Harley Davidson DRESSERS TUNED-FLOW SLIP-ON MUFFLERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-03-2012

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Installing the Tips: 1. Use a long 3/16″ ball drive Allen wrench to remove the two hidden retaining screws. 2. Rotate the tip to the desired position and relocate the retaining screws and lock washers inside the tip. 3. Apply a small amount of anti-seize compound to the threads and tighten to 8 ft./lbs. 4. Check the tip bolts after a brief test ride. Adjusting the Hooker Tuned-Flow┬« Muffler: 1. Loosen the socket head bolts located in the aluminum ring at the end of the muffler approximately 5 turns using a 3/16″ Allen wrench. Alternate back and forth between each bolt 1/2 turn at a time to keep from binding. 2. Using your fingers, pull the center barrel of the muffler approximately 1/8″ towards the back of the motorcycle and rotate to the desired setting. If warm, use a rag or gloves. 3. By rotating the exhaust barrel and aligning the notch in the barrel with the index marks in the aluminum ring, the power band can be adjusted. The “H” setting will bias the power towards High RPM Horsepower, while the “T” setting will provide more Low RPM Torque. The muffler is infinitely adjustable between these two settings

Harley-Davidson MSD Pulse Ignition Installation Manual

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Filed Under (Harley Davidson) by admin on 11-03-2012

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PICKUP PLATE INSTALLATION Remove the existing trigger/points plate and rotor, points cam and advance. Refer to the bike’s Service Manual for the proper procedure. EVOLUTION AND LATE MODEL SHOVELHEAD V-TWINS 1. From inside the cam/ignition housing, feed the free end of the MSD pickup harness through the wire access port. Note: The harness includes a heat-resistant acrylic sleeve that fits snugly inside the port opening. Do not pull the sleeve completely through the port. It must be positioned to protect the wires as they pass through the port opening. 2. Mount the MSD pickup plate inside the housing (Figure 1). Note the “adjusting notch” on the edge of the plate. This notch must be located over the series of “steps” inside the housing (about the 7 o’clock position as you face the housing). One of the sensor units will be at approximately 12 o’clock. SPORTSTER MODELS 1. On Sportsters, the wire access port must be enlarged. Use a 9/32″ drill bit to enlarge the wire port. 2. Remove the wire harness clamp of the pickup assembly and route the wires through the port. 3. Mount the MSD pickup plate inside the housing (Figure 2). Note the “adjusting notch on the edge of the plate. This notch must be located over the “cast notch” inside the housing (about the 11 o’clock position as you face the housing). The shorter of the two sensors will be approximately in the 9 o’clock position. 4. Install the hold-down/standoff screws with flat washers until they are snug – do not tighten at this time (Figure 3). 3. Put the MSD rotor in place on the end of the camshaft. The locating pin in the rotor bore must align with the groove in the cam. Do not force the rotor on the camshaft! Push the rotor into place until it is tightly against the end of the cam then snug the retaining screw. 4. Check the distance from the outer surface of the pickup plate to the end of the installed rotor (Figure 4). If necessary, add shims until the measured rotor height is 9/16″ (+/- 1/32″). 5. When the rotor height has been verified, remove the retaining screw, place a drop of Red Loctite on the threads and reinstall the screw to the factory recommended torque

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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HARLEY DAVIDSON DYNA DETACHABLE UPRIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-04-2011

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INSTALLATION Install Docking Point Kit Install the docking point kit following the instructions in that kit. Passenger Upright Installation 1. See Figure 1. Stand behind the motorcycle, and place (10) the front upright notches (2) into the front docking points (3). 2. See Figure 2. Check for correct notch engagement. NOTE Failure to correctly engage the sideplate notches to the docking points may result in damage to the docking points. 3. See Figure 1. Pull (11) the rotary latches (4) into a rearward position. Align the latches over the rear docking points (7), making sure the latches and rear notches (6) fit into the neck (8) of the rear docking points. NOTE This may require some gentle squeezing or spreading of the upright sideplates. 4. Push downward (12) on the side plates and close the rotary latches by rotating the latch levers as far forward as they will go (13). A click will be heard when the latch is in place. If the latch does not close, do not force it.

HARLEY DAVIDSON HEEL/TOE SHIFT LEVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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INSTALLATION NOTE The shift levers in these kits have opposite counterbored screw holes. When the toe and heel levers are positioned correctly, the socket head cap screws will be installed from the bottom of both levers. 1. Before removing the original shift levers, note the orientation. You may want to replace them at the same position and angle. NOTE The original equipment shift levers may have the socket head screws that secure the shift levers to the splined shifter shaft installed from the top or bottom, depending on your model motorcycle. 2. See Figure 1. Remove the original equipment shifter pegs (A) and retain for re-attachment to the new levers if desired. Remove the socket head screws (3) that clamp the shift levers onto the splined shifter shaft. Remove the original equipment shift levers. 3. First, position the toe shifter lever (1) so the counterbored screw hole is at the bottom. Slide the toe shifter lever onto the splined shifter shaft and position to the desired angle, aligning the screw hole with the notch on the shaft. 4. Install the heel shift lever (2) with the counterbore at the bottom. 5. Add a few drops of Loctite® 243 (blue) to the socket head screws (3), and insert the screws into the counterbored holes. Tighten to 24-26 ft-lbs (32-35 Nm) . 6. Install the shifter pegs onto the new shift levers. If using the original pegs, place a few drops of Loctite blue onto the screw threads prior to installation. Tighten the shifter peg screws. 7. Check for proper operation and clearance

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HARLEY DAVIDSON BULLET FRONT TURN SIGNAL LENS KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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INSTALLATION 1. See Figure 1. Locate the removal notch (B) on the turn signal lens and carefully pry lens from housing (A). Discard lens. 2. Repeat for other lens. 3. Install new bulb (1) into the front turn signal assembly. 4. Install new lens (2 or 3) from kit by snapping into place. 5. Repeat for other turn signal. 6. Check turn signals for proper operation. SERVICE PARTS A 1 3 B 2 is05689 Figure 1. Service Parts: Bullet Front Turn Signal Lens Table 1. Service Parts Part Number Description (Quantity) Item Kit 69226-09 – Clear 69324-02 Lens, clear (2) 1 69331-02 Bulb, amber (2) 3 Kit 69208-09 – Smoked 69325-02 Lens, smoked (2) 2 69331-02 Bulb, amber (2) 3 Items referenced, but not included in kit Bullet-style turn signal housing A Notch B

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

HARLEY DAVIDSON XL SOLO CUSTOM SEAT KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. 1 2 4 1 3 is03341 1. Stock retention nut and washer 2. Plastic cap 3. Rearward fender hole 4. Center fender hole Figure 1. Retention Nut and Plastic Cap Location 2. For models that had a solo seat: Proceed to Step 3. For models that had a 2-up seat: The retention nut and washer must be moved from the rearward mounting hole to the center fender hole where the rear seat bracket will be attached. Use a cable strap to aid in this step as fol- lows: a. See Figure 1. Remove retention nut from rearward fender hole (3) and plastic cap (2) from center fender hole (4). b. Install plastic cap into the rearward fender hole. c. See Figure 2. Place the retention nut over the cable strap 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 center fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib of the retention nut seated into the notch in the fender hole, slide the retention washer into place from the rear. This will lock the retention nut in place. 3. Position the solo seat on the motorcycle frame with the mounting bracket at the rear. Bring the seat forward and engage the tab on the seat into the slot at the base of the fuel tank. 4. See Figure 3. Secure the seat to the fender using the knurled knob (3) and neoprene washer (4) from the kit. Install the washer on the knob and tighten the knob securely to the fender seat nut

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 FXD SOLO SADDLE REMOVAL AND INSTALLATION MANUAL

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

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Removal of Stock Seat 1. Remove screw (6) to detach rear seat mounting bracket (9) from fender. 1996 models will have a nylon washer under the bracket that should also be saved for installation of new seat. 2. Slide seat rearward to unhook front of seat from frame, then pull seat forward out of passenger strap. 3. Remove two capscrews (10) that attach seat mounting bracket to bottom of stock seat. Install original seat mounting bracket to bottom of new solo saddle with original capscrews. Tighten capscrews securely. 4. Remove nut (7) and washer (8) that hold passenger strap (11) in place and remove strap. Installation of Kit Seat This seat is for solo driver use only. Do not attempt to carry a passenger with this solo seat installed. Use of a luggage rack, fender, or tail section as an additional seat may result in death or serious injury. NOTE When a solo seat is installed without a passenger seat, the passenger footpegs or footboards and the passenger grabstrap must be removed. For 1996 models: 1. Slide seat into position until front seat tab engages frame, then place original nylon washer under hole in rear seat mounting bracket and secure bracket to fender with screw (6). NOTE For 1997 models, a retention nut and washer must be installed into the fender hole, covered with a plastic cap, where the rear seat bracket will be attached. A cable strap is included to aid in this installation. For 1997 models: 1. Remove plastic cap from hole in fender where the rear seat bracket will be attached. 2. Place retention nut (3) over cable strap (2) so wide end of nut rests on eye of cable strap. Thread cable strap up under fender and through fender hole. Pull up on cable strap to hold nut snug against underside of fender. 3. With rib on retention nut seated into notch in fender hole, slide retention washer (4) into place from the rear. This will lock the retention nut in place. 4. Slide seat into position until front seat tab engages frame, then secure rear seat bracket to fender with screw (6). Install chrome cap (5) in rear retention nut