HARLEY DAVIDSON SOFTAIL REAR AXLE COVER KIT INSTALLATION MANUAL

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

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INSTALLATION 1. 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. 2. All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. 3. 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. 4. All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. 5. All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. 1 2 4 3 is04788 1. Axle adjuster screw 2. Jamnut 3. Castle nut 4. Cotter pin (or spring clip) Figure 1. Rear Axle Hardware

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HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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HARLEY DAVIDSON SECONDARY BELT EMERGENCY KIT INSTALLATION MANUAL

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

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The 40101-80 kit, with a 126 tooth belt, fits: •1980-1986 FXB and 1984-1986 FXWG models This kit may also be used on 1989-1992 international Softail models with a 127 tooth belt. The 40171-97 kit, with a 130 tooth belt, fits: •1995 and later domestic Softail models •1994 and later international Softail models •1994 and later international Dyna models The 40109-86 kit, with a 132 tooth belt, fits •1986-1992 and 1994 domestic Softail models •1989-1993 international FLT and FXR models This kit may also be used on the following models with 133 tooth belts: •1991 and later domestic Dyna models •1991-1992 international Dyna models •1994-1995 international FLT models The 40100-85 kit, with a 136 tooth belt, fits: •1985-1994 domestic FXR models •1985-1996 domestic FLT models •1996 international FLT models The 40112-97 kit, with a 139 tooth belt fits •1997 FLT models Installation 1. Put transmission in ‘Neutral’. 2. Loosen rear axle nut. Loosen rear axle adjuster nut on each side of motorcycle, and move rear wheel to full forward position. 3. Remove the damaged/broken belt. 4. Inspect sprockets and belt guard for damage and/or debris. Remove any debris. If sprockets and belt guard are not damaged, proceed with the installation. 5. See Figure 1. Remove belt guard. 6. See Figure 2. Install feeder strip on emergency belt. Feed strip around transmission sprocket in a counterclockwise direction over frame cross support.

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HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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Harley-Davidson EMERGENCY DRIVE BELT REPLACEMENT KIT Installation Manual

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Shift transmission to neutral. Before installation of the emergency belt, to avoid personal injury and/or vehicle damage, secure the motorcycle. Both stand and motorcycle must be on solid, level ground. Failure to follow instructions could result in death or serious injury. 2. See Figure 1. Remove spring clip (4) (if present) and loosen rear axle nut (1). 3. Loosen rear axle adjuster (3) (or adjuster nut, if so equipped) on each side of motorcycle, and move rear wheel to full forward position. 4. Remove the damaged/broken belt. 5. Inspect sprockets and belt guard (2) for damage and/or debris. Remove any debris. If sprockets and belt guard are not damaged, proceed with the installation. 6. Remove belt guard. 40171-97,40146-00 1 WARNING i06186 Figure 1. Axle 1. Axle nut 2. Belt guard 3. Adjuster 4. Spring clip 2 4 1 3 7. See Figure 2. Install feeder strip on emergency belt. 8. Feed strip around transmission sprocket in a counterclockwise direction over frame cross support. 9. See Figure 3. Interlock the “v” ends of the emergency belt. a. Insert a hex socket key in the fourth (4) and ninth (6) tooth holes. b. Place the splice block (2) over the seventh (5) tooth hole. c. Install a socket head set screw (3) in the seventh tooth. Tighten using another hex socket key. d. Move the block to the next tooth, and repeat installation steps (b) and (c) in each tooth until all 12 screws are installed. NOTE There are 16 screws included in this kit. However, only 12 screws will actually be installed in the belt. The remaining four screws are spares. 10. See Figure 4. Grasp the emergency belt at the mid point of the lower run between your thumb and forefinger and lift the belt up to take up any slack in the belt. Measure the distance that the belt deflects (2) under tension (1). When two pounds of tension is applied to the lower run of the emergency belt, the belt deflection should be within the following measurements

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