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

HARLEY DAVIDSON HERITAGE CHROME FRONT FENDER RAIL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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INSTALLATION NOTE See Figure 1. Be careful not to crack plastic fender lamp lens (2) or chrome plate when removing lens. 1. Remove fender lamp light lens (2) by placing screwdriver in slot in top of lens and carefully prying cover loose. Retain lens and gasket for later installation. 2. Loosen four hex socket head screws (1) which attach fender (4) to fender mount. 3 2 4 1 is03805 1. Fender mount screws (4) 2. Fender lamp light lens 3. Fender Rail 4. Fender Figure 1. Installed Front fender Rail NOTE When installing fender rail (3), be sure fender rail supports are inside of fender. 3. Place fender rail (3) from kit into position, aligning the front bracket hole of rail with hole in front of fender (4). Fender rail supports will fit snugly inside fender. NOTE Be careful not to damage the fender lamp wire when securing front fender rail into place. 4. Use a magnet to place a 10-32 x 1/2 inch phillips screw through the hole in front fender and through front bracket hole of fender rail (3). 5. Loosely secure fender rail (3) to fender (4) with 1/2 inch flat washer and hex locknut. 6. On right side only, remove two hex socket head screws and nuts. Retain nuts for installation. 7. Replace original two socket head screws with 5/16-18 x 2 inch screws from kit. 8. For vehicles without caliper/rotor covers: On left side of fender (4) only, install a washer between rail (3) and fender for both screws. Replace original two hex socket head screws with 5/16-18 x 2 inch screws from kit. For vehicle with caliper/rotor covers: Do not replace hex socket head screw that supports caliper/rotor cover. On left side of fender (4), install a washer between fender (4) and rail (3) on screw that does not support the caliper/rotor cover (towards the front of the vehicle). Replace remaining hex socket head screw with 5/16-18 x 2 inch screw from kit. 9. Install four original nuts. 10. Tighten front bracket Phillips screw securely. Tighten four hex socket head screws to 14-18 ft-lbs (19-24 Nm). 11. Install gasket and fender lamp lens removed earlier

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HARLEY DAVIDSON V-LOGO TURN SIGNAL INDICATOR FORROAD KING INSTALLATION MANUAL

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

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1. Disconnect battery cables, negative cable first. 2. Following instructions in applicable Service Manual, remove the windshield. 3. Remove the phillips screw at the bottom of the of the headlamp door (chrome ring). Remove the headlamp door. 4. Remove the seven Phillips screws to free the headlamp housing from the headlamp nacelle. 5. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside. 6. See Figure 1. Reaching inside the headlamp nacelle, remove the speed nut to release the chrome strip at the top of the nacelle. 7. Remove the wire form clip holding the halves of the nacelle together at the bottom. 8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate. 9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove). 10. Loosen the two acorn nuts from the left and right side fork studs. 11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle. 12. Carefully align the template over the handlebar shroud cover and tape into place. 13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means. 14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure. 15. Drill one 1/4″ hole and two 5/32″ holes as indicated on the Drill Template (attached)

HARLEY DAVIDSON CRUISE CONTROL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION NOTE if the motorcycle is equipped with the optional Harley-Davidson Smart Siren, the main fuse MUST be removed BEFORE the alarm is activated. This WILL happen within 5 seconds of turning the ignition switch to the OFF position (except for HD- Japan models). If the main fuse is not removed promptly, the siren WILL SOUND. 1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Remove the outer fairing per the instructions in the service manual. For FLHR models: Follow the instructions in the service manual to remove only the handlebar clamp shroud. Removing the nacelle is not necessary. a. Remove the windshield and headlamp door. Remove the headlamp housing assembly. b. Release the chrome trim strip at the top of the nacelle. c. Remove the two Phillips screws beneath the fork lock plate. d. Loosen the Phillips screw at the front of the handlebar clamp shroud, and the four acorn nuts on the side of the headlamp nacelle. e. Raise the shroud slightly, separate the nacelle halves and slide the shroud forward to remove it from the nacelle. NOTE Before disconnecting the handlebar switch wiring, note the wire routing. 3. For ALL models: Refer to the service manual. Disconnect the right-side handlebar MOLEX socket housing from the black six-way main harness pin housing [22B] inside the fairing or headlamp nacelle

Kawasaki Vulcan 400/ 800 Preload Improvement Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 01-12-2010

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1. Begin by removing both side compartment covers. The RH compartment cover requires the use of the ignition key for removal; the LH compartment cover is secured by a large Phillips screw. Once you’ve removed the LH cover, place the Phillips screw back into the hole in the frame (so you don’t misplace it) and set both covers aside. In many applications, you must remove the upper exhaust pipe (from the rear cylinder), and loosen the other pipe, to remove the inner parts of the RH side compartment cover (see below). Before attempting step #2 below, try step #3 first… depending on the brand of exhaust pipes you have, you may be able to avoid removal in step #2, if you are successful with step #3 first. Some brands of exhaust pipes provide access to the fasteners securing the RH side covers, eliminating the requirement to remove pipes for rear suspension access. 2. Remove the rear cylinder’s exhaust pipe. To do so, remove the two Allen nuts on the exhaust header, where it attaches to the engine, using an 8mm Allen wrench. Most often, this goes much more smoothly if you first spray the inside of the allen nut with a penetrating lubricant like WD-40. Remove the black acorn nut from the discharge end of the exhaust pipe (under the upper exhaust pipe, near the discharge end of the pipe) using a 12mm open-end wrench or socket. You’ll find a black metal spacer, through which the bolt goes, that is pressed through the rubber grommet. To avoid the potential of having it fall out unnoticed, remove it and place it aside with the nut. Remove the black bolt from the pipe just aft (to the rear) of where the pipe enlarges and above the pipe. This is actually a bracket that holds the two pipes together at a joint. Loosen the bolt using a 12mm socket, then slide it back onto the pipe you’re removing. Once you have the pipe off of the bike, the clamp will be loose. Be sure to keep it with the pipe, along with the rest of the removed parts. Loosen the pipe from the front cylinder BEFORE trying to remove the pipe from the rear cylinder. By loosening the header nuts on the pipe from the front cylinder, and removing the two black Allen bolts (6mm Allen wrench) under the forward pipe that attach it to the frame, you will be able to remove the rear pipe. There are more spacers in grommets where the 6mm Allen bolts secure the lower pipe to the frame (like those used in the rearmost connection o

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