Harley- Davidson FX/ FL Big Twin 1965-1984 Two-Piece Seat Mounting Suggestions

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Filed Under (Harley Davidson) by admin on 15-04-2012

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Stock One-Piece Seat Removal Steps 1. Remove rear fender screw located behind the passenger seat and set aside. The stock rear fender screw will be used to attach your new Mustang Two-Piece Seat. 2. Slide seat back and up. Mounting of Mustang Solo & Passenger Seat 1. Remove two screws from back of Mustang solo seat. 2. Align two chrome tabs located at the front of the passenger seat with the mounting holes in back of solo. 3. Screw rear seat and solo together. 4. Slide solo front forks under frame. 5. Align chrome rear tab located at back of passenger seat with stock hole in fender. 6. Secure in place with stock fender screw to complete the installation process. Note: Use of side brackets optional and would use the rubber expansion plugs, threaded inserts, and bolts used for a solo only installation.

HARLEY DAVIDSON FORK MOUNTING KIT INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 10-04-2012

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1. Insert two additional screws into the rear of the extrusion of the light head. See instruction sheet packaged with light head for details. 2. See figure 1. Secure the mounting brackets to the directional Cuda TriOptic light head using the #8-32 KEPS nuts and screws supplied with this kit and light heads. Ensure that drain holes in the light head will be pointing down when installed on the motorcycle. Refer to instructions packaged with light head for details. 3. See figure 2. Remove and retain the top screw from the fork as shown. Attach the assembled bracket to the fork using the previously removed screw and hand tighten the screw. 4. See figure 3. Remove and retain the bottom screw. Rotate the bracket assembly to align with the bottom hole. Replace the previously removed screw. Tighten all hard he Model 350213-03 is a kit for mounting Cuda TriOptic light heads 351012 & 351023 devices to the side of the forks on a Harley Davidson motorcycle. This kit uses hardware supplied with Cuda TriOptic light heads. B. UNPACKING. After unpacking the kit, inspect it for damage that may have occurred in transit. If the unit has been damaged, do not attempt to install or operate it. File a claim with the carrier, stating the extent of damage. Carefully check all envelopes, shipping labels, and tags before removing or destroying them. Ensure that the parts listed in the KIT CONTENTS LIST are included in the package.

Harley-Davidson FXWG, FXST (all except FXSTS), FXDWG Light Bar INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2012

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1. Put a pair of male and female clamp halves together just above the lower triple-clamp. Squeeze the ends of the clamp together with a pair of pliers. Diagram A. 2. Have an assistant position the Light Bar Assembly so the lightbar bracket is to the outside of the clamp assembly. Make sure the wires from the Light Bar Assembly are below the lower triple clamp. Diagram B. 3. Insert a Screw through the clamp and Light Bar Assembly mounting bracket and thread on an Acorn Nut. 4. Hold the Light Bar Assembly in place in front of the lower triple clamp, assemble and attach the remaining clamps. 5. With all four clamp assemblies in place, tighten the clamping screws and nuts to 15 ft. lbs. (21 Nm). Refer to the service manual to gain access to the wire harness inside the fuel tank tunnel or inside the frame backbone. Also, verify the appropriate color wires for hook-up of the passing lamps and turnsignals and running lights. Route the wires from the Light Bar Assembly, around the lower triple- clamp, and up to the frame backbone. Secure the wires so they cannot become pinched when turning the fork. A. The short black wires from the Light Bar Assembly connect to the wires powering the running lights. B. The short red wires from the Light Bar Assembly connect to the wires powering the turnsignals. C. The long blue wires from the Light Bar Assembly connect to the wire powering the headlight low beam. After the wires are connected, verify the operation of the passing lamps, running lights and turnsignals. Correct any connection problems before reassembling the motorcycle. Reinstall the fuel tank. Check all fasteners used during this installation for tightness

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Harley-Davidson 39mm Fork FXR, FXD, XL from 87 to Current, Light Bar N935 & N935E INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Remove Headlight from Headlight Shell (Screwdriver) set aside. 2. Disconnect Turnsignal wires behind or inside Headlight Shell. 3. Unbolt Headlight Shell from Eyebrow (3/4″ Socket & Wrench). Let hang from wires. 4. Remove front Turnsignal Assemblies from motorcycle. 4a. If Turnsignals are mounted to the Handlebar use the 1/2″ Wrench. 4b. For fork mounted Turnsignals, 1996 to current, use the Torx Wrench 4c. For fork mounted Turnsignals 1987-92 use the 5/16 Hex Key Set turnsignals aside, they will not be reused. 5. Remove screw from Brake Hose Clamp and Clutch Cable Guide (Hex Key Wrench, 3/16″) located on the bottom of the lower Triple Clamp. Set aside, it will not be reused. 6 . Remove the Pinch Bolts from the lower Triple Clamp (Torx Wrench, 1993 to Current, or 5/16 Hex Key, 1987 to 92). Set aside, they will not be reused. INSTALLATION 1. Mount the Light Bar Assembly: A. Hold the Light Bar assembly up to the lower Triple Clamp, the center bracket will be below the Triple Clamp. B. Start the 1/4-20 x 3/4 Screw, with Washer, through the Brake Hose Clamp, clutch cable guide then the center bracket and into the threaded hole previously used for the Brake Hose Clamp. C. Position a Spacer between the Outer Brackets and the Triple Clamp and start the 3/8-16 x 2″ Hex Bolts through the Outer Bracket, then the Spacer and into the Pinch bolt location on the lower Triple Clamp. Do this on both sides of the lower Triple Clamp.

harley davidson CRUISE CONTROL KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 23-02-2012

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See Figure 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 5. Refer to the service manual, and follow the instructions to loosen the brake hand lever/master cylinder assembly and remove the right-side upper and lower switch housing sub-assemblies from the handlebar. It is not necessary to remove the throttle control grip. For FLHR models: Refer to the service manual. Disconnect the left-side handlebar MOLEX socket housing from the gray eight-way main harness pin housing [24B] inside the headlamp nacelle. Refer to the service manual to remove the clutch hand lever and left-side upper and lower switch housing subassemblies from the handlebar. 6. For ALL models: See Figure 2. The friction shoe (1) is a loose fit on the end of the tension adjuster screw (2). Make sure the shoe has been removed with the switch housing sub-assemblies, and is not lodged in the groove of the throttle control grip (4). 3 4 1 2 is06318 1. Friction shoe 2. Tension adjuster screw 3. Right-side lower switch housing 4. Throttle control grip Figure 2. Throttle Tension Adjuster Screw and Friction Shoe 7. See Figure 1. Verify that the 5/32-inch (4 mm) thick insert is in place between the brake lever and the lever bracket. Obtain the new right-side handlebar switch housing assembly (Item 4 or 5, depending on model) from the kit. Separate the upper and lower halves of the housing assembly. Refer to the service manual, and follow the instructions to install the switch housing assembly and brake hand lever/master cylinder assembly to the handlebar. 8. Route the right-side switch harness along the same path as the original harness (along the right handlebar). Connect the pin housing to the black socket housing disconnected in Step 3. 9. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Continue at Step 11. For FLHR models: Obtain the new left-side switch housing assembly (6) from the kit. Separate the upper and lower halves of the switch housing assembly. Refer to the service manual, and follow the instructions to install the left-side switch housing assembly and clutch hand lever assembly to the handlebar. 10. Route the left-side hand control harness along the same path as the original harness (along the left handlebar). Connect the pin housing to the gray socket housing disconnected in Step 5

2007 KTM 250 SX-F 450 SX-F INSTALLATION MANUAL

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Filed Under (KTM) by admin on 06-02-2012

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Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hot start lever If you pull the red hot start lever [2] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a “lean” fuel-air mixture of the type needed for hot starts. 2 1 A Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. OPERATION INSTRUMENTS »
Starter button (450 SX-F) Pushing the black starter button [3] will actuate the E-starter. ENGLISH 6 Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see “Maintenance”). Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open the filler cap: Turn the filler cap 45 ° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. OFF ON 1 A 2 3 ENGLISH 7 OPERATION INSTRUMENTS » Choke If you pull the choke button [1] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat” fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral is located between first and second gear. Kickstarter (250 SX-F) The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). Plug in stand The plug-in stand can be attached to the wheel spindle on the left side of the motorcycle

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Yamaha Royalstar Royal Star Tour Deluxe Speedo Healer Installation

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Filed Under (Yamaha) by admin on 07-01-2012

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he speed sensor is on the left side (looking from the back towards the front of the motorcycle). Just FYI, here is the speed sensor coming off of the drive shaft behind the left saddlebag. – 7/2 -The speed sensor connection for the Speedo Healer is behind this red cover. Take off the seat. There are two screws. One pointed out by the arrow and one on the opposite side. Also, remove the screw on the red cover. After removing the screw on the red cover, remove the cover by pulling it straight away from the bike. It is held on by 2 rubber grommets. – 7/3 -The arrow points to the speed sensor coupler. Pull the connection apart. There is a little tab holding the connector together that will need to be depressed in order to get it apart. – 7/4 -Hook the SH harness into the appropriate connectors. It only goes one way. The Yamaha plug and go kit works perfectly with no splicing required. Here is a close-up of the connection. – 7/5 -Run the cable up under the bar towards the battery and hook the wires up to the Speedo Healer unit. – 76 -The speedo healer fits nicely right behind the battery. You can barely see it next to the intercom. Note, none of the wires in this example have been secured yet. Put the red cover back on. Figure out the error that needs to be adjusted and make the adjustments to the Speed Healer per their instructions. Put the seat back on and you’re good to go. Be sure to verify that your adjustment was correct before believing your speedometer to be accurate. With the right adjustment, it will be, but don’t wait for a cop to tell you that you miscalculated! The electronic cruise control was not affected by the installation of this unit. I ended up setting mine to -7.5% after chasing my wife’s ’03 Vue for a couple of times. I ended up reading 59mph to her 60mph (previously it read 65mph to her 60mph) which is right where I wanted it since her speedometer reads a little fast, too. My back tire is about halfway worn. Your adjustment may vary

HARLEY DAVIDSON BILLET SHIFTER PEG INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Kit Contents See Figure 1 and Table 1. INSTALLATION 1. Remove and discard the original equipment shifter peg. If needed, use a heat gun to apply heat to the shift lever and shifter peg threads to aid in peg removal. 2. See Figure 1. Insert the screw through the peg into the shift lever. Tighten the screw to 11-15 ft-lbs (15-20 Nm) . -J04379 1 of 2 SERVICE PARTS 1 2 B C 1 2 3 1 2 3 A is05070 Figure 1. Service Parts: Billet Shifter Peg Kits Table 1. Service Parts Table Part Number Description (Quantity) Item A – Kit 49256-99 3396 Screw, 5/16-24 x 2.25 socket head cap, lockpatch 1 Not Sold Separately Shifter peg 2 11306 Rubber (4) 3 B – Kit 49254-99 3396 Screw, 5/16-24 x 2.25 socket head cap, lockpatch 1 Not Sold Separately Shifter peg 2 11306 Rubber (4) 3 C – Kit 49238-98 3396 Screw, 5/16-24 x 2.25 socket head cap, lockpatch 1 Not Sold Separately Shifter peg 2

HARLEY DAVIDSON BADLANDER SEAT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-04-2011

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Installation When performing the following procedures, be careful not to scratch painted surfaces (fender, tank, etc.) with metal tabs on seat. 1. Remove existing seat strap from motorcycle. Retain all hardware. Discard seat strap. 2. Remove existing seat from motorcycle by removing Phillips head screw with lockwasher, and nylon washer from rear fender mounting bracket. Retain all hardware except discard nylon washer. 3. Disengage seat from frame tab at front of seat. 4. Install new seat onto motorcycle, making sure bracket on front of seat fully engages into seat mounting tab on frame. NOTE On rear fenders of 1997-1999 models, a captive nut secured with a plastic retention washer has replaced the previously used weld nut. Do not remove the plastic retention washer unless the captive nut is damaged and must be replaced. The plastic retention washer also prevents seat bracket from contacting paint on fender. Therefore, no nylon washer is required between bracket and fender on 1997-1999 models. 5. On pre- 1997 models , secure seat onto rear fender with original screw and lockwasher and place guide washer (1) between seat bracket and rear fender. 5a. On 1997-1999 models , secure seat onto rear fender with original screw and lockwasher. After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation, resulting in loss of control of vehicle and death or serious injury. 6. Use original hardware to install new seat strap (2) in same location as old seat strap. On FXSTC, Softail Custom models, fasten seat strap to fender support

HARLEY DAVIDSON DETACHABLE PASSENGER BACKREST LUGGAGE RACK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-04-2011

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INSTALLATION 1. See Figure 1. If not already assembled in package, assemble V-logo onto each mounting bracket (2 and 3) using #4-40 thread-forming screws (5). 2. Position luggage rack between sideplates of detachable passenger backrest assembly. 3. Thread button head screws (7) through washers (6), then through holes in luggage rack support and passenger backrest sideplate and into mounting brackets (2 and 3). Apply LOCTITE 243 (Blue) to screws (7) before installation. Finger tighten. 4. Tighten button head screws to 19 ft-lbs (26 Nm) . NOTE The backrest shown in Figure 1 is not included in this kit and must be purchased separately. -J01851 1 of 2 SERVICE PARTS 8 1 7 6 3 2 4 5 is04290 Figure 1. Service Parts: Detachable Passenger Backrest Luggage Rack Kit Table 1. Service Parts Table Part Number Description (Quantity) Item Part Number Description (Quantity) Item 2711 Screw, #4-40 thread-forming, steel, zinc plated (4) 5 Not sold separately Passenger backrest rack kit 1 94066-90T Washer, chrome (4) 6 53046-00 Bracket, mounting, right side (includes items 4 and 5) 2 94392-92T Button head screw, hex socket, chrome (4) 7 53045-00 Bracket, mounting, left side (includes items 4 and 5) 3 Not Sold Separately Warning label 8 Not sold separately V-logo (2) 4