HARLEY DAVIDSON FLSTC SOFTAIL SADDLEBAG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Additional Fitment Information Detachables NOTE If motorcycle has not been altered from fixed saddlebag hardware to accessory mounting detachable docking points. the separate purchase of Turn Signal Mounting Bar (Part Number 68611-98) is required for sufficient lock clearance. This kit is available at your Harley-Davidson Dealer. Installing these saddlebags on models equipped with a detachable sissy bar or detachable luggage rack requires the additional purchase of mounting hardware kit as follows: Hardware Kit Fitment 53075-03 2003 and later FLSTC models with detachables 53009-03 1987 through 2002 FLSTC models with detachables See Service Parts Page for kit contents. Additional weight can affect motorcycle stability, handling characteristics, and safe operating speed. Do not exceed 7 lbs. (3.18Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury. Wide Tire If a wide tire kit has been installed, utilize the hardware and installation instructions found in that kit to reorient the fasteners to come from the inside to the outside of the finder. Button head screws from wide tire kit must be installed from the inside out, with the button heads on the inside of the fender. Failure to do so could result in bolt contacting tire, which could result in death or serious injury. Installation NOTE A Service Manual for your vehicle is available at your Harley-Davidson Dealer. 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect the negative (-) battery cable first. If positive (+) cable should contact ground with the negative (-) cable connected, the resulting sparks may cause a battery explosion which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Following instructions in applicable Service Manual, remove original saddlebags from supports. Install Turn Signal Mounting Bar If motorcycle is not equipped with accessory mounting detachable docking points, install Turn Signal Mounting Bar (Part No. 68611-98) following instructions provided with the kit. See Figure 1

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HARLEY DAVIDSON NARROW BEACH HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Loosen the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a

HARLEY DAVIDSON SOFTAIL 6 SPEED TRANSMISSION – COMPLETE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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Removal of Original Transmission 1. Position motorcycle on a suitable lift. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 2. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 3. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps. 4. Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 5. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly. 6. Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. 7. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation. 8. Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch. 9. Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. 10. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. 11. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. 12. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. 13. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation

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HARLEY DAVIDSON AUXILIARY BRAKE/RUN/TURN SIGNAL CONVERTER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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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) 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 cables, negative side first. 2. Remove the seat according to the procedures in the applicable Service Manual. NOTE Federal regulations require that red turn signal lenses need to be a minimum of 4 inches from the tail or stop lamp, edge to edge. In order to ensure this spacing requirement, new directional stand-offs are provided in kit and must be used to replace the original (stock) directional stand-offs. To install the new directional stand-offs, perform the following. 3. See Figure 1. Insert a small screwdriver into middle hole (1) of license plate light cover assembly (2). Push forward to release tail lamp spring clip. -J03679 1 of 4 2 1 is01493 1. Middle hole 2. License plate lamp assembly Figure 1. Removing Tail/Stop Lamp Assembly 4. See Figure 2. Lift tail lamp assembly upward and disconnect tail lamp connector (1). Disconnect left (2) and right (3) turn signal 2-place connectors. 5. See Figure 3. Remove two left side fender support front socket head screws (1). Save hardware for installation. 6. Remove left fender support capscrew (2) (under fender) near end of support and washer (3). Remove capscrew (4) at approximate midpoint of fender support and washer (5). Save hardware for installation. 7. Remove directional lamp screw (6) and washer (7). NOTE Prior to removing turn signal wires, carefully note routing. In particular, pay close attention to the locations of cable straps which must be replaced. 8. Carefully remove fender support (8), turn signal lamp (9) and directional lamp support (10) along with wiring through elongated hole in fender (11). Discard directional lamp support and cap screw. Save turn signal lamp for installa- tion. 9. Perform Steps 5 through 8 for the right fender support and signal lamp assembly. NOTE At this point, the two turn signal pin terminals must be removed from the two-place connector in order to remove the turn signal and directional stand-off from the fender support. The pin terminals will be re-installed to the connector after routing wiring through new directional stand-off and installing stand-off and turn signal to fender support. Follow the instructions under AMP MULTILOCK CONNECTORS in the applicable Service Manual to remove the pin terminals from the two-place con- nector. 10. See Figure 3. Obtain new directional stand-off and cap- screw from kit. Route wiring from turn signal lamp (9) through new directional lamp support (10) and elongated fender support hole (11). Install capscrew (6) through fender support, new directional lamp support then into turn signal. Tighten capscrew securely. 1 3 2 is 01494 1.4-place tail/stop lamp connector 2. Left turn signal 2-place multi-lock connector 3. Right turn signal 2-place multi-lock connector Figure 2. Disconnect Tail Lamp and turn Signal Connectors 11. Perform step 10 for the right side

HARLEY DAVIDSON BRAIDED OIL HOSES INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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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. Disconnect battery negative cable. 2. Drain engine oil according to Service Manual instructions. 3. Removing the rear exhaust pipe may aid in giving access to the oil lines and fittings. If necessary, remove the rear exhaust pipe according to Service Manual instructions. 4. See Figure 5 and Figure 1 for description and location of the three oil hoses that are replaced with the braided hoses in this kit. Remove the original equipment oil feed, return and vent lines. 5. See Figure 2. Remove and discard the original hex threaded quick disconnect fittings (1), (2) and (3) at the engine for each of the hoses removed in Step 4. To remove the fittings, turn the hex in a counterclockwise direction until free. 6. See Figure 5. Install the threaded adapter from the kit onto the corresponding oil line. The adapters for the return and vent lines are the same size. The adapter for the feed line is larger in size. Coat the male threads of the adapters with Loctite 565 thread sealant. NOTE Be sure to install hoses on the correct fittings. If you mix up the hoses, you will change the direction of the engine oil flow, causing severe engine damage. 2 3 1 is04165 1. Oil Return Hose 2. Oil Feed Hose 3. Oil Vent Hose Figure 1. Installed Oil Hoses

HARLEY DAVIDSON HIGH OUTPUT ALTERNATOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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this kit is designed for use on 1980 and later FLT and FLTC models, 1982 and later FXR, FXRS, and FXRT models and 1984 and later FXRD, FLHT, FLHTC, FXRDG, FXRS-SP, FXLR, FLHS and FXRC model vehicles. This kit contains the following parts: QTY DESCRIPTION 4 Screw, sockethead torx 1 Ring terminal 6 Cable strap 1 Rotor assembly 1 Spacer, thick 1 Spacer, thin 1 Stator assembly 1 Regulator Installation 1. Refer to applicable Service Manual for detailed removal and installation procedures. 1 CAUTION Disconnect battery (negative cable first) before performing any electrical system servicing. 2. Observe the following guidelines to ensure proper operation. A. Do not drop or pound on the new rotor assembly. Permanent damage can result. B. Do not install a new style rotor with an old style rectifier. Permanent rectifier damage can result. C. Do not install a new style rectifier with an old style rotor. Permanent rectifier damage can result. D. Route the black rectifier wire away from hot or moving parts. Secure it to the frame with cable straps. Trim excess wire length, crimp on ring terminal and attach to positive battery terminal. 3. See Figure 1. When installing rotor and stator use thin spacer inside and thick spacer outside of rotor

HARLEY DAVIDSON HIGH INTENSITY DISCHARGE (HID) DUAL BULB HEADLAMP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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REMOVAL 1. Remove seat according to the instructions in the service manual. 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) 2. 2003-Earlier Models: Disconnect battery cables, negative (-) cable first. Refer to the service manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 3. 2004-Later Models: a. Remove left saddlebag. Refer to the service manual. b. Remove left side cover and main fuse. Refer to the service manual. 4. Remove fuel tank according to the instructions in the service manual. 5. See Figure 1. Remove the Phillips screw (1) at the bottom of the bezel and remove the bezel. Save parts for installa- tion. 1 2 is03916 1. Phillips screw 2. Bezel Figure 1. Remove Bezel 6. See Figure 2. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle. 7. Gently pull headlamp assembly out far enough to disconnect wiring. Save short wire harness for installation. 8. Remove wire connector at the back of the headlamp bulb. 9. See Figure 2. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

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ARLEY DAVIDSON FXDL INSTRUMENT CONSOLE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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Installation CONSOLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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. Remove seat and disconnect battery, negative cable first. 2. Remove fuel tank mounting bolts. Lift fuel tank far enough to remove the speedometer sensor cable from the mounting clips under the tank. 3. See Figure 1. The 3-place speedometer sensor connector is located on the frame beneath the seat. Remove from t-stud and disconnect the connector. Cut the cable strap that holds sensor wires to right rear frame tube. 4. Remove instrument console mounting screws and lift console from tank. SPEEDOMETER REMOVAL 1. See Figure 2. Disconnect 8-place connector under console. Remove assembly from tank. 2. Cut remaining cable straps holding wires to instrument mounting bracket. Remove screws holding bracket to back of instruments. Remove bracket. 3. See Figure 3. Remove nuts and washers from terminal studs (1, 2 and 3). Remove wires from studs. 4. Unscrew the rubber function switch cover that protrudes from the left side of the console. Remove the function switch (3). 5. Gently push on bottom of speedometer and remove speedometer from top side of console. Remove gasket from speedometer. TACHOMETER REMOVAL 1. See Figure 3. Remove nuts and washers from terminal studs (3, 4 and 5). Remove wires from studs. 1 WARNING 1 WARNING

HARLEY DAVIDSON SPORTSTER CHOPPED FENDER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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INSTALLATION Preparation 1. Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 2. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 3. Remove the battery from the vehicle per the instructions in the service manual. 4. Raise the rear of the vehicle to relieve the load on the shock absorbers. 5. Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle. Save the fasteners for later assembly. 6. Raise the rear of the vehicle further to allow access to the underside of the rear fender. 7. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. Rear Fender Removal NOTE Note the location and orientation of rear fender mounting hardware, and save for later assembly. 1. Refer to the service manual and follow the instructions given to remove the rear fender, with the following exceptions: a. Removal of the tail lamp from the fender is not necessary. Rear Lamp Wiring 1. Cut off and discard the socket housings and terminal ends from the turn signal wires. 2. See Figure 1. Unscrew and remove the turn signal stalk (15) from one of the turn signal lamps, and discard. Remove and retain the turn signal lamp and support (14) from the rear fender support cover. 3. Insert the blade of a small screwdriver into the slot at the bottom of the turn signal lamp lens (2), and twist to unsnap the lens from the housing (1)

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