bottom edge of the fender). Make sure that the distances are equal so that the template is centered on the fender. 5. Tape the template to the fender using high quality masking tape. NOTE Before proceeding, stand directly in front of the fender and carefully check to make sure the template is centered on the fender. 6. Center punch the center point of each of the four holes. 7. Remove the template from the fender. 8. Block motorcycle under frame so the front wheel is raised off the ground. 9. Follow appropriate Service Manual procedures and remove the front axle. 10. Place a rag on the top of the front brake caliper, then lower the front wheel so that it is resting on top of the brake caliper. NOTE When drilling fender holes, use care not to hit tire with drill bit. 11. While holding the fender firmly, and using caution to make sure that your drill bit does not hit the tire, drill the four holes at the points marked by the center punch. Begin with a 1/8 inch drill bit, followed by a 9/32 inch, and finally a 3/8 inch drill bit. 12. Remove the masking tape and any burrs that may have formed. 13. Remove the adhesive backing from each of the foam pads on the bottom of each of the stanchions. 14. Place the studs from each of the end stanchions into the holes (you may need to rotate the rails 180 degrees if they appear to be bowed out). 15. Reaching from the front of the fender, place kit washer, and then a locknut, over each of the studs on the underside of the fender. 16. Securely tighten each locknut so that the stanchion is firmly clamped to the fender. 17. Follow appropriate Service Manual procedures and replace the front wheel and axle

HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

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

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INSTALLATION (2000 THROUGH 2002) Refer to the instructions included with kit 53388-03 for installation on 2000 through 2002 models. INSTALLATION (2003 AND LATER) NOTE To keep the fender aligned, completely install the sideplate on one side of the motorcycle before proceeding to the second side. The sissy bar should be installed last. 1. For models equipped with saddlebags: a. Remove the saddlebag, and retain the mounting hardware for later reinstallation. b. See Figure 1. Remove the bolt (A) and washer (4) that secures the rear fender to the fender brace. Discard the bolt and washer. Remove and retain the two saddlebag mounting studs (C) and nut plate (D) for later use. For models NOT equipped with saddlebags: a. See Figure 1. Remove the two rearmost bolts (A), washers (4) and nut plate that secure the rear fender to the fender brace. Discard the bolts and washers. b. Remove the bolt (B) and washer (4) that secure the fender and brace to the frame. Discard the bolt and washer. 2. See Figure 1. Position the correct sideplate to the outside of the fender brace. 3. With saddlebags: Apply LOCTITE 243 (blue) to the 3/8- 16 threads of the saddlebag mounting studs (C) and reinstall the studs through the sideplate, fender brace, frame and fender, and thread into the stock nut plates (D). Install one chrome 3/8-16 screw (3) and chrome washer (4) from the kit through the rear hole in the sideplate, fender brace and fender, and thread into the stock nut plate (D). Without saddlebags: Install three chrome 3/8-16 screws (3) and chrome washers (4) from the kit through the holes in the side plate, fender brace and fender, and thread into the stock nut plates (D). 4. Repeat steps 1-3 for the opposite side. 5. Install a sissy bar (not included in the kit) into the side- plates. Apply LOCTITE 262 (red) to the threads of the chrome 1/4-20 capscrews (5) and insert them into the sideplate holes. Tighten to 8-10 ft-lbs (11-14 Nm) . 6. Tighten the bolts (3) and/or saddlebag mounting studs to 21-27 ft-lbs (28.5-36.6 Nm) . 7. Reinstall the saddlebags

HARLEY DAVIDSON SLOTTED CUSTOM FOOTPEG INSTALLATION MANUAL

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

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INSTALLATION 1. See Figure 1. Remove locknuts (1) and screws (2) that hold existing footpegs in place. Save hardware for installation of new footpegs. 2. Remove existing footpegs along with spring washers (3). Save spring washers for installation of new footpegs. 3. Install new footpegs in the same manner as old footpegs were installed: •Place a spring washer (3), along with the mount end of the footpeg, inside the slots of the footpeg supports (4). •Make sure the spring washer is positioned inside the footpeg support with the square edge toward the inside of the support. •Secure each footpeg and spring washer with a screw (2) and locknut (1). •Tighten locknuts to 19 ft-lbs (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) 4. For each footpeg, remove the screw (5) and rubber pad (6). Loosen the adjusting screw (7) until the footpeg (8) rotates. Position the footpeg (8) as desired, then tighten the adjusting screw to 19 ft-lbs (26 Nm) . Place the rubber pad (6) on the footpeg and tighten the screw (5)

SUZUKI SV1000 ELECTRICAL SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COUPLER •With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. (C” -78-14) • * Bend the clamp properly so that the wire harness is clamped securely . • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . ELECTRICAL SYSTEM 7- 3 7-4 ELECTRICAL SYSTEM BATTERY •The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. • Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE HARNESS ROUTING” section. (CJ8-14)

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SUZUKI SV650 ELECTRICAL SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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CAUTIONS IN SERVICING CONNECTOR • * When connecting a connector, be sure to push it in until a click is felt. • * Inspect the connector for corrosion, contamination and breakage in its cover . COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. ( r- 79-14 to 9-16) • * Bend the clamp properly so that the wire harness is clamped securely. • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . i SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . BATTERY • The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. •Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire, first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE ROUTING” section. (C’9-14 to 9-16) ELECTRICAL SYSTEM 8- 3
8-4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER •Properly use the multi circuit tester Oand Oprobes. Improper use can cause damage to the motorcycle and tester. • * If the voltage and current values are not known, begin measuring in the highest range . • * When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged . • * After using the tester, be sure to turn the switch to the OFF position. CAUTION Before using the multi circuit tester, read its instruction manual.

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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

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