Yamaha Road Star Trike Conversion Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. c. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for re-installation after modification are noted. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model Installation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster

HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON SOFTAIL REAR SADDLEBAG GUARDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION 1. Remove saddlebag, if equipped, from motorcycle. 2. Remove passenger footpeg or passenger footboard assembly (including footboard mount) from vehicle. 3. See Figure 1. Remove nut (1), seat strap bracket (if equipped) and 3/8 inch diameter bolt (2) from indicated position on rear fender support (immediately to the rear of the front seat) Discard the bolt, but save the nut for reinstallation. This location is where the upper part of the saddlebag guard will mount. 2 1 is03883 1. Rear fender support nut 2. Rear fender support screw Figure 1. Hardware Removal 4. See Figure 2. Install saddlebag guard (4) top flange (5) against fender support (3). Install 3/8-16 x 1-3/4 inch button head bolt with the seat strap bracket (if equipped) and hardware removed in Step 3 (if equipped) and nut in same direction as bolt removed in Step 3. Finger tighten only. 5. Position bottom flange (6) of saddlebag guard (4) against inboard surface of motorcycle frame (7) at location where passenger footpeg (2) (or passenger footboard bolt) attaches. If Heritage-Style Saddlebag relocation kit, Part Number 90238-00 is to be installed, the bracket should be positioned between the saddlebag guard flange and the motorcycle frame member. Follow installation instructions included with that kit. 6. See Figure 3. Determine your model application and follow the applicable installation procedure below: On models with passenger footpeg, but without saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support (B). Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Install lower saddlebag guard flange over bolt protruding from inboard surface of frame member. Install 3/8-16 lock nut to end of bolt. Tighten to 35-45 ft-lbs (47-61 Nm). Install footpeg (C) according to Service Manual instructions. On models with passenger footpeg and saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support. Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Position saddlebag relocation

HARLEY DAVIDSON SMOKED AND CLEAR FENDER TIP LENS KITS Preparation MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) 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 cables, negative cable first. 2 . See Figure 1. Insert blade of small screwdriver into slot at top of front fender tip lamp lens (2). Rotate end of screwdriver to unsnap lens from lamp bracket. Repeat for rear fender tip lamp lens. 3. Remove bulb (3) from socket (4). 4. From the kit, find the LED marked “Amber” (5) and install into front fender tip lamp assembly.lamp socket. 5. From the kit, find the LED marked “Red” (5) and install into rear fender tip lamp assembly.lamp socket. Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 6. Connect the battery cables, positive cable first. 7. Apply power and check for proper function of front and rear fender tip lamps

HARLEY DAVIDSON XL SPRING SEAT MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION 1. Refer to service manual and remove the existing seat, seat post, washer and screw. Do not remove grommet or T-spacer from rear fender. Save the washer and screw for later installation. 2. See Figure 1. Clean the frame surface where the hook- and-loop strip will be attached with a 1:1 mixture of isopropyl alcohol and water. Let it dry completely. 3. Install the frame cover to the frame as follows: a. Remove the loop side of the hook-and-loop (3) from the bottom of the frame cover (1). b. Remove the protective tape from the hook-and-loop strip and attach it to the frame as shown. Wrap it under the frame or trim excess length, if necessary. c. Orient the frame cover so that it covers the seat pan and secure the cover to the frame with the hook-and- loop strips. 4. See Figure 3. Install two springs (2) to the mounting bracket (1), oriented as shown, with screws (3). Tighten screws to 25-30 ft-lbs (34-41 Nm) . 5. See Figure 3. Install mounting bracket to frame tab a. Install mounting bracket (1) over frame tab. Orient it so that the two retaining tabs on the mounting bracket will hold down and be fully seated on the frame cover. b. Secure mounting bracket with screw (B), washer (C) and nut (4). Do not tighten. c. Center the frame cover and mounting bracket to the motorcycle frame. d. Tighten mounting bracket screw and nut to 15-20 ft- lbs (20-27 Nm) . 6. Install seat pivot bracket (15), washers (14) and screws (13) to the seat. Tighten screws to 48-72 in-lbs (5.5-8.0 Nm) . 7. Remove the rear fuel tank mounting screw, washers, nut and thread protector. Save washers for later installation

HARLEY DAVIDSON AUXILIARY BRAKE/ RUN/ TURN SIGNAL CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) -J03990 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 Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 2. See Figure 1. Locate the rear wiring harness coming out of the rear fender in the area underneath the seat. Disconnect the rear fender lighting wiring connector (1) from the main harness connector (2). 3. Obtain the turn signal module from the kit, and mate the module connectors to the male and female rear fender wiring harness connections. Snap into place. NOTE Due to variations between models, there is no single best location to secure the module. When deciding on a location for securing the module, make sure that the connectors and module will not be bound, and that the wiring will not be pinched when the seat is re-installed. Also, be certain to maintain clearance between the wiring harness and the rear wheel underneath the fender. 4. Using cable straps from the kit, secure the module, connector and wiring in the area underneath seat. 1997-1999 FLHR and FLHRCI models: Go to Step 5. All other models: Proceed to Step 6.

HARLEY DAVIDSON AM/FM ANTENNA RELOCATION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Owner’s Manual and follow the instructions given to remove the left-side saddlebag. Gently pull the left-side cover from the frame downtubes (no tools are required), and remove the main fuse. 2. See Figure 1. Disconnect the antenna cable from the antenna base assembly (1). 3. Unscrew the antenna mast (2) from the antenna base, and set it aside for later installation. 4. Remove the lower locknut (3), and remove the antenna base from the mounting bracket (5). Save both locknuts, but discard the lockwasher (4). 5. Remove the two TORX® head screws (6) and lockwashers (7) retaining the antenna mounting bracket to the saddlebag rear support bracket (8). Discard the bracket and fasteners. 6. Carefully remove and discard any cable straps securing the antenna cable to the fender support and saddlebag rear support brackets. 8 9 6 3 2 5 7 4 3 1 is05436 1. Antenna base assembly 2. Antenna mast 3. Locknut (2) 4. Lockwasher 5. Original antenna mounting bracket 6. TORX head screw (2) 7. Split lockwasher (2) 8. Saddlebag rear support bracket 9. TORX Pan head screw and flanged locknut Figure 1. Original Antenna Mount 7. Remove and discard the TORX head screw and nut (9) that fastens the lower saddlebag support bar to the rear fender support bracket. 8. See Figure 2. Obtain the new antenna bracket (1), button head screw (2), flat washers (3 and 4) and flange nut (5) from the kit. NOTE If V-Logo Rear Fender Trim Rail Kit 91100-09 has been installed, the thick washer (4) is not used, and can be dis- carded.

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HARLEY DAVIDSON LAYBACK LICENSE PLATE AND TURN SIGNAL RELOCATION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION 3 2 1 is00851 1. Tail/stop lamp connector 2. Left turn signal connector 3. Right turn signal connector Figure 1. Rear Lamp Connectors 1. Raise the vehicle on a motorcycle lift to allow access to the underside of the rear fender. 2. Refer to the Service Manual and follow the instructions given to remove the negative battery cable (earlier Dyna models) or Maxi® Fuse (all XL’s and later Dyna models). 3. Remove the license plate from the vehicle (if installed). Remove and discard the original equipment license-plate bracket and attaching hardware from the fender. Clean the mounting area on the fender with a soft, damp cloth. 4. See Figure 1. Remove the two screws securing the tail/stop lamp lens assembly, and remove the lens and bulb assembly. Depress the latch on the four-way tail/stop lamp connector (1), and disconnect the connector from the circuit board. 5. Depress the latches on the left-side (2) and right-side (3) two-way turn signal connectors, and disconnect the connectors from the circuit board. 6. Remove the turn signal wires from the retention clips under the fender.

HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

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HARLEY DAVIDSON TOURING SEATS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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REMOVAL NOTE Cover painted surfaces with protective material to prevent scratches or other damage. 1. Remove the left and right side saddlebags from the motorcycle per the instructions in the owner’s manual. Save all hardware for installation. 1 3 2 4 5 is05863 1. Stock screw 2. Stock washer 3. Stock grab strap 4. Saddlebag mounting bracket 5. Grab strap (kit 53051-09) Figure 1. Remove Grab Strap and Install Kit 53051-09 NOTE Before removing the saddlebag mounting bracket attaching bolts, note the mounting orientation of the saddlebag mounting brackets. 2. See Figure 1. Remove the left side screw (1) and washer (2) to remove the bracket (4) and the passenger grab strap (3). Repeat for the right side saddlebag mounting bracket. 3. See Figure 4. Remove the screw with lockwasher (A) from the rear of the currently installed seat. Pull the seat rearward to remove the seat from the motorcycle. Save the screw. 4. For All Kits Except 53051-09: Remove the two flanged nuts (B) from the studs (C) near the front of the rear fender. INSTALLATION For All Kits Except 53051-09: 1. Install the grab strap (2) onto the studs as shown in Figure 2. Secure the grab strap to the studs with the nuts, and tighten to 96-156 in-lbs (11-18 Nm) . 2. See Figure 3. Slide the rear of the seat (1) through the grab strap, from the front, until the slot (2) on the front underside of the seat is behind the seat mounting tongue (1) on the fuel tank rear bracket