HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. 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 references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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HARLEY DAVIDSON STAMPED MINI AND SHORT BACKREST KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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These Stamped Backrest kits are designed for installation on all vehicles with Mini and Short sissy bar uprights. Kit Number 52527-01 is only for models equipped with a Mini sissy bar upright. Kit Number 52531-01 is only for models equipped with a Short sissy bar upright. See Service Parts illustration for kit contents. Installation 1. Remove stock chrome backrest bracket. Discard hardware. 2 Install backing plate (2) with 1/4 inch x .50 long screws (4) supplied with kit through mounting bracket and into backrest. Tighten screws to 7 ft-lbs (9.5 Nm). 3. Position stamped cover (1) so tabs and cover are slightly below notches in backing plate. Slide stamped cover (1) into position by sliding upwards until cover locks in position. 4. Install two #8 screws (3) through bottom of stamped cover (1) and then into backing plate (2). Tighten screws to 18-24 in-lbs (2.0 to 2.7 Nm)

HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

HARLEY DAVIDSON V-ROD CHROME REAR TURN SIGNAL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION Prepare the Motorcycle 1. Remove the right cover and the maxi-fuse. 2. Follow Service Manual instructions to remove the air box cover. Remove the Existing Rear Turn Signals 1. For 2006 and Earlier Models: See Figure 1. Insert a screwdriver into middle of hole of license plate light cover. Push forward to release tail lamp housing retaining clip. 2. See Figure 3. Identify the white left [19] (1) and black right [18] (2) 2 pin rear turn signal connectors. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To remove the rear turn signal wires from the socket terminal housing, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. 6. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 7. Repeat for the opposite turn signal. 1. For 2007 and Later Models: See Figure 2. Open seat and remove the nut and washer (3), seat post (2), passenger pillion and passenger seat (1) per the instructions in the Service Manual. 2. See Figure 4. Identify the left (1) and right (2) rear turn signal wires and 6 pin rear turn signal connector [94]. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. See Figure 5. Remove the turn signal wires from the 6 pin socket terminal housing. To remove the wires, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. Repeat for all four turn signal wires. Do not remove the license light wires from the socket terminal housing. 6. Gently pull the loose turn signal wires through the sheath toward the rear of the vehicle until completely removed from the sheath. 7. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 8. Repeat for the opposite turn signal

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HARLEY DAVIDSON SHORT RAIL BACKREST PADS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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These Backrest Pad kits are designed for installation on 1984 and later models equipped with a sissy bar sideplate kit in combination with a Short Rail upright kit, Part No. 52737-94 or 52728-95. The 52513-94 Backrest Pad kit is only for models equipped with Badlander seats and one of the following Mini Rail upright, kits: 52738-94A, 52744-94 or 51512-02. The 52568-01 Backrest Pad Kit is designed for installation on 2001 FXDWG2 model motorcycles and should be used with mini rail upright part number 52744-94 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. The 52901-01 Backrest Pad Kit is designed for installation on 2002 FXDWG3 model motorcycles and should be used with mini rail upright part number 51512-02 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. Kit Contents See Figure 3 and Table 2. There are no Service Parts available with this kit. INSTALLATION NOTE Figures 1 and 2 show pad being mounted on short upright, Part No. 52737-94, before short upright is mounted on side- plates. The pad may be installed before or after short upright is mounted. 1. See Figure 1. Remove protective film from mounting bracket (1) and attach the mounting bracket with the 1/4- 28 x 3/8 in. screw (2) onto short upright, Part No. 52737- 94 or 52728-95; or onto Mini Rail upright, Part No. 52738- 94 or 52744-94. Check that mounting bracket is parallel with upright and tighten screw to 48-60 in-lbs (5.4-6.8 Nm). 2. See Figure 2. Position backrest pad (1) on the upright. Place mounting plate (2) in position and secure with two chrome screws (3) as shown. Tighten screws to 48-60 in- lbs (5.4-6.8 Nm)

HARLEY DAVIDSON LEFT SIDE TOOL BOX KIT INSTALLATION MANUAL

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

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INSTALLATION NOTE While handling and installing tool box, be careful not to scratch surface. 1. See Figure 1. Attach the toolbox (4) to the toolbox mounting bracket (1) using the three pan head screws (2) and Nylock nuts (3) from the kit. 2. Remove the two button head screws (I) which secure left rear fender support (B) to motorcycle frame (C). Retain screws for reassembly. 3. On models with passenger footpegs: a. For FLSTN models: Remove button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E). b. For all other models: Remove the locknut (G), hex head bolt (J), spring washer (H) and footpeg (E). Remove the socket head cap screw (K) that secures the footrest support (F) to the frame (C). c. Remove the two bolts, nuts and washers which secure the bottom of the splash guard to the swingarm. This will allow you to move splash guard when installing the new passenger footrest bolt. d. Retain all removed components. 4. On models with passenger footboards: a. Remove the screw securing the passenger footboard assembly to the frame. Remove the footboard assembly. b. Retain all removed components. 5. Slide the top of mounting bracket (1) between rear fender support (B) and frame (C). Align top holes in bracket with fender support holes. Align lower bracket hole with footrest mounting hole in frame. Install the two screws (I), removed in Step 2, in fender support. Do not tighten screws at this time. 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) 6. On models with passenger footpegs: a. For FLSTN models: Install button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E) on top of the toolbox bracket (1). Tighten screw to 35-45 ft-lbs (47.5-61.0 Nm). b. For all other models: Refer to instructions in footpeg extension kit, Part Number 49352-00 for installation, and install the extention kit, footrest support and footpeg on top of the toolbox bracket (1). c. Install the two bolts, nuts and washers and secure the bottom of the splash guard to the swingarm. 7. On models with passenger footboards: a. Position footboard assembly, in the same orientation as removed, on top of tool box bracket. b. Install screw removed in Step 4. Tighten to 35-45 ft- lbs (47.5-61.0 Nm)

HARLEY DAVIDSON FLSTN SADDLEBAG GUARD KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL All Models 1. If equipped with saddlebags, removal may ease installation. Follow the instructions in the appropriate Service Manual or Instruction Sheet. 2. See Figure 1. Remove and discard the forwardmost fender support bolt (1). Repeat for the other side. 3. See Figure 2. On the left side, remove the footrest support mounting bolt (1) and footrest support bracket assembly (2). Discard the mounting bolt. 2005 – 2006 Models 1. Loosen the exhaust shields as necessary following the instructions in the appropriate Service Manual. Move as necessary for access. 2. Loosen the exhaust header nuts following the instructions in the appropriate Service Manual. 3. See Figure 3. Remove bolt (1) connecting the exhaust system (2) to the support bracket (3). 4. See Figure 4. Remove the two rear muffler bracket bolts (1). 5. See Figure 5. Move mufflers enough to access the rear bolt attaching the exhaust mounting bracket to the frame. Remove bolt (1) and discard. 2007 – Later Models NOTE On 2007 – later models, the frame tab (4) has a plug instead of a bolt (see Figure 6, item 1). 1. Remove plug and discard. 1 is05313 1. Fender support bolt (discard) Figure 1. Remove Docking Hardware 1 2 is05320 1. Footrest support mounting bolt 2. Footrest support bracket assembly Figure 2. Footrest Support Bracket Assembl NSTALLATION Right Side See Figure 5 or Figure 6. 1. See Figure 7. Install upper screw (7) in the fender support. Tighten screw finger-tight. 2. Install the lower screw (4 or 5) with the saddlebag guard, washer (9) and locknut (6) inside the frame. Tighten screw finger-tight. 3. Tighten the upper screw to 30 ft-lbs (41 Nm) . 4. Tighten the lower screw to 40 ft-lbs (54 Nm) . Tighten nut to 30 ft-lbs (41 Nm) . 5. 2005 – 2006 Models: a. Loosely install the exhaust header bolts. b. See Figure 4. Loosely install two rear muffler bracket bolts (1). c. See Figure 3. Loosely install bolt securing exhaust system (2) to support bracket (3). d. Tighten exhaust header bolts following the instructions in the appropriate Service Manual. e. Tighten support bracket bolt and rear muffler bracket bolts following the instructions in the appropriate Service Manual. f. Tighten exhaust shields following the instructions in the appropriate Service Manual. 6. Install saddlebag (if removed) following the instructions in the appropriate Service Manual or Instruction Sheet. 1 2 3 4 is05333 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Exhaust support bracket Figure 5. Install Saddlebag Guard – Right Side Shown (2005 Models) -J04645 2 of 4
2 1 3 4 is05332 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Frame tab Figure 6. Install Saddlebag Guard – Right Side Shown (2007-Later Models) Left Side 1. Loosely install upper screw (7) through the saddlebag guard and the fender support. NOTE Spacer (8) must be installed with the chamfer facing out. 2. See Figure 7. For 2005-2006 Models: Install lower screw (3) through the saddlebag guard, saddlebag guard spacer (8), footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . For 2007 and later Models: Install lower screw (10) through the saddlebag guard, footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . 3. Tighten upper screw to 30 ft-lbs (41 Nm)

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HARLEY DAVIDSON SOFTAIL DELUXE SEATS INSTALLATION MANUAL

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

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These kits fit 2005 and later FLSTN model motorcycles. Additional Parts Required NOTE A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 3 and Table 1. INSTALLATION 1. Remove existing seat according to Owner’s Manual Instructions. Save all attaching hardware. 2. See Figure 1. Install two flange nuts (1) from kit onto the seat mounting studs. Tighten flange nuts to 5-8 ft-lbs (7- 11 Nm) . 1 is03023 1. Install flange nuts Figure 1. Flange Nut Locations NOTE See Figure 3 for Steps 3-6. 3. Remove two screws (A) and rear mounting bracket (B) from stock seat. Save all hardware. 4. Install the rear mounting bracket (B) removed in Step 3 onto the new seat using the seat bracket screws (A). Tighten screws to 19 in-lbs (2.1 Nm) . 5. Install new seat (1) on the motorcycle by inserting the tab at the front of the seat into the slot at the rear of the fuel tank. 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) 6. Fasten rear seat bracket (B) to fender nut using stock mounting screw (C). 7. See Figure 2. To install grabstrap, remove front screw and washer from rear fender support. Install grabstrap with thick washers (1), thin washers (3) and screws (4) from kit. Tighten to 21-27 ft-lbs (28-37 Nm)

HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. 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 references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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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

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