2002-2003 HONDA GL1800 BANK ANGLE SENSOR MOUNTING SCREWS REPAIR MANUAL

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

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REPAIR PROCEDURE 1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the cen- ter pins in. Remove the two screws. Disconnect the opener  cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws  securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the under- side of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been per- formed on this unit

HARLEY DAVIDSON LIGHTED CHROME DIRECTIONAL BAR INSTALLATION MANUAL

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

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INSTALLATION 1. Disconnect turn signal wires at connectors located in directional bar. On 1994 and later models there are two wires for each turn signal lamp. Earlier models have only 1 wire per lamp. 2. Remove existing directional bar from motorcycle. Save all hardware for reattachment. If the turn signal connector is too large to be removed from the directional bar, remove the wires from the connector as follows: Bend back the connector latches on the sides of the connector slightly to free the secondary lock. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing. With a paper clip sharpened to a chisel point, insert the paper clip into the connector housing cavity until it stops. Pivot the end of the paper clip and gently tug on the wire to pull the terminal from the cavity. Do not tug on the wire until the tang that holds the terminal in the cavity is released. Take your time, a few tries may be required before you develop a feel for releasing the terminal from the connector. 3. Remove screws that mount turn signals lamps to existing directional bar. Remove lamps and turn signal wires (with their attached connector halves) from existing bar. 1 2 3 4 is02199 1. Ground wire 2. Hold lamp in place 3. Backing plate 4. Self-tapping screw Figure 1. Remove Backing Plate 4. See Figure 1. For each end of new directional bar, remove self-tapping screw that holds corner of backing plate and ground wire in place and remove backing plate. 1 2 is 02200 1. Hold lamp in place with this screw 2. Turn signal connector(s) are behind LED Figure 2. Assembling Directional Bar 5. See Figure 2. For each end of bar, place turn signal lamp in position with wires routed as shown. Move LED light out of the way and thread 5/32 inch Allen socket screw into lamp to hold lamp in place. Tighten screw.

HARLEY DAVIDSON TIMER COVER KITS INSTALLATION MANUAL

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

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INSTALLATION 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) NOTE For kits 32972-04A, 32924-04A, 32675-04A, and 32923-04A, refer to step 1 and 2 for installation instructions. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. See Figure 2. Remove and discard the original screws and timer cover. 2. Place new timer cover (1) in position and secure with chrome screws (2). NOTE For kits 32584-88TA, 32668-98A, and 32571-98A, refer to steps 3 through 8. 3. Use a 3/8 in. drill bit and drill the heads off the original timer cover rivets. Remove original timer cover. NOTE If the inner timer cover has been riveted in place and access to the cam position sensor is required, use a left hand drill and carefully remove the rivet heads. If a right hand drill is used, the sensor plate screw heads could break off when trying to remove the rivet. NOTE To make the cam position sensor tamper proof, follow steps 4 through 6. If the cam position sensor is not required to be tamper proof, skip steps 4 through 6. 4. Remove and discard inner cover retaining screws. Leave gasket (if used) and inner cover in position. 5. See Figure 1. Place washers (4) over rivets (3) and place rivets into inner cover holes so the backs of the rivets go into the sensor plate screws’ tapped holes. 6. Use a standard rivet tool and install rivets, securing inner cover to sensor plate screws. 7. Use the self-tapping screw (5) to cut threads into the remaining inner cover holes. Discard screw after use. 8. Place new timer cover (1) in position over inner cover (A) and secure with chrome screws (2). NOTE For kit 32581-90TB, refer to steps 9 and 10. 9. Use 3/8 in. drill bit and drill the heads off the timer cover rivets. Remove original timer cover. 10. Place new timer cover in position and secure with chrome screws (Part Number 9462) from kit

2002-2003 GL1800 BANK ANGLE SENSOR MOUNTING SCREW REPAIR PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the center pins in. Remove the two screws. Disconnect the opener cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the underside of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been performed on this unit