HARLEY DAVIDSON FLHRS SADDLEBAG LOCK SET KIT INSTALLATION MANUAL

0

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

download
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.

Incoming search terms:

HARLEY DAVIDSON BILLET CLUTCH CABLE ADJUSTER COVER KIT INSTALLATION MANUAL

0

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

download
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)

ARLEY DAVIDSON FXDL INSTRUMENT CONSOLE INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 28-03-2011

download
Installation CONSOLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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. Remove seat and disconnect battery, negative cable first. 2. Remove fuel tank mounting bolts. Lift fuel tank far enough to remove the speedometer sensor cable from the mounting clips under the tank. 3. See Figure 1. The 3-place speedometer sensor connector is located on the frame beneath the seat. Remove from t-stud and disconnect the connector. Cut the cable strap that holds sensor wires to right rear frame tube. 4. Remove instrument console mounting screws and lift console from tank. SPEEDOMETER REMOVAL 1. See Figure 2. Disconnect 8-place connector under console. Remove assembly from tank. 2. Cut remaining cable straps holding wires to instrument mounting bracket. Remove screws holding bracket to back of instruments. Remove bracket. 3. See Figure 3. Remove nuts and washers from terminal studs (1, 2 and 3). Remove wires from studs. 4. Unscrew the rubber function switch cover that protrudes from the left side of the console. Remove the function switch (3). 5. Gently push on bottom of speedometer and remove speedometer from top side of console. Remove gasket from speedometer. TACHOMETER REMOVAL 1. See Figure 3. Remove nuts and washers from terminal studs (3, 4 and 5). Remove wires from studs. 1 WARNING 1 WARNING

HARLEY DAVIDSON V-ROD CHROME UPPER SIDE COVERS INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 23-03-2011

download
INSTALLATION 1. See Figure 1. Remove and discard screw (1) at upper side corner of side cover (2). 1 2 3 is01410 1. Screw 2. Side cover 3. Frame Figure 1. Existing Side Cover Removal (right side shown) 2. Lift up slightly to remove side cover from frame (3). Discard side cover. 3. Repeat for left hand side cover. 4. See Figure 2 and Table 1. Place rubber mounts (1) (installed on covers) over tabs in frame and use screws (2) from kit to fasten side covers (3) and (4). 5. Tighten side cover screws to 11-17 Nm (98-150 in-lbs ). 2 4 3 1 1 is01411 Figure 2. V-Rod Chrome Upper Side Covers Table 1. V-Rod Chrome Upper Side Covers Part Number Description (Quantity) Item 11524 Rubber mount (4) 1 Not Sold Separately Screw (2) 2 Not Sold Separately Side cover, right (chrome) 3 Not Sold Separately Side cover, left (chrome

HARLEY DAVIDSON TOURING CHROME DEBRIS DEFLECTOR COVER INSTALLATION MANUAL

0

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

download
This kit is designed for installation on all 1997 and later Touring Model Motorcycles. NOTE The chrome debris deflector cover mounts over the existing deflector. Kit Contents Qty Description 1 Cover, debris deflector, chrome Installation 1. Remove left side saddlebag. 2. Remove the stock debris deflectors two rear screws. Save screws for installation. 3. Slide the debris deflector cover over the stock debris deflector making sure the lower edge of the deflector is inserted into the edge clip of the cover. 4. Install the two screws saved from Step 2. Tighten securely. 5. Make sure that debris deflector cover does not contact the drive belt, tire or wheel. If necessary, loosen the mounting screws and reposition for clearance

HARLEY DAVIDSON PASSENGER PILLION UPRIGHT KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 21-03-2011

download
INSTALLATION 1. See Figure 1. Install the luggage rack following the instructions in the kit. 2. Insert the ends of the upright (2) into the pillion (3) (purchased separately) and align the holes in the upright with the holes in the pillion. 3. See Figure 2. Apply LOCTITE 243 to screws (2) and install with washers. Tighten screws to 84-108 in-lbs (9.5-12.2 Nm) . 4. Install the pillion and upright assembly onto the luggage rack following the instructions in the detachable passenger pillion kit. 1 2 3 4 is05507 1. Passenger backrest pad (optional) 2. Passenger pillion upright 3. Detachable pillion (purchased separately) 4. Luggage rack (purchased separately) Figure 1. Upright SERVICE PARTS 3 1 2 is05508 Figure 2. Service Parts: Passenger Pillion Upright Table 1. Service Parts: Passenger Pillion Upright Kit Part Number Description (Quantity) Item Not Sold Separately Passenger pillion upright 1 3787 Screw, 1/4-20 x 0.75 inch (4) 2 6703

HARLEY DAVIDSON DYNA GLIDE FRONT SPOILER KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 20-03-2011

download
INSTALLATION Assemble Front Spoiler and Bracket 1. See Figure 1. Position front spoiler as shown and orient bracket (1) with the angled end toward the top of the spoiler. 2. Install two screws (2) and washers (3) to secure upper part of bracket to spoiler. Tighten to 15-20 in-lbs (1.7-2.3 Nm). 1 3 2 2 3 is04350 1. Bracket 2. Screw (2) 3. Washer (2) Figure 1. Assemble Top of Bracket to Spoiler 2 1 3 1 2 is04351 1. Screw (2) 2. Washer (2) 3. Bracket Figure 2. Assemble Bottom of Bracket to Spoiler 3. See Figure 2. From the bottom of the spoiler, loosely install screws (1) and washers (2) into formed nut on bracket (3). This will allow for adjustments (if necessary) after installing the spoiler to the lower frame crossmember. Install Front Spoiler Assembly NOTES When removing engine mount screws, use a small bottle jack or similar device (placed directly under the crankcase) to hold the engine in position and maintain hole alignment between the front engine mounts and holes in the lower frame cross- member. If this safety measure is not followed, the engine may shift slightly making it difficult to align the front engine mount and new screws. 1. See Figure 3. Remove and discard existing bottom screw (1), lockwasher (2), and washer (3) from engine mount (4) at lower frame crossmember. 2. See Figure 4. Thread screw (1) and lockwasher (2) into bottom hole of lower frame crossmember until about 5/8 in. (3) remains visible. 3. Remove and discard existing top hardware (screw, lock- washer, and washer) (4) from engine mount (5).

HARLEY DAVIDSON BLADE FRONT WHEEL KITS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 20-03-2011

download
INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. 2. See Figure 2. Install valve stem assembly (L) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. • For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. • For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. • For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08: • Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side. • For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. 4. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. 5. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

Incoming search terms:

HARLEY DAVIDSON TOUR-PAK SPOILER LIGHT KIT INSTALLATION MANUAL

0

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

download
Installation 1. If the motorcycle was previously equipped with a Tour-Pak Spoiler Light, disconnect the light wires from the motorcycle. 2. Remove the Tour-Pak Spoiler from the Tour-Pak and disassemble original light or chrome trim (as equipped). Save the original mounting hardware for later installation. 3. Attach light assembly to spoiler using 10-24 x 7/8 in. long screws. 4. See Figure 1. Route light wires through 3/8 in. hole in Tour-Pak lid. Attach spoiler to Tour-Pak lid using original hardware removed in step 2. 5. See Figure 1. Attach the wires to the inside of the Tour- Pak with adhesive backed clips as shown. Route wires out front left corner of Tour-Pak bottom and support wires inside Tour-Pak bottom with the remaining adhesive backed clips as needed. Wires will exit out the bottom of the Tour-Pak through the antenna cable grommet. NOTE On Chopped Tour-Paks drill a 3/8 in. hole in the front left corner of the Tour-Pak bottom. Route the spoiler light wires through this hole for connection to the main motorcycle wiring. 6. On 1994 and later models, proceed to step 7 for wire connection instructions. On 1993 and earlier models, go to step 11 for wire connection instructions. WIRING INSTRUCTIONS FOR 1994 AND LATER MODELS 7. Remove the seat and locate the accessory circuit connector. Route the light wires along the frame and secure with cable straps from kit. 8. Refer to the Deutsch connector section in a 1994 or later FLT Service Manual and assemble the spoiler wires into the socket connector half supplied with the LED assembly. The wire terminals shall be inserted in the connector half as follows: WIRE COLOR CODECONNECTOR CAVITY Blue 1 Red/yellow 2 Sealing plug 3 Black 4 9. Remove the plug from the accessory connector located under the seat (connector number [4A] in wiring diagram in Service Manual). Connect wire from spoiler. Turn on ignition switch and test the spoiler light operation with taillight and brake light. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact the ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 10. Reattach battery

Incoming search terms:

HARLEY DAVIDSON FRONT AND REAR FENDER TIP TRIM INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 13-03-2011

download
Installation GENERAL The original equipment (stock) fender tip lamp assemblies must be removed and the wire(s) must be unplugged or removed as specified in the following instructions. FRONT FENDER TIP REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1994 AND LATER FLT MODELS 1. Refer to the applicable FLT Service Manual. Remove headlamp assembly with housing. 2. Locate the 3-place connector [32 in wiring diagram] through which 12vdc and electrical ground are connected to the fender tip lamp assembly. The connector locations are as follows: FLTC Ultra: Under fuse and circuit breaker block FLHT/C/C-U: On bottom of left outer fairing bracket FLHR: On left front above air suspension valve NOTE Before disassembling the connector in the next step, refer to the applicable wiring diagram and check wire colors and connections to assure that connector [32] has been located. 3. Refer to the “DEUTSCH ELECTRICAL CONNECTOR” section in the FLT Service Manual and remove the leads, connected to the fender tip lamp, from the socket half, connector [32B]. 4. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 5. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wires connected to lamp assembly. 6. Reach under left side of fender and gently pull wires through rear hole in left side of fender and then through clips on left side of fender and finally through front hole and out of trim strip. REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1993 AND EARLIER FLT MODELS, FLSTC AND FLSTN 1. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 2. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wire connected to lamp assembly. 3. Unplug wire connector located about 3 in. from lamp assembly. Cover the socket half of connector (connected to motorcycle wiring) with electrical tape. INSTALLING FRONT FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in fender and guide outer ends of fender tip trim into trim strips on sides of fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs . REAR FENDER TIP REMOVAL OF STOCK REAR FENDER TIP LAMP ON ALL MODELS Follow steps 1 through 3 given above for “1993 AND EARLIER FLT MODELS, FLSTC & FLSTN” INSTALLING REAR FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in rear fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs

Incoming search terms:

Incoming search terms: