HARLEY DAVIDSON BILLET CLUTCH CABLE ADJUSTER COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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INSTALLATION 1. Dyna Models: Remove the plastic clip that fastens the clutch cable to the frame downtube just below the clutch cable adjuster and boot. Leave the clip above the adjuster in place. Softail Models: Remove the plastic clip and screw that attaches the clutch cable to the frame downtube just above the clutch cable adjuster and boot. 2. ALL Models: See Figure 1. Cut the original rubber boot (B) from the clutch cable (A). Make sure that the clutch cable covering is not cut or damaged. 3. Obtain the two halves of the clutch cable adjuster cover (items 1 and 2) and two cushions (8). Peel the paper backing from one cushion (8), and center the cushion on the inside of one cover half. Repeat for the other cushion and cover half. 4. Obtain the two screws (7) from the kit. Position the cover halves on each side of the cable adjuster, and align the screw holes at each end. Place a drop of Loctite 243 – Blue on the screw threads, and fasten the cover halves with the two screws. Tighten to 21 in-lbs (2.4 Nm)

HARLEY DAVIDSON ROAD KING FORK LOCK COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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INSTALLATION 1. See Figure 1. At the handlebar cover, carefully pry under black plastic area of the lock plate and remove the lock plate. Discard the lock plate. 1 2 is00632 1. Lock plate 2. Pry location Figure 1. Remove Fork Lock Plate 2. See Figure 2. Remove and discard the two Phillips cover screws beneath the lock plate. 1 is00633 1. Cover screws Figure 2. Remove Cover Screws 3. See Figure 3. Obtain the rubber gasket (4) and flat spring (3) from kit. Place the gasket over the mounting location and align the screw holes. Place the flat spring over the gasket and align the screw holes. 4. See Figure 3. Obtain two chrome socket head screws (2) from kit. Place the cover assembly (1) into position, and install screws to secure cover

HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (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 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

HARLEY DAVIDSON FL BACKREST PAD KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. See Figure 1. If necessary, cut the plastic rain seal away from the three pre-cut screw holes (D) in the backrest pad (1) to prevent the plastic from catching in the threads. 2. On motorcycles with Detachable Sissy Bar Upright installed: a. Install three long spacers (3) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the sissy bar upright (A). On motorcycles with Detachable Short Passenger Sissy Bar Upright installed: a. Install three long spacers (3) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the detachable short passenger sissy bar upright (B), inserting the three spacers through the slots in the sissy bar tabs (C). On motorcycles with Luggage installed: a. Install three short spacers (4) into the pre-cut holes in the backrest pad. b. Position the backrest pad against the upright (A). 3. Place the mounting bracket (2) against the spacers, so that the holes of the mounting bracket align with the spacers. NOTE To avoid misalignment and cross threading of the screws, start all three screws into the backrest before tightening. 4. Insert a screw (5) from the kit through one of the spacers, and carefully thread it 4-5 turns into the mating hole in the backrest pad. Repeat with the other two screws. DO NOT tighten a screw until all three screws have been started. NOTE Spacers must seat squarely against the mounting bracket. 5. Once all three screws have been carefully started into the three holes of the backrest pad, tighten the screws to 7-10 in-lbs (0.8-1.1 Nm)

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HARLEY DAVIDSON SCREAMIN' EAGLE VENTILATOR PERFORMANCE AIR CLEANER INSTALLATION MANUAL

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

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the main fuse. Refer to the service manual. 2. Remove the existing air cleaner backplate. Refer to the service manual. Save the original equipment (OE) button head screw that secures the air cleaner cover. Discard the remaining parts. 3. Remove the fuel tank. Refer to the service manual. 4. See Figure 1. Remove and discard the induction module support bracket. is05912 Figure 1. Remove Induction Module Support Bracket INSTALLATION Air Cleaner Installation Use only supplied air cleaner cover. Use of another air cleaner cover could cause element failure and detachment of the air cleaner cover, which could distract the rider and result in death or serious injury. (00596b) NOTE When servicing the air cleaner, apply Loctite 243 – Blue to the threads of all fasteners. 1. See Figure 3. Install two O-rings (1) from the kit in the grooves around the breather bolt holes on the induction module side of the backplate assembly (2). Install the remaining two O-rings in the grooves in the underside of the heads of the breather bolts (5). 2. Remove the liner from the adhesive backing of the gasket (3). Carefully position the adhesive side of the gasket to the backplate, aligning to the equally spaced screw holes, and press the gasket firmly into place. 3. Insert new breather bolts (5) through the backplate. 4. Apply Loctite 243 – Blue to the breather bolt threads and the mating tapped holes in the cylinder head. 5. Thread the bolts into the cylinder head, but do not tighten. 6. Thread the air cleaner mounting studs (4) all the way through the backplate (2) until the screw threads are captured in the induction module. Do not tighten completely at this time. 7. Alternately tighten the two breather bolts to 120-144 in- lbs (13.6-16.3 Nm) . 8. Tighten the three air cleaner studs to 55-60 in-lbs (6.2- 6.8 Nm) . 9. Install the fuel tank. Air Cleaner Element and Cover Installation

HARLEY DAVIDSON BACKREST PAD KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. With your hand, feel through the backrest material to locate the mounting holes. 2. Carefully cut the clear plastic rain seal away from the screw holes in the backrest pad to prevent the plastic from catching in the screw threads. 3. See Figure 1. Secure the backrest to the sissy bar upright using the screws from the kit. 4. Tighten the screws to 35-60 in-lbs. (4-7 Nm) . SERVICE PARTS 1 2 is00400 Figure 1. Service Parts: FL Backrest Pad Kits Table 1. Service Parts Part Number Description (Quantity) Item Not Sold Separately Backrest pad 1 1000 Screw, Pan head (2

HARLEY DAVIDSON SADDLEBAG RAIL BRACKET KIT INSTALLATION ISNTRUCTIONS

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

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Installation 1. See Figure 1. Remove two stock screws and nuts from one side of the saddlebag rail assembly. 2. See the Service Parts illustration. Insert two screws (3) through the screw holes from the opposite direction as the stock screws removed from the rail bracket in Step 1. 3. Place a spacer (2) on the outboard screw. 4. Place a Saddlebag Rail Bracket over the rail assembly. Position the bracket with the square notch on the inboard side of the rail assembly. 5. Fasten the screws from step 2 into the Saddlebag Rail Bracket. Torque the fasteners to 10 ft-lbs (13.5 Nm). 6. Repeat steps 1 – 5 for the saddlebag rail assembly on the other side of the motorcycle

HARLEY DAVIDSON SPORTSTER FORWARD CONTROL KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 6. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is03193 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw (2) Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is03194 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove the exhaust to access the brake rod. Follow the instructions in the appropriate Service Manual. 3. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod INSTALLATION Install Forward Control Brake Pedal and Footrest Assemblies 1. See Figure 5 and Figure 6. At the lower front of the right frame downtube, remove the two screws securing the J- clip (B) to the frame. Discard the screws but save J-clip for installation. 2. Install the other end of the brake rod into the brake pedal assembly (8). Tighten to 84-144 in-lbs (9.5-16.3 Nm) . NOTE Assemble the brake pedal and footpeg clevis onto the footrest support bracket (as described in the next step) prior to mounting the support bracket to the frame. This will allow easier installation of the footrest mount clevis retaining ring (installed to grooved end of footrest mount clevis). 3. Slide the brake pedal (8) onto footrest mount clevis (11) then slide clevis into footrest/brake pedal support bracket (9). Align hole in the clevis with hole in the support bracket and install screw (6). Tighten the screw to 18-22 ft-lbs (24.4-29.9 Nm) . 4. Install the footrest mount clevis retaining ring (18) to the groove at the end of the footpeg clevis. 5. Position the J-clip (from Step 1) against the frame aligning the mounting holes. Mount the footrest/brake pedal support bracket (9) and J-clip to frame using the new screws (3). Tighten the bracket to 45-50 ft-lbs (61.1- 67.9 Nm) . 6. Obtain the brake rod (15) from kit and thread one end into the master cylinder bell crank. Tighten to 120-180 in-lbs (13.6-20.3 Nm) . 7. Install footpeg on clevis with spring washer (2). Make sure spring washer is positioned inside clevis (11) with the square edge toward the inside. Align holes and push clevis pin (7) from top down through hole in clevis. Secure clevis pin using the new retaining ring (17). 8. Install exhaust following the instructions in the appropriate Service Manual. Install Forward Control Shift Lever Assembly

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HARLEY DAVIDSON HEADLAMP VISORS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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These kits fit all motorcycle models equipped with 7-inch headlamps. These kits do not fit models equipped with Headlamp Trim Ring Kits part numbers 69626-99, 69627-99, 69733-05, and 69734-05.INSTALLATION 1. See Figure 1. Remove original equipment bottom screw (1) and trim ring (2). Save parts for later use. 2. See Figure 3 and Table 2. Install headlamp visor (1) from kit and trim ring (A) previously removed. NOTE Make sure the screw holes in the trim ring and the headlamp assembly are aligned as it is difficult to rotate the trim ring when it is fully seated. 3. Loosely install bottom screw (C) previously removed on trim ring. Do not tighten at this time. 4. See Figure 2. Visually check to ensure that rubber bumpers on inside face of headlamp housing are not caught. 5. Snug bottom screw on trim ring and headlamp visor. 6. Rotate visor from side to side around headlamp assembly (B) if ring is caught on face of headlamp. 7. Push down on top of trim ring and push in on the bottom of the trim ring to fully seat the headlamp visor. 8. While tightening the bottom screw, continue to maintain inward pressure on bottom of headlamp visor, until screw is tight and trim ring is fully seated. 3 2 1 is00923 1. Bottom screw 2. Trim ring 3. Headlamp Figure 1. Original Equipment Headlamp Trim Ring

HARLEY DAVIDSON SCREAMIN' EAGLE "HEAVY BREATHER" PERFORMANCE AIR CLEANER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 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) 1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) Original Equipment (OE) Air Cleaner Removal For carbureted models: Refer to the service manual and check the warm-slow idle speed adjustment before removing the OE air cleaner backplate. For EFI (fuel-injected) models: Have a Harley-Davidson dealer recalibrate the ECM prior to air cleaner installation. 2. Remove the air cleaner backplate following the instructions in the service manual. Retain the two breather screws (A) removed from the backplate (see Figure 1). The remaining parts can be discarded. 3. See Figure 1. Remove and discard induction module bracket (B). “Heavy Breather” Air Cleaner Installation NOTE When servicing the air cleaner, apply Loctite 243 (blue) to all threaded fasteners (both male and female threads). 4. Install the new O-rings (4) in the grooves around the breather screw holes on the carburetor or induction module side of the backplate (1 or 2)