HARLEY DAVIDSON VRSC TURN SIGNAL RELOCATION KIT INSTALLATION MANUAL

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

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INSTALLATION Removing Turn Signals 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. Remove the 40 amp Maxi-Fuse or disconnect the battery cables, negative cable first. Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Grab the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210a) 2. For VRSCA models, remove headlamp assembly. For VRSCB models, continue to Step 4. a. While facing the headlamp from behind (looking toward front of motorcycle), reach behind the headlamp bucket and twist the headlamp bulb approximately 45 degrees counterclockwise, then gently pull straight out of the headlamp. Repeat for remaining bulb. Temporarily secure bulbs out of the way for the following steps. b. See Figure 1. Remove the two mounting screws securing the headlamp bracket to the upper triple clamp and remove headlamp assembly. Save hard- ware

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the owner’s manual and follow the instructions given to disarm the security system and remove the left- side cover. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Refer to the owner’s manual and follow the instructions given to remove the main fuse. ALL models: 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) 3. Refer to the owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 4. Remove the battery from the vehicle. 2 1 3 4 is 01377 1. Three-pin connector on siren harness 2. Three-pin connector [142B] on vehicle harness 3. Siren harness 4. Frame rear crossmember (not visible) Figure 1. Connect the Siren Harness to the Vehicle Harness 5. See Figure 1. Locate the siren connector (2) on the main harness, behind the harness shield forward of the battery location. It is covered by a dust cap. Pull the dust cap from the connector, and feed the connector downward and out from behind the shield. 6. Select the correct siren harness (3) for this model year vehicle from the kit. Route the three-pin connector (1) of the siren harness from the bottom of the motorcycle, between the primary cover and frame tube. Plug the connector into the siren harness connector (2) on the vehicle main harness. 7. Secure the connectors to the diagnostic harness using a cable strap from the kit. Route the long lead of the siren harness over the frame rear crossmember

HARLEY DAVIDSON LIGHTED MIRRORS REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL Prepare for Service Touring Models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG and MAXI-FUSE in Service Manual. Softail and Dyna Models: 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. Remove seat according to the instructions in the Service Manual. 2. Disconnect battery cables, negative (-) cable first. 3. Remove fuel tank according to the instructions in the Service Manual. Sportster Models: Remove left side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. V-Rod Models: Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. Remove Existing Mirrors Touring and Softail (Except FXSTD, FLSTF) Models Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. Right side: See Figure 2. Remove acorn nut (1), star washer (2), and existing mirror (3) from front brake hand control assembly. Discard star washer and mirror but save acorn nut. 2 1 3 is03431 1. Acorn nut 2. Star washer 3. Mirror, left Figure 1. Remove L.H. Mirror (Except Sportster) 2 1 3 is03432 1. Acorn nut 2. Star washer 3. Mirror, right Figure 2. Remove R.H. Mirror (Touring, Softail – Except FXSTD, FLSTF) Dyna, FXSTD, FLSTF, and VRSC Models 1. Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. 2. Right side: See Figure 3. Loosen ball stud clamp (1) to remove directional lamp assembly (2). Remove retainer (3), star washer (4), and existing mirror (5) from front brake hand control assembly. Discard star washer and mirror but save remaining parts. 2 5 3 1 4 is03428 1. Ball stud clamp 2. Directional lamp assembly 3. Retainer 4. Star washer 5. Mirror, right Figure 3. Remove R.H. Mirror (Dyna, FXSTD, FLSTF, VRSC) Sportster Models Left side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (3) from clutch hand control assembly. Discard washer and mirror but save locknut. Right side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (4) from front brake hand control assembly. Discard washer and mirror but save locknut. 3 2 1 2 1 4 is03414 1. Locknut (2) 2. Washer (2) 3. Mirror, left 4. Mirror, right Figure 4. Remove Mirrors (Sportster) INSTALLATION Install Lighted Mirrors Touring and Softail (Except FXSTD, FLSTF, FXSTS, FLSTS) Models 1. Left side: See Figure 5. Install mirror stem (1) through clutch hand control assembly.

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HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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

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1995 Models 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) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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HARLEY DAVIDSON CHROME FAN KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to 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 battery negative cable. Horn Relocation NOTE This cooling fan is designed to provide supplemental cooling for motorcycles subjected to long periods of idling/parade duty. The fan is mounted on the left side of the engine in the area where the horn is mounted. The stock horn must be removed. Remove Stock Horn 1. Follow Service Manual instructions to remove stock horn and its bracket. 2. Assemble new horn 69043-96B to bracket 69135-04 using screws 3658 and washers 7069. 3. Remove right front fuel tank TORX® screw. 4. Mount horn at front of fuel tank with TORX screw. Verify there is adequate room between horn bracket and fuel tank to prevent paint damage. Tighten screw to 15-20 ft- lbs (20-27 Nm) . 1 is05140a 1. Horn mounting location Figure 1. Horn Relocation Remove Stock Upper Engine Mounting Bracket 1. Remove screw securing rear of fuel tank and gently raise fuel tank to gain access to upper engine mounting bracket. Place suitable blocking under tank. 2. On 2007 models remove bolt attaching stabilizer link to upper engine mounting bracket. 3. Remove two bolts and washers securing upper engine mounting bracket to front and rear cylinder heads. Retain bolts and washers for attaching new upper engine mounting bracket from kit. 4. Note position of fuel hose. Remove upper engine mounting bracket. 5. Connect horn relocation harness to horn. 6. Route stock horn wires forward towards relocated horn. 7. See Figure 7. Cut ends off stock horn wires and strip wires 3/8 inch. Follow instructions in Service Manual, “SEALED

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HARLEY DAVIDSON AUXILIARY LAMP WITH CLEAR LENS AND VERTICAL REFLECTOR OPTICS INSTALLATION MANUAL

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

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1. Disconnect the battery cables, negative cable first. 2. See Figure 1. Remove passing lamp molding screw (1) and nut (2) from passing lamp molding (3). Remove molding and hardware. Retain for future use. 3. Disconnect the wire harness plug from back of auxiliary lamp assembly (4). 4 See Figure 2. Remove assembly (1) and nesting ring (2). Discard lamp but retain nesting ring. 5. Place the nesting ring at back of new lamp with concave side facing away from lamp. Install new harness provided in kit. Attach leads to the wires inside the lamp hous- ing. 6. Connect new wire harness to the new lamp. Locate lamp in housing and be sure to align tabs on lamp (3) with pockets in the nesting ring. 7. Install passing lamp molding over lamp. Rotate lamp molding so that screw is centered at bottom. Install nut and screw and secure until snug. 8. Repeat for the lamp on the opposite side. Connect positive (+) 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. (00068a) 9. Connect the battery cables, positive cable first. 10. Test the auxiliary lamps for proper operation. If necessary, aim the lamps (see AUXILIARYLAMPS, ADJUSTMENT in the Service Manual), and tighten the lamp mounting nuts

HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings 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, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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HARLEY DAVIDSON FLSTF TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL 1. Remove seat according to the instructions in the Service Manual. 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. See Figure 1. Disconnect battery cables, negative (-) cable first. 2 1 is03242 1. Negative (-) cable 2. Tail lamp connector Figure 1. Negative Battery Cable and Tail Lamp Connector 3. See Figure 2. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 2. Remove Tail Lamp Lens 4. See Figure 3. Using a Terminal Pick Tool (1), depress locking tabs and disconnect turn signal connectors (2- place) (2, 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. 6. See Figure 4. Remove turn signal wiring (1, 2) from clips (3) under rear of fender INSTALLATION NOTE Proper installation of kit requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Route Turn Signal Wiring Through Rear Fender and Support 1. See Figure 5. Remove three rear screws (1) from fender support (2). 2. Loosen, but do not remove two front screws (3) from fender support. 1 3 2 is03285 1. Screw, rear (3) 2. Fender support 3. Screw, front (2) Figure 5. Fender Support Screws and Fender Support 3. Pull fender support away from rear fender to gain access to turn signal mount. 4. Remove stock screw and washer from turn signal mount. 5. See Figure 7. Pull turn signal (B) and turn signal mount (A) away from fender support. 6. Remove turn signal and wires from vehicle by routing turn signal wiring and connector through holes in rear fender and fender support. Gently guide wires through holes to ensure they do not get damaged. Feed Wiring and Install Relocation Bracket 1. See Figure 6. Feed turn signal wiring and connector through middle hole in turn signal relocation bracket and under rear of fender support. 1 is04635 1. Wire harness Figure 6. Wire Harness Routing 2. See Figure 7. Insert stock screw and washer through rear hole of relocation bracket (1) and turn signal mount (A). 3. Thread screw into turn signal (B). Tighten to 12-16 ft-lbs (16.3-21.7 Nm). 4. Align relocation bracket (1) with rear of fender support and install with screw (2) and nut (3) from kit. Tighten nut to 12-16 ft-lbs (16.3-21.7 Nm). Complete Turn Signal Relocation Wiring 1. See Figure 5. Install one rear screw (1) to hold fender support in place while routing wiring. Install screw snugly but do not fully tighten

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HARLEY DAVIDSON DYNA SECURITY SYSTEM SMART SIREN II KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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This kit fits 1996 through 2003 Dyna INSTALLATION 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 Owner’s Manual and follow the instructions given to disarm the security system, remove the seat, and disconnect the battery cables (negative cable first). Retain all seat mounting hardware. 2 1 is 01366 1. Siren connector 2. Dust cap Figure 1. Siren Connector 2. See Figure 1. Locate the siren connector (1). It is covered by a black dust cap (2) and is at the end of an unconnected 10 inch (254 mm) long harness leg starting near the rear fender, close to the rear lighting connector. Free the siren connector from its constraints. 3. Remove the dust cap from the connector. 4. See Figure 2. Snap the siren (2) into the siren bracket (3) so that the sounder disc (4) fits the notch in the bracket as shown. Connect the siren connector (1) to the siren.

HARLEY DAVIDSON SUPPLEMENT ARY 12 VOLT POWER SOURCE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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Installation NOTE This power source can be mounted on either side cover of the motorcycle, except on models with cruise control, which must have the power source mounted on the right side cover. 1. Remove seat and the side cover chosen for installation (see note above). 1 WARNING To avoid accidental start-up of motorcycle, and possible personal injury, disconnect the battery cables (negative cable first) before performing any of the following procedures. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 2. Disconnect battery, negative cable first. 3. See Figure 1. A 7/8 inch diameter hole needs to be drilled in the top of the side cover to mount the power source. It is important that the hole is properly located as follows, before cutting : a. Cut out template on page 3. Line the template up on the outside top of the cover using the top and rear cover edges as guides as shown in the illustration. Tape the template in place. b. After the template is in place, locate the appropriate hole on the template that matches the applicable year and side cover. Check to be sure that the entire hole area is on the flat top surface of the cover. No part of the hole should extend onto the sharply curved edge of the cover. 4. Carefully drill a 7/8 inch diameter hole at the location marked on the template. Drill from the outside of the cover to the inside. 5. See Figure 2. Unscrew outer sleeve of socket assembly (1) from socket body. Place the socket body into the cover hole and secure the socket in place by screwing