1996+ HARLEY DAVIDSON FLH INNER AND OUTTER FAIRING MOUNT FOR HONDA VTX 1300 installation

0

Filed Under (Tips and Review) by admin on 09-04-2012

download
This mount was made to attach the HD FLH assembled fairing to the 4 fork mounting points on the VTX 1300 using the Memphis Shades mounts. This allows use of the MS allen wrench to quickly remove the fairing if needed. You will have to make or buy a headlight extension. Has to be done first. I used a 5″ x 5″ x .5″ piece of aluminum stock and made one to bump the headlight out 4″. There will be some trimming and relocating of brackets. And you’ll have to buy longer bolts to mount everything correctly. Get the headlight squared away first, then do the fairing. Take a length of 1″ aluminum angle stock and cut two 17″ pieces from it. These will be the uprights for the “H” brace. Measure 5.5″ from the bottom of one piece and center punch for a hole. Drill a large enough hole to slip over the MS mounting hardware on the forks. Start at about ½” bit and notch out as necessary. Center of this hole has to be 5.5″ from the absolute bottom of the angle iron. In the same location, drill out another notch for the bottom mounting point. A drill press is handy for these modifications and you can hog out the mounting notches with a file, dremmel, etc., until they fit. Do the same for the other length of 1″ angle stock but make sure it is a mirror image of the first one. Test fit these by mounting them to the MS fork brackets using the MS bracket hardware. Bottom notch goes in first, then the top notch. I epoxied the back “nuts” of the mounting hardware to the fork mounting brackets. It keeps it in place when you’re taking the fairing on and off the bike. On the top mounting points, I epoxied a washer with one side ground flat to the bolt’s mounting ferule. This allowed better contact between the H brace and the fork mounting bracket. Didn’t want that fairing falling off. Adjust as necessary and after the test fit, remove.

Incoming search terms:

HARLEY DAVIDSON MOUNTING BRACKET SERVICE MANUAL

0

Filed Under (Harley Davidson) by admin on 12-04-2011

download
INSTALLATION 1. See Figure 1. Note position of mounting brackets (1). Remove old mounting brackets and discard. NOTE On 1997-2000 models, the air fittings are installed to the two mounting holes on the right-hand right side bracket. On 2003 and later models, the single air fitting is installed to mounting hole on the left-hand side bracket. 2. See Figure 2. Install new mounting brackets from kit on each side of the motorcycle using new locknuts as follows: a. Use the 5/16-18 x 1 inch screws (5) in the upper two holes with 2 chrome washers (3) placed between the mounting bracket and the saddlebag support at each of the two locations. Install a 5/16-18 flange locknut (2) behind the screw that does not screw into a weld nut. Tighten to 15-19 ft-lbs (20-26 Nm). b. On each side, install a 1/4-20 x 7/8 inch screw (9) through the bottom hole of the mounting bracket and the saddlebag bracket as shown, with a chrome washer (3) placed between the mounting bracket and the saddlebag bracket. Tighten to 10-14 ft-lbs (13.5- 19.0 Nm). On 1997-2002 models, install the air line fittings to the lowest two holes drilled in the right side bracket. On 2003 and later models, install the single air line fitting to the lower front hole drilled on the left side bracket. c. See Figure 2. On each side, attach docking points (6) in their proper location on mounting bracket with 3/8- 16 x 1-1/2 in. buttonhead screws (7), washers (3) and locknuts (8) but leave locknuts slightly loose so docking points can be adjusted for proper fit. On 1997and later models, the docking point will attach through the front hole of the mounting bracket as shown. On 1994-1996 models, the docking point will attach through the rear hole of the mounting bracket. d. Place detachable passenger backrest into docking points as described in the Backrest Instruction Sheet. Make sure that the forward notches of the sideplates are pushed completely into the forward docking points, then tighten the rear docking points securely to 45-47 ft/lbs (61.0-64.0 Nm

Incoming search terms:

HARLEY DAVIDSON DYNA DETACHABLE UPRIGHT KIT INSTALLATION MANUAL

0

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

download
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 XL DETACHABLE UPRIGHT KIT INSTALLATION MANUAL

0

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

download
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 rear docking points. 3. See Figure 1. Push (11) the rotary latches (4) into their most forward 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 sideplates, and close the rotary latches by pulling (13) the latch levers as far back as they will go. A click will be heard when the latch is in place. If the latch does not close, do not force it. 2 12 3 7 4 1 5 9 10 5 7 8 6 4 13 11 is06182a 1. Upright 2. Front notch 3. Front docking point 4. Rotary latch 5. Release button 6. Rear notch 7. Rear docking point 8. Rear docking point neck 9. Fender support bracket 10. Place front notches into front docking points 11. Push latches forward 12. Lower rear notches onto rear docking points 13. Pull rearward to close latches Figure 1. Detachable Upright

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 20-03-2011

download
REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

Incoming search terms:

HARLEY DAVIDSON FLHR 2-UP RACK REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 20-03-2011

download
INST ALLATION/REMOVAL 1. See Figure 1. While standing behind the motorcycle, place the front rack notches (1) into the front docking points (2). (Most of the rack, except a typical sideplate, has been removed for illustration purposes). 4 4 1 3 2 5 3 6 7 is03799 1. Front rack notches 2. Front docking points 3. Rotary latches 4. Rear docking points 5. Sideplates 6. Neck 7. Release button Figure 1. Attaching 2-Up Rack NOTE Rear docking points may be damaged if rotary latches and sideplates are not properly aligned. If the latch does not easily close, do not force. Check alignment as described in Step 2. 2. Pull the rotary latches (3) back into their rearmost position. Position the rear rotary latches over the rear docking points (4), making certain the latches and sideplates (5) fit into the neck (6) of the rear docking points. This may require some gentle squeezing or spreading of the sideplates or docking point brackets. 3. Push downward and close the rotary latches by pressing the latch lever as far forward as it will go. You will hear a click when the latch is in place. If the latch does not easily close, do not force. Recheck alignment as described in Step 2. 4. To remove the rack, press the release button (7), and pull the rotary latch lever back. Carefully lift the rear of the rack up and pull the rack out of the front docking points

HARLEY DAVIDSON SOFTAIL DETACHABLE SIDEPLATE KIT INSTALLATION MANUAL

0

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

download
Kit Contents See Figure 5 and Table 1. INSTALLATION Sissy Bar Installation to Sideplates 1. See Figure 5. Insert the legs of the sissy bar upright (A) all the way into the channels (B) of the sideplates (1 and 2) as shown. 2. Apply a few drops of Loctite 262 – Red to the threads of the button head screws (4). Thread the screws into the holes in the sideplate channels, and tighten to 96-120 in-lbs (11-14 N-m) . Sissy Bar and Sideplate Installation to Docking Points 3. See Figure 1. While standing behind the motorcycle, place the left-side and right-side front sideplate notches (2) into the front docking points (4) on the fender supports (3). See Figure 2 for views of correct and incorrect sideplate engagement. NOTE Failure to properly align the front docking points and sideplates may result in damage to the rear docking points. 1 3 2 4 is05682 1. Sissy bar and sideplate assembly 2. Front notch 3. Right side fender support 4. Front docking point Figure 1. Place Front Notches into Front Docking Points 4 4 3 2 2 1 1 1 2 is00963 1. Sideplate (right side) 2. Right front docking point 3. Correct: sideplate fully engaged in docking point 4. Incorrect: sideplate NOT fully engaged in docking point Figure 2. Sideplate Fit to Front Docking Points

HARLEY DAVIDSON STAMPED MINI AND SHORT BACKREST KITS INSTALLATION MANUAL

0

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

download
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 ONE-PIECE DETACHABLE SISSY BAR UPRIGHT AND PAD KITS INSTALLATION MANUAL

0

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

download
INSTALLATION 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 rear docking points. 3. See Figure 1. Pull (11) the rotary latches (4) back into their rearmost 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 sideplates, and close the rotary latches by pressing (13) the latch lever as far forward as it will go. A click will be heard when the latch is in place. If the latch does not close, do not force it. 13 4 1 5 2 9 3 7 10 7 8 5 4 6 11 12 is00058 1. Passenger upright 2. Front notch 3. Docking point, front 4. Rotary latch 5. Release button 6. Rear notch 7. Docking point, rear 8. Rear docking point neck 9. Fender support bracket 10. Place front notches into front docking points. 11. Pull latches back. 12. Lower rear notches onto rear docking points. 13. Push forward to close latches. Figure 1. Detachable Passenger Upright

HARLEY DAVIDSON SOFTAIL SPORT LUGGAGE RACK INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 22-02-2011

download
INSTALLATION NOTE Cover the rear fender with a clean shop towel to prevent scratching. Damage to the finish could result. 1. See Figure 1. Remove the four button-head TORX screws attaching the sissy bar (5) to the sideplates (4). Discard the screws 2. Remove the sissy bar and set it aside. For Rigid-Mount Sideplates only: Loosen, but do not remove, the hardware securing the sideplates to the motorcycle. 3. Position the luggage rack between the sideplates. Reinstall the sissy bar into the sideplate channels. 4. Apply Loctite 271 (Red) to the flat head TORX screws (2) from the kit, and insert through the holes in the luggage rack (1), sideplate, and sissy bar. Tighten the screws to 8-10 ft-lbs (10.8-13.6 Nm) . For Rigid-Mount Sideplates only: Apply Loctite 271 (Red) to the screws securing the sideplates to the motorcycle, and tighten to 21-27 ft-lbs (28.5-36.6 Nm) . 5. Remove the backing strip from the two rubber bumpers (3) and install onto the luggage rack. a. Align the notches in the bumper with the bottom edge of the channel on the sideplate. b. Wrap the bumper up the side of the luggage rack channel and across the bottom of the sissy bar. When properly installed the bumpers will cover the lower flat head screws, and will bend around the lower edge of the channel. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg)

Incoming search terms: