HONDA GL1800 Windshield Panel Light Installation Manual

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Filed Under (Honda) by admin on 04-03-2011

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Note: Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Remove the following per manual instructions. A. Rear view Mirror (Figure 1) -Remove the meter panel. -Remove the trim clip, screw and mirror cover. -Remove the three screws, bracket and mirror. -Disconnect the turn signal light 3P connector. B. Windshield Garnish (Figure 2) -Remove the left and right rearview mirrors per above instructions. -Remove the two bolts, washers and mounting rubbers. -Release the four bosses from the grommets and remove the windshield garnish. 3. Line up the windshield panel light in the windshield vent opening as shown in figure 3. Mark spots for final application. 4. Remove tape backing and carefully apply light at pre-marked spots. 5. Splice wires to mirror light as follows: a. Black to Ground b. Red to Orange/white wire to left mirror. 6. Reassemble all parts removed

HONDA GL1800 WINDSHIELD VENT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 04-03-2011

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NOTE: CAUTION is required when drilling and cutting to prevent cracking and scratching the windshield material. A professional glass service is highly recommended for this purpose. Should you attempt to install the windshield vent on your own, follow the instructions below. Add On Inc. will not be held liable or responsible for any damage to the windshield. 1. Place bike on center stand. 2. Cut out the template provided and center on windshield approximately 2 ¾” above the tint line. Tape the template to windshield using masking tape. Use enough masking tape to cover the area to be cut out to prevent scratching. If using a power sabre saw to cut the pattern out, put masking tape on the foot to prevent scratching the windshield. Drill the four corners using a sharp power sabre saw, electric drill (using a 7/16″ drill bit), and or hack saw. 3. Smooth cut edges with sand paper. 3. Install the vent. The two pieces will snap together in the windshield. Use chrome screws provided to secure vent in the windshield.

HARLEY DAVIDSON SPORT WIND DEFLECTOR AND WINDSHIELD KITS INSTALLATION MANUAL

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

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HEADLAMP VISOR INSTALLATION (2004 ONLY) 1 2 is 01467 1. Headlamp 2. Headlamp bracket mounting screws Figure 1. Remove Headlamp Mounting Screws (Left Side Shown) 1. See Figure 1. While holding the headlamp (1), remove the left and right headlamp bracket mounting screws (2). 2. See Figure 5. Obtain the headlamp visor (2) from the kit. 3. See Figure 2. Orient the headlamp visor (1) between the headlamp and headlamp mounting bracket (2) and reinstall the headlamp bracket mounting screws (3) securing the visor and headlamp to the headlamp mounting bracket. 4. Refer to the Service Manual and adjust the headlamp for the correct angle. 2 1 3 is01468 1. Headlamp visor 2. Headlamp mounting bracket 3. Headlamp mounting bracket screw Figure 2. Install Visor Between Headlamp and Mounting Bracket (Left Side Shown) 1 2 3 is03212 1. “RT” or “LFT” marking 2. Hinge-pin head faces up 3. Clamp post socket faces outward Figure 3. Fork Tube Clamp and Post Identification (Right-Side Clamp Shown) WINDSHIELD INSTALLATION 1. See Figure 5. Obtain one of the lower mount kits from the windshield kit carton. Identify the fork tube clamp for right- side (RT) or left-side (LFT) installation as indicated in Figure 3. NOTE The lower grommets (4) have been pre-installed into the Lexan® windshield. 2. Insert the rounded end of the post into the socket in the fork-tube clamp, oriented as shown in Figure 5. Lining up the hole in the end of the post with the hole in the clamp. With a 3 mm hex key, fasten the post to the clamp with the flat-head screw (16) from the kit, and tighten to 6.8 Nm (60 in-lbs ). 3. Place the clamp around the correct-side fork tube with the hinge-pin head facing up. Insert the two longer screws (15) from the lower mount kit through the counterbored holes in the outboard side of the clamp, and thread the screws part-way into the tapped holes in the inboard half. 4. Position the clamp so the top surface is approximately 6 to 13 mm (1/4 to 1/2 inch) below the upper triple-tree, and the hinge pin is straight forward. With a 4 mm hex key, tighten the screws just enough to hold the clamp in posi- tion. 5. Obtain the remaining lower mount kit and repeat Steps 2 through 4 to install the clamp to the opposite fork tube. 6. Obtain the upper mount kit from the windshield kit carton. NOTE The upper grommets (4), socket assemblies (3), windshield mount caps (6) and 5 mm screws (9) have been pre-installed into the windshield. 7. Place one of the handlebar clamps (5) onto one side of the handlebar, in the straight section between the riser and the handlebar controls, oriented as shown in Figure 4. NOTE Temporarily disengage the switch harness retainer from the handlebar to allow installation of the clamp.

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

HARLEY DAVIDSON STREET STALKER FRONT FENDER KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. If model has mechanical speedometer drive, remove cable from fender bracket. Disconnect speedometer cable from the speedometer head. 2. Remove front wheel according to the Service Manual. 3. Disconnect and remove fender tip light power wire. 4. Remove hardware that holds fender in place and remove fender. INSTALLATION 1. See Figure 1 and Table 1. For each support bracket (4), remove backing from one side of tape (3), and affix tape to support bracket, carefully matching the contours of the bracket and tape for proper fit. 2. Remove backing from tape and place support brackets into position on the inside of fender (one on each side), aligning the mounting holes in each bracket with the holes in the fender. The tape side will affix to the inside of the fender. 3. Carefully place fender in position and secure fender with screws and flanged locknuts in kit. Tighten hardware to 12 ft-lbs (16.27 Nm). 4. Install front wheel according to the Service Manual. 5. Install mechanical speedometer cable. Use tie wrap (10081) to secure

HARLEY DAVIDSON AILERON HAND GRIPS REMOVAL AND INSTALLATION MANUAL

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

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LEFT GRIP REMOVAL AND INSTALLATION 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp, and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left hand grip if so equipped. With “glueless” grip: Remove the grip from the han- dlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. NOTE Make sure that the handlebar surface and the inside of the new grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) 4. Position the new left grip (4) so the larger diameter portion of the flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8- 9.0 Nm). 9. Using a T25 TORX drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm)

HONDA GL1800 CLEAR FRONT TURNSIGNAL LIGHT INSTALLATION MANUAL

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Filed Under (Honda) by admin on 28-02-2011

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GL1800 CLEAR FRONT TURNSIGNAL LIGHT Read instructions thoroughly before installing. 1. Place bike on center stand. 2. Remove the screw and mirror from the rearview mirror housing. Figure 1 3. Remove the bulb socket from the turnsignal light by turning it counterclockwise. 4. Pull out the bulb and replace it with the amber bulb. 5. Remove the three screws holding the directional light in the housing. Install the new clear turnsignal light and put the three screws back in to hold. Figure 2 6. Reinstall in the bulb and mirror.

HONDA GL1800 CHROME MIRROR HOUSINGS INSTALLATION MANUAL

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Filed Under (Honda) by admin on 28-02-2011

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NOTE: Read instructions thoroughly before installing. USE SCREWS PROVIDED WHEN REASSEMBLING. 1. Place bike on center stand. 2. Remove the screw and mirror from the rearview mirror housing. Figure 1 3. Remove rearview mirror: Figure 2 a. Remove the mirror boot from the front fairing. b. Remove the trim clip, screw and mirror cover. c. Remove the three screws, bracket and mirror. d. Disconnect the turn signal light 3P connector. 4. Remove the three screws holding the directional light in the housing. Remove the turnsignal. Figure 3 5. Install new chrome housing using the screws provided and install parts in reverse order

HARLEY DAVIDSON PASSENGER HANDRAIL GRIP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits all 1999 through 2005 Electra Glide model motorcycles with passenger handrail. Kit Contents See Figure 1 for a list of the kit contents. No Service Parts are available for this kit. INSTALLATION NOTE The passenger handrail grips are side-specific. Install the grips so that the Bar-and-Shield logo is oriented properly. 1. See Figure 1. Obtain a rubber grip insert (4) from the kit. 2. Open up the rubber insert along the horizontal split (A), and fit it over the forward curve of the handrail. Ensure that the insert is positioned to fit the curve properly, with no kinks or gaps. 3. Obtain an inner grip (1), the correct-side outer grip (2 or 3), and six screws (5) from the kit. 4. Position the inner and outer grips over the insert, pressing them firmly together and lining up the holes. 5. Insert a screw through one of the holes in the inner grip, and carefully thread part way into the mating hole in the outer grip. Repeat for the remaining five screws. 6. Use the hex socket wrench (6) provided to tighten all six screws securely. 7. Repeat Steps 1 through 6 for the opposite side

HARLEY DAVIDSON FENDER SUPPORT COVER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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REMOVAL NOTE Complete all removal and installation procedures on one side before performing on the other side. 1. See Figure 1. Remove rear turn signal assembly (2) following the instructions in the service manual. Save all hardware for installation. 2. Remove the upper shock absorber hardware (3) following the instructions in the service manual. Save all hardware for installation. 3. Remove the rear fender support cover (4) following the instructions in the service manual. Save all hardware for installation. INSTALLATION 1. See Figure 1. Install the rear fender support cover (4) with the stock hardware. Tighten finger-tight. 2. Install the rear turn signal assembly (2) following the instructions in the service manual. 3. Install the upper shock absorber hardware (3) following the instructions in the service manual. 4. Remove the rear fender support cover hardware and apply Loctite Threadlocker and Sealant 243 (Blue) to the threads of the screws. Tighten screws to the specifications in the service manual. 5. Thoroughly clean the mounting surface of the fender support cover with an equal mixture of water and isopropyl alcohol. Peel the paper backing from the new reflector and install reflector (1). Press the reflector firmly. Allow AT LEAST 24 hours after applying the reflectors before exposing the areas to vigorous washing, strong water spray or extreme weather