Harley-Davidson FL Caliper Mount Installation Manual

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Filed Under (Harley Davidson) by admin on 26-02-2012

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Motolight® Caliper mounts are designed to be mounted on the brake caliper mounting boss. Before removing the caliper bolt make certain you have the manufacturer’s recommended torque settings for your make, model and year. 2 . Disconnect your battery. Never work on the electrical system of a motorcycle while the battery is connected. If you’re not sure how, check your owner’s manual, or consider having your dealer install the lights. 3 . Motolights®, like any light, get hot when operating. Do not touch any part of the housing when the Motolights® are in operation and for at least 15 minutes after they have been turned off. 4 . If you are transferring your Motolights® to another bike or have obtained the lights secondhand, it is VERY IMPORTANT that you contact us at 800-567-8346 or 513-474-7530 for new caliper bolts of proper grade and size. Step 1. Unpack the Motolight® system . Take this chance to familiarize yourself with everything. Below is the list of included items: Item # Quantity Description 1 (2) º” x 20 x 5/8″ stainless steel socket head cap screws 2 (2) Housings, aluminum, assembled with lens, lamp and leads 3 (2) Mounting blocks, aluminum, left and right 4 (2) Caliper replacement bolts 5 (2) Lock washers 6 (1) Motolight wiring harness with relay and 20 amp fuse 7 incl. Special Harley auxiliary plug connector in wiring harness (included) 8 (2) Motolight decals (1 helmet size, 1 regular) 9 (1) Aiming tube (cardboard ring) 10 (1) 3/16″ hex wrench 11 (1) Pin wrench (for standard lamp retaining rings-not required for knurled/grooved rings) 12 (15) Cable ties, long and short

HARLEY DAVIDSON SOFTAIL 6 SPEED TRANSMISSION – COMPLETE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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Removal of Original Transmission 1. Position motorcycle on a suitable lift. 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) 2. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 3. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps. 4. Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 5. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly. 6. Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. 7. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation. 8. Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch. 9. Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. 10. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. 11. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. 12. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. 13. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation

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HARLEY DAVIDSON FLHRS SADDLEBAG LOCK SET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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INSTALLATION 1. Lay a clean pad or blanket on the work surface to protect the saddlebag leather surfaces. 2. Open the saddlebag lid. Remove the saddlebag from the motorcycle, leaving the lid open. See SADDLEBAG REMOVAL in the Service Manual. Lay the saddlebag flat on the pad or blanket with the inboard side facing up and the lid furthest from you. 3. See . Obtain the templates (10) from the kit. Lay the correct (left or right) template in the upper rear corner of the hard plastic inboard face of the saddlebag. Fit the template around the rear of the lid hinge and against the curve of the raised surface in the middle of the saddlebag, and tape it into place. is03044 Figure 1. Template Placement (Left Side Shown) 4. Drill four 3/16 (0.19)-inch holes in the saddlebag inboard face where indicated on the template. 5. Drill four 5/32 (0.15)-inch holes in the saddlebag inboard face as indicated on the template. 6. Remove the template. Cut out the area in between the four smaller holes to create a rectangular opening for the lock arm. Stand the saddlebag upright, with the cover open. 7. See the Figure 2. Obtain one lockset (1) and two screws (5) from the kit. Position the lockset to the saddlebag as shown, with the actuator rod protruding through the rectangular opening cut in step 6. Insert the screws through the lockset mounting holes and into the saddlebag. 8. Position a backing plate (3) over the screw threads inside the saddlebag. Fasten the lockset and backing plate to the saddlebag with two lockwashers (6) and hex nuts (7) from the kit. 9. Using a 3/16-in. hex wrench, remove the two screws holding the inside cover over the existing pushbutton lid release. Remove the cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 10. Remove the retaining ring fastening the lid release cable to the pushbutton. Unhook the cable from the pushbutton lever, and pull the cable sheath out of the retaining channel on the inboard wall of the saddlebag. Remove the flat washer from the cable end. Do not discard the retaining ring and washer. 11. Trim about one inch (25 mm) from the rearmost part of the retaining channel, and re-insert the cable into the channel so the free end is at the rear of the saddlebag. 12. Insert the cable end through the hole in the backing plate, and slip the washer over the end of the cable fitting. Insert the cable into the slot in the lockset actuator rod so the ball on the end of the cable fits into the depression.

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HARLEY DAVIDSON HEEL RAISER FOOTPEG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. If the motorcycle is equipped with a pin and retaining ring, remove them and retain for future use. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs and the spring washers. Save the spring washers for installation. NOTE See Figure 1. When performing the next step, verify that the spring washer is positioned inside of the footpeg support with the square edge (2) towards the inside of the support. 1 3 2 is02094 1. Spring washer 2. Spring washer square edge 3. Footpeg support slot Figure 1. Footpeg Spring Washer Installation 3. See Figure 1. Install the new footpegs in the same manner as the old footpegs were installed. Insert a spring washer (1) and the mount end of the footpeg inside the slots (3) of the footpeg supports. 4. Secure each footpeg and spring washer to the footpeg support with the screw and locknuts or pin and retaining rings removed earlier. Tighten the locknuts to 19 ft-lb (26 Nm) . Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a)

HARLEY DAVIDSON HAND LEVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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BRAKE LEVER INSTALLATION 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) is 01010 Figure 1. 5/32 in. (4 mm) Cardboard Insert 1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (4) from the groove in the pivot pin (B) and discard retaining ring. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. NOTE New brake levers come with the pivot lever bushing installed. NOTE Follow the instructions in Steps 3 and 4 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04342 1 of 3 4. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 5. Install the pivot pin removed in Step 2 and new retaining ring (4) from kit. 6. Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is per- missible. A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) 7. To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. 8. Reinstall the master cylinder cover. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 9. Check that the stop light goes on when the brake lever is actuated. CLUTCH LEVER INSTALLATION See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures. SERVICE PARTS

HARLEY DAVIDSON HANDLEBAR RESERVOIR COVER SET INSTALLATION MANUAL

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

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Kit 46098-98 fits the following models with single-disc front brake. •1996 through 2003 XL (Sportster®) models •1996 and later Dyna models •1996 and later Softail® models Kit 46099-98 fits the following models with dual-disc front brake. •1996 through 2003 XL (Sportster) models •1996 and later Dyna models •1996 and later Softail models •1996 and later FL Touring models INSTALLATION Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 1. Adjust the clutch cable for maximum free play. With snap ring pliers, remove and retain the external snap ring from the bottom of the clutch lever pivot pin. Remove the pivot pin, clutch lever, clutch cable and rear-view mirror from the clutch bracket. NOTE Apply anti-seize (10) (Harley-Davidson part number 98960-97) from the kit to all screw threads prior to installation. 2. See Figure 1. Install the new chrome clutch bracket (1) using a clamp half (2), washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). -J01271 1 is01004 Figure 2. Clutch Cable Adjustment 3. Re-install the clutch cable and clutch lever, mirror and pivot pin and snap ring. See Figure 2. Re-adjust the clutch cable so there is a 1/16-1/8 inch (1.6-3.1 mm) gap between the clutch cable ferrule and the end of the clutch bracket (1). 4. Remove the original clamp half from the front brake master cylinder assembly. 5. See Figure 1. Install the new chrome clamp half (2) on the front brake master cylinder assembly using washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). 6. Remove the two screws retaining the brake master cylinder reservoir cover. See Figure 3. Replace with the two standoff studs (1) in the kit. Tighten to 6-8 in-lbs (0.7-0.9 Nm)

HARLEY DAVIDSON HAND CONTROL LEVER KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Dav- idson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) Brake Lever Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Do not remove handlebar clamp or switch housing assembly to remove brake lever. 1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A). Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a) 2. Place a 4 mm (5/32-inch) thick insert between the brake lever and the lever bracket. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1. 3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar. 4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly. 5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to the area where the master cylinder pushrod seats against the brake lever. DO NOT apply grease to the stop-light switch contact surface of the lever. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever

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

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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 placed into 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. 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. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

HARLEY DAVIDSON XL HAND LEVER INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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These kits fit all 2004 and later XL Sportster® model motorcy- BRAKE LEVER INSTALLATION Removing the Brake Lever 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) is 01010 Figure 1. 5/32 in. (4 mm) Cardboard Insert 1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See Figure 2. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. Save the pivot pin for re-use, discard the retaining ring. 3. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Installing the Brake Lever NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch

HARLEY DAVIDSON CUSTOM HAND LEVER KIT BRAKE LEVER INSTALLATION

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

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1. See Figure 1. Squeeze the brake lever and place the cardboard insert between the brake lever and lever bracket. NOTE Use the eyelet of an ordinary cable strap if the cardboard insert is not available. NOTE Do not remove the handlebar clamp or switch housing assembly to remove the brake lever. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 2. See the Figure 2 and the FRONT BRAKE MASTER CYLINDER section of the Service Manual. Remove the retaining ring (B) from the groove in the pivot pin (C). Inspect the retaining ring (part number 11143) and replace if needed. 3. Remove the pivot pin and retain for re-use. Remove and discard the original equipment brake lever and pivot lever bushing. 4. Insert the pivot lever bushing (2) from the kit into the new brake lever (1). NOTE Follow the instructions in Steps 4 and 5 carefully in order to prevent the actuating tab on the brake lever from damaging the rubber boot and plunger of the front stoplight switch. -J04165 1 of 3
5. Gently press and hold the piston cap (A) forward with a screwdriver. Slip the brake lever into position and align the pivot pin holes. 6. Install the pivot pin and retaining ring removed in Steps 1 and 2. 7. Check the front brake for proper operation. There should be no free play in the hand lever. A slight preload is per- missible. A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury. (00288a) 8. To verify proper operation of the master-cylinder relief port, actuate the brake lever with the reservoir cover and gasket removed. A slight spurt of fluid will break the surface if internal components are working properly. 9. Reinstall the master cylinder cover. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Check that the stop light goes on when the brake lever is actuated. CLUTCH LEVER INSTALLATION See the CLUTCH CONTROL section of the appropriate Service Manual for all clutch lever removal, installation and adjustment procedures.

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