HARLEY DAVIDSON POWER LOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove seat following the instructions in the appropriate Service Manual. Preparing the Saddlebags for Power Locks 1. Remove saddlebags following the instructions in the appropriate Service Manual. 2. See Figure 1. Remove lid (1) and hinge (2) from sad- dlebag. 3. Remove lock (3) from saddlebag. 4. See Figure 2. Set drill template on hinge surface of the saddlebag aligning the template (5) with hinge mounting holes (7). 5. See Figure 3. Drill 0.344 (11/32) inch diameter hole (1). 6. Place the template on the back of the saddlebag (4) aligning front mounting grommet (2) and forward latch bracket (1). 7. See Figure 4. Drill 0.500-0.515 inch diameter hole (1). 8. Repeat on the other saddlebag. 1 2 3 is04988 1. Saddlebag lid 2. Saddlebag hinge 3. Saddlebag lock Figure 1. Remove Lid, Hinge and Lock from Saddlebag

HARLEY DAVIDSON NARROW BEACH HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Preparation 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) 2. Loosen the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a

HARLEY DAVIDSON HIGH INTENSITY DISCHARGE (HID) DUAL BULB HEADLAMP KIT INSTALLATION MANUAL

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

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REMOVAL 1. Remove seat according to the instructions in the service manual. 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) 2. 2003-Earlier Models: Disconnect battery cables, negative (-) cable first. Refer to the service manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 3. 2004-Later Models: a. Remove left saddlebag. Refer to the service manual. b. Remove left side cover and main fuse. Refer to the service manual. 4. Remove fuel tank according to the instructions in the service manual. 5. See Figure 1. Remove the Phillips screw (1) at the bottom of the bezel and remove the bezel. Save parts for installa- tion. 1 2 is03916 1. Phillips screw 2. Bezel Figure 1. Remove Bezel 6. See Figure 2. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle. 7. Gently pull headlamp assembly out far enough to disconnect wiring. Save short wire harness for installation. 8. Remove wire connector at the back of the headlamp bulb. 9. See Figure 2. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation

HARLEY DAVIDSON PRIMARY COVER CHROME HARDWARE KIT INSTALLATION MANUAL

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

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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) 1. Disconnect the negative (-) battery cable from the battery. Disconnect the positive (+) battery cable from the battery. 2. Replace existing zinc hardware with chrome plated hardware one at a time so the primary chaincase and clutch cover gasket do not need to be replaced. 3. Consult the Service Manual for screw locations and torque values. Connect positive (+) 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. (00068a) 4. Connect the positive (+) battery cable to the battery. Connect the negative (-) battery cable to the battery

HARLEY DAVIDSON PASSING LAMP/DIRECTIONAL SIGNAL RELOCATION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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INSTALLATION 1. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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) 2. Disconnect battery cables, negative cable first. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) NOTE There are two possible methods of connecting the directional signal wires; using the 6-place connector, or by splicing the wires using connectors supplied in the kit. If the splicing method is selected, it will not be necessary to remove the fuel tank. However, the splices will be visible. Proceed to Step 4. 3. Remove the fuel tank according to the procedure in the appropriate Service Manual. 4. See Figure 1. Remove the existing right directional signal according to the procedure in the appropriate Service Manual. Save the internal-tooth lockwasher (1) and spacer (2). 5. Place the internal-tooth lockwasher (1) and spacer (2) (saved in Step 4) on the mirror shaft, and install the mirror (3) in the mounting bracket. Secure the mirror using an internal-tooth lockwasher (4) and acorn nut (5) (both supplied in the kit). If the acorn nut (5) “bottoms” without tightening, add a spacer (6) from the kit in the location shown. 6. Repeat Steps 4 and 5 for the left directional signal.

HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. A Service Manual is needed to install this kit. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation of this kit could result in death or serious injury. 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, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

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HARLEY DAVIDSON ROAD KING FAT HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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PREPARATION – ALL MODELS 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. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled D.O.T. 4 brake fluid. 2. See the service manual and drain the brake fluid from the front brake reservoir. ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 1. Using a T-40 TORX┬« drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the service manual. 3. Remove the old brake lines from the motorcycle. 4. Using a T27 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies (refer to CLUTCH CABLE in the service manual) from the stock handlebar.

HARLEY DAVIDSON LIGHTED MIRRORS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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REMOVAL Prepare for Service Touring Models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG and MAXI-FUSE in Service Manual. Softail and Dyna Models: 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. Remove seat according to the instructions in the Service Manual. 2. Disconnect battery cables, negative (-) cable first. 3. Remove fuel tank according to the instructions in the Service Manual. Sportster Models: Remove left side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. V-Rod Models: Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. Remove Existing Mirrors Touring and Softail (Except FXSTD, FLSTF) Models Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. Right side: See Figure 2. Remove acorn nut (1), star washer (2), and existing mirror (3) from front brake hand control assembly. Discard star washer and mirror but save acorn nut. 2 1 3 is03431 1. Acorn nut 2. Star washer 3. Mirror, left Figure 1. Remove L.H. Mirror (Except Sportster) 2 1 3 is03432 1. Acorn nut 2. Star washer 3. Mirror, right Figure 2. Remove R.H. Mirror (Touring, Softail – Except FXSTD, FLSTF) Dyna, FXSTD, FLSTF, and VRSC Models 1. Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. 2. Right side: See Figure 3. Loosen ball stud clamp (1) to remove directional lamp assembly (2). Remove retainer (3), star washer (4), and existing mirror (5) from front brake hand control assembly. Discard star washer and mirror but save remaining parts. 2 5 3 1 4 is03428 1. Ball stud clamp 2. Directional lamp assembly 3. Retainer 4. Star washer 5. Mirror, right Figure 3. Remove R.H. Mirror (Dyna, FXSTD, FLSTF, VRSC) Sportster Models Left side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (3) from clutch hand control assembly. Discard washer and mirror but save locknut. Right side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (4) from front brake hand control assembly. Discard washer and mirror but save locknut. 3 2 1 2 1 4 is03414 1. Locknut (2) 2. Washer (2) 3. Mirror, left 4. Mirror, right Figure 4. Remove Mirrors (Sportster)┬áINSTALLATION Install Lighted Mirrors Touring and Softail (Except FXSTD, FLSTF, FXSTS, FLSTS) Models 1. Left side: See Figure 5. Install mirror stem (1) through clutch hand control assembly.

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HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings 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. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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HARLEY DAVIDSON FLSTF TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL 1. Remove seat according to the instructions in the Service Manual. 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) 2. See Figure 1. Disconnect battery cables, negative (-) cable first. 2 1 is03242 1. Negative (-) cable 2. Tail lamp connector Figure 1. Negative Battery Cable and Tail Lamp Connector 3. See Figure 2. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 2. Remove Tail Lamp Lens 4. See Figure 3. Using a Terminal Pick Tool (1), depress locking tabs and disconnect turn signal connectors (2- place) (2, 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. 6. See Figure 4. Remove turn signal wiring (1, 2) from clips (3) under rear of fender INSTALLATION NOTE Proper installation of kit requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Route Turn Signal Wiring Through Rear Fender and Support 1. See Figure 5. Remove three rear screws (1) from fender support (2). 2. Loosen, but do not remove two front screws (3) from fender support. 1 3 2 is03285 1. Screw, rear (3) 2. Fender support 3. Screw, front (2) Figure 5. Fender Support Screws and Fender Support 3. Pull fender support away from rear fender to gain access to turn signal mount. 4. Remove stock screw and washer from turn signal mount. 5. See Figure 7. Pull turn signal (B) and turn signal mount (A) away from fender support. 6. Remove turn signal and wires from vehicle by routing turn signal wiring and connector through holes in rear fender and fender support. Gently guide wires through holes to ensure they do not get damaged. Feed Wiring and Install Relocation Bracket 1. See Figure 6. Feed turn signal wiring and connector through middle hole in turn signal relocation bracket and under rear of fender support. 1 is04635 1. Wire harness Figure 6. Wire Harness Routing 2. See Figure 7. Insert stock screw and washer through rear hole of relocation bracket (1) and turn signal mount (A). 3. Thread screw into turn signal (B). Tighten to 12-16 ft-lbs (16.3-21.7 Nm). 4. Align relocation bracket (1) with rear of fender support and install with screw (2) and nut (3) from kit. Tighten nut to 12-16 ft-lbs (16.3-21.7 Nm). Complete Turn Signal Relocation Wiring 1. See Figure 5. Install one rear screw (1) to hold fender support in place while routing wiring. Install screw snugly but do not fully tighten

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