Harley Davidson Touring Bikes TRUMPET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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COMPRESSOR INSTALLATION TOUR MODELS 1992 -2000 On the Dressers and Tour bikes, remove the seat. If the battery is located underneath the seat, then remove the right saddlebag and right hand side cover. Using a zip tie, mount the compressor to the main wiring harness at the front of the covered area with the compressor air outlet facing down. If the battery is not under the seat and is located beside the right saddlebag, the compressor will be mounted underneath the seat, utilizing a bolt to the frame The air hose routes from the air horns, behind the fuel valve, over the rear cylinder and to the right side cover or underneath the seat. Do not cut hose until you connect it to the compressor. TOUR MODELS 2001 & NEWER On the Dressers and Tour bikes, the compressor will mount under the seat, in the square hole in front of the frame, just in front of the battery. The air output will face left toward the air horns. The hose routes thru a hole at the bottom of the square hole, then to the air horns. WIRING Connect both black wires from the relay to the original horn wires. It does not matter which wire you connect. The fuse wire on the relay will connect to the positive terminal on the battery. Observe negative and positive terminals on compressor. Ground the negative terminal to the battery. The positive terminal connects to red wire on relay. Refer to wiring schematic on the next page

2010 Harley Davidson Touring Model Power Commander Installation manual

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Filed Under (Harley Davidson) by admin on 29-02-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Plug the PCV connectors in-line of the stock ECM and wiring harness (Fig.B). 4 Tuck the PCV to wiring harness connection into the opening in front of the battery box (Fig. C). 5 Using the supplied velcro attach the PCV to the top of the ECM (Fig. C) FIG.A FIG.C Remove Ground wire FIG.B PCV connector PCV connector Stk connector Connection 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 4 6 Remove the right hand saddlebag and sidecover. 7 Locate the stock O2 sensor connections and unplug both connectors (Fig. D) The stock O2 sensors will NOT be connected to anything at this time. The sensors can be removed from the exhaust if you have a way to plug the hole. Unplugging the sensors does NOT cause an engine light but will cause a historic code in the ECM for non-active O2 sensor. This is not causing any issues with the running of the bike. FIG.D Follow these instructions when using the Auto tune kit – part #AT-100B 1 Remove the left hand side cover. 2 Place the Autotune modules in front of the battery as shown in Figure H. If using velcro make sure the velcro does not cover the designation of the unit on the back (AT #1 or AT#2). The modules are coded to the front and rear cylinders. FIG.E 3 Remove the rubber plug for the diagnostic connector. Plug the lead from the Autotune kit into the stock diagnostic connector (Fig. J).This connection is under the LH sidecover. DO NOT connect to the accessory connection in front of the battery. 4 Reinstall the sidecover. FIG.F 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 5 5 Connect the longer harness to the front O2 sensor. Route the harness along the front down tube and along the backbone of the frame to Autotune module AT#1. Wire the harness to the module per Figure G. The harness can be cut to length if desired. 6 Repeat step 4 for the rear cylinder. Wire the harness to Autotune Module AT#2. The harness can be cut to length if desired. If your exhaust does not accept the M18x1.5mm O2 sensor you will need to install the supplied O2 bungs with the Auto tune kit into your exhaust. See Auto tune instructions for more information

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2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

HARLEY DAVIDSON POWER LOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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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) 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, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove seat following the instructions in the appropriate Service Manual. Preparing the Saddlebags for Power Locks 1. Remove saddlebags following the instructions in the appropriate Service Manual. 2. See Figure 1. Remove lid (1) and hinge (2) from sad- dlebag. 3. Remove lock (3) from saddlebag. 4. See Figure 2. Set drill template on hinge surface of the saddlebag aligning the template (5) with hinge mounting holes (7). 5. See Figure 3. Drill 0.344 (11/32) inch diameter hole (1). 6. Place the template on the back of the saddlebag (4) aligning front mounting grommet (2) and forward latch bracket (1). 7. See Figure 4. Drill 0.500-0.515 inch diameter hole (1). 8. Repeat on the other saddlebag. 1 2 3 is04988 1. Saddlebag lid 2. Saddlebag hinge 3. Saddlebag lock Figure 1. Remove Lid, Hinge and Lock from Saddlebag

HARLEY DAVIDSON VRSCD SADDLEBAG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Prepare Bike for Hardware Installation 1. Use a suitable lift to support the motorcycle under the frame until the rear suspension is fully extended. NOTE To remove the tether from the hole in the frame, reach under the frame tube to align the metal tee (located on the end of the seat tether) with the tether cable. 2. See Figure 1. Unlatch and open seat. Remove tether (4) by sliding small clip (3) sideways through hole in frame. NOTE To remove the tubular plastic seat-hinge sleeve from the hinge, turn the sleeve to reveal the slotted length. Push on the slot with your finger to pop the sleeve off the hinge pins. Closing the seat slightly allows the sleeve to fall from the hinge-side of the seat, so be prepared to catch the sleeve. 3. Remove plastic sleeve (2) from hinge pins (1) and slide pins toward rear of bike. Remove seat. 2 1 4 3 is 00449 1. Hinge 2. Sleeve 3. Clip 4. Remove tether from frame Figure 1. Remove Seat 3 1 2 is 00450 1. Grabstrap 2. Passenger Pillion 3. Screw and Washer Figure 2. Remove Passenger Pillion 4. See Figure 2. Remove screw and washer (3) securing passenger pillion to frame. Slide pillion under grabstrap (1) and forward to disengage from tongue to remove. Save pillion mounting screw and washer for later use

HARLEY DAVIDSON DYNA SADDLEBAG KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL Remove Turn Signals 1. Locate and separate tail lamp connector (8-place multilock) under seat. Then remove wires from connector. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual. 2. 1996-1998 Models: Pull turn signal wires through clips (if present) and rear fender. 1999 and Later Models: a. See Figure 1. Remove two screws and tail lamp lens (1) from base (2). b. See Figure 2. Using a Terminal Pick Tool (HD-41475- 100) (1), depress locking tabs and remove turn signal connectors (2-place) (2, 3). Save connectors for kit installation. Refer to AMP MULTILOCK ELECTRICAL CONNECTORS in Service Manual. c. Remove wires from turn signal connectors. Note location of terminal for proper reassembly. d. Remove turn signal wiring from clips under rear of fender and pull wires out

HARLEY DAVIDSON SADDLEBAG HINGE STOP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 2 and Table 1. Remove the saddlebag by opening the lid and turning the two bail head studs (1) 1/4 turn. Save the washers (A) and discard one of the studs (1). The rear stud and isolator will be replaced with new ones from the kit. NOTE Do Not remove the hinge assembly from the saddlebag lid. 2. See Figure 1. Drill the rivets out of the backing plate (C) from the lower rear saddlebag hinge. •Enlarge the backing plate holes by drilling with a #19 drill bit. 3. Remove the rear isolator and install the new rear isolator (2) from the kit to the saddlebag. NOTE It is recommended to use Loctite® 262, threadlocker and sealant on the threads of the hinge screws. 4. See Figure 2 and Table 1. Position the backing plate (C) inside the saddlebag and align with the rear hinge (B) and hinge stop (3) on the outside of the saddlebag. Assemble using the two TORX® head screws (5). 2 1 is05974 1. Rear hinge rivets (2) 2. Rear isolator Figure 1. Drill Out Rivets From Rear Hinge and Backing Plate 5. Install the saddlebag to the motorcycle using the longer bail head stud (1) from the kit and a washer for the rear of the saddlebag and the washer and front bail head stud previously removed for the front of the saddlebag. 6. Repeat steps 1-5 for the opposite saddlebag

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HARLEY DAVIDSON TRUNK MOUNT FLAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Installation Water may enter Tour-Paks/saddlebags with flag mast installed during inclement weather. Attaching a flag mast to a Tour-Pak or saddlebag without wear pads in place may result in damage to the Tour-Pak or saddlebag exterior. Periodically check to ensure the flag mast remains in contact with wear pads. 1. See Figure 1. Remove adhesive backing from wear pad and place on area where mast base will hit the painted portion of the Tour-Pak and/or saddlebag. Attach flag mast to Tour-Pak or saddlebag as shown. Attaching flag mast to Tour-Pak or saddlebag without rubber pads in place may result in damage to exterior of Tour-Pak or saddlebag. 2. Cut the self adhesive rubber pad in half. Remove the backing from the rubber pads and place on the inside of the Tour-Pak or saddlebags on each side of the flag mast as shown. CAUTION CAUTION CAUTION INSTRUCTIONS -J01143 REV. 11-20-01 TRUNK MOUNT FLAG KITS ® Kit Numbers 94612-98, 94617-98, 94618-98, 94626-98 Figure 1. Flag mast installed on Tour-Pak Place wear pad on area where mast base will hit the painted portion of the Tour-Pak and/or saddlebag i01121 Figure 2. Rubber pads installed on interior of Tour-Pak

HARLEY DAVIDSON CHROME SADDLEBAG COVER WINGTIP TRIM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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Installation NOTE The following procedures can be performed with the saddlebags on or off of the motorcycle, and the covers on or off of the saddlebags. Figures show saddlebag covers removed. 1. Open the saddlebags and remove all loose contents. 2. Thoroughly clean the left and right saddlebag covers, and let them dry completely. 3. See Figure 2 for your saddlebag material. Position a straightedge against the check strap mounting posts of one of the covers, and mark or scribe a guide line along the straightedge as shown. NOTE When applying the templates in the following steps, make sure the templates are aligned as instructed, and the respective “LEFTSIDE” or “RIGHTSIDE” lettering is clearly readable when applied to the applicable (left or right side) cover. The templates are designed to be easily removed from the first cover and re-applied to the remaining cover When applying the templates, ensure that each template is correctly positioned BEFORE drilling the first hole

HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION (2000 THROUGH 2002) Refer to the instructions included with kit 53388-03 for installation on 2000 through 2002 models. INSTALLATION (2003 AND LATER) NOTE To keep the fender aligned, completely install the sideplate on one side of the motorcycle before proceeding to the second side. The sissy bar should be installed last. 1. For models equipped with saddlebags: a. Remove the saddlebag, and retain the mounting hardware for later reinstallation. b. See Figure 1. Remove the bolt (A) and washer (4) that secures the rear fender to the fender brace. Discard the bolt and washer. Remove and retain the two saddlebag mounting studs (C) and nut plate (D) for later use. For models NOT equipped with saddlebags: a. See Figure 1. Remove the two rearmost bolts (A), washers (4) and nut plate that secure the rear fender to the fender brace. Discard the bolts and washers. b. Remove the bolt (B) and washer (4) that secure the fender and brace to the frame. Discard the bolt and washer. 2. See Figure 1. Position the correct sideplate to the outside of the fender brace. 3. With saddlebags: Apply LOCTITE 243 (blue) to the 3/8- 16 threads of the saddlebag mounting studs (C) and reinstall the studs through the sideplate, fender brace, frame and fender, and thread into the stock nut plates (D). Install one chrome 3/8-16 screw (3) and chrome washer (4) from the kit through the rear hole in the sideplate, fender brace and fender, and thread into the stock nut plate (D). Without saddlebags: Install three chrome 3/8-16 screws (3) and chrome washers (4) from the kit through the holes in the side plate, fender brace and fender, and thread into the stock nut plates (D). 4. Repeat steps 1-3 for the opposite side. 5. Install a sissy bar (not included in the kit) into the side- plates. Apply LOCTITE 262 (red) to the threads of the chrome 1/4-20 capscrews (5) and insert them into the sideplate holes. Tighten to 8-10 ft-lbs (11-14 Nm) . 6. Tighten the bolts (3) and/or saddlebag mounting studs to 21-27 ft-lbs (28.5-36.6 Nm) . 7. Reinstall the saddlebags