Harley-Davidson MSD Pulse Ignition Installation Manual

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Filed Under (Harley Davidson) by admin on 11-03-2012

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PICKUP PLATE INSTALLATION Remove the existing trigger/points plate and rotor, points cam and advance. Refer to the bike’s Service Manual for the proper procedure. EVOLUTION AND LATE MODEL SHOVELHEAD V-TWINS 1. From inside the cam/ignition housing, feed the free end of the MSD pickup harness through the wire access port. Note: The harness includes a heat-resistant acrylic sleeve that fits snugly inside the port opening. Do not pull the sleeve completely through the port. It must be positioned to protect the wires as they pass through the port opening. 2. Mount the MSD pickup plate inside the housing (Figure 1). Note the “adjusting notch” on the edge of the plate. This notch must be located over the series of “steps” inside the housing (about the 7 o’clock position as you face the housing). One of the sensor units will be at approximately 12 o’clock. SPORTSTER MODELS 1. On Sportsters, the wire access port must be enlarged. Use a 9/32″ drill bit to enlarge the wire port. 2. Remove the wire harness clamp of the pickup assembly and route the wires through the port. 3. Mount the MSD pickup plate inside the housing (Figure 2). Note the “adjusting notch on the edge of the plate. This notch must be located over the “cast notch” inside the housing (about the 11 o’clock position as you face the housing). The shorter of the two sensors will be approximately in the 9 o’clock position. 4. Install the hold-down/standoff screws with flat washers until they are snug – do not tighten at this time (Figure 3). 3. Put the MSD rotor in place on the end of the camshaft. The locating pin in the rotor bore must align with the groove in the cam. Do not force the rotor on the camshaft! Push the rotor into place until it is tightly against the end of the cam then snug the retaining screw. 4. Check the distance from the outer surface of the pickup plate to the end of the installed rotor (Figure 4). If necessary, add shims until the measured rotor height is 9/16″ (+/- 1/32″). 5. When the rotor height has been verified, remove the retaining screw, place a drop of Red Loctite on the threads and reinstall the screw to the factory recommended torque

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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the owner’s manual and follow the instructions given to disarm the security system and remove the left- side cover. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Refer to the owner’s manual and follow the instructions given to remove the main fuse. 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) 3. Refer to the owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 4. Remove the battery from the vehicle. 2 1 3 4 is 01377 1. Three-pin connector on siren harness 2. Three-pin connector [142B] on vehicle harness 3. Siren harness 4. Frame rear crossmember (not visible) Figure 1. Connect the Siren Harness to the Vehicle Harness 5. See Figure 1. Locate the siren connector (2) on the main harness, behind the harness shield forward of the battery location. It is covered by a dust cap. Pull the dust cap from the connector, and feed the connector downward and out from behind the shield. 6. Select the correct siren harness (3) for this model year vehicle from the kit. Route the three-pin connector (1) of the siren harness from the bottom of the motorcycle, between the primary cover and frame tube. Plug the connector into the siren harness connector (2) on the vehicle main harness. 7. Secure the connectors to the diagnostic harness using a cable strap from the kit. Route the long lead of the siren harness over the frame rear crossmember

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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) INSTALLATION 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 HANDLEBAR RESERVOIR COVER SET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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Kit 46098-98 fits the following models with single-disc front brake. •1996 through 2003 XL (Sportster®) models •1996 and later Dyna models •1996 and later Softail® models Kit 46099-98 fits the following models with dual-disc front brake. •1996 through 2003 XL (Sportster) models •1996 and later Dyna models •1996 and later Softail models •1996 and later FL Touring models INSTALLATION 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. 1. Adjust the clutch cable for maximum free play. With snap ring pliers, remove and retain the external snap ring from the bottom of the clutch lever pivot pin. Remove the pivot pin, clutch lever, clutch cable and rear-view mirror from the clutch bracket. NOTE Apply anti-seize (10) (Harley-Davidson part number 98960-97) from the kit to all screw threads prior to installation. 2. See Figure 1. Install the new chrome clutch bracket (1) using a clamp half (2), washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). -J01271 1 is01004 Figure 2. Clutch Cable Adjustment 3. Re-install the clutch cable and clutch lever, mirror and pivot pin and snap ring. See Figure 2. Re-adjust the clutch cable so there is a 1/16-1/8 inch (1.6-3.1 mm) gap between the clutch cable ferrule and the end of the clutch bracket (1). 4. Remove the original clamp half from the front brake master cylinder assembly. 5. See Figure 1. Install the new chrome clamp half (2) on the front brake master cylinder assembly using washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). 6. Remove the two screws retaining the brake master cylinder reservoir cover. See Figure 3. Replace with the two standoff studs (1) in the kit. Tighten to 6-8 in-lbs (0.7-0.9 Nm)

HARLEY DAVIDSON LED TAIL LAMP WITH BAR AND SHIELD LOGO INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION For models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and maxi-fuse. Retain all seat mounting hardware. For models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. NOTE Figure 1 shows the original equipment tail/stop lamp mounted to a full fender. The lamp is rotated 180° when mounted to a Bobtail fender. 2. See Figure 1. Loosen the two Phillips head screws (2) retaining the tail/stop lamp assembly (1) to the lamp base (3), and pull the lamp assembly away from the base. 3. Depress the locking tab (button), and disconnect the tail/stop lamp four-way Multilock socket housing [93B] (4) from the circuit board. Remove the lamp from the vehicle. 3 1 4 2 is02969 1. Tail/stop lamp assembly 2. Tail/stop lamp retaining screw (2) 3. Tail/stop lamp base 4. Tail/stop lamp connector [93B] Figure 1. Removing the Tail/Stop Lamp Assembly 7 6 2 5 1 3 4 is02970 1. Socket housing 2. Secondary lock 3. Locking tab (button) 4. Cavity 5. Socket terminal 6. Slot 7. Crimp tails Figure 2. Socket Terminal Installation 4. On the new tail/stop lamp assembly, the Blue wire and socket terminal are not installed in the four-way socket housing. Refer to the original lamp removed in Step 3, and observe which cavity contains the Blue wire. Note that the cavities are numbered on the face of the secondary lock. The Blue wire and terminal must be

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HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle 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 owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. 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. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

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Harley-Davidson FLOATING BRAKE ROTOR (DISC) KITS Removal and Disassembly

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. Models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Removal and Disassembly 2. Refer to FRONT WHEEL: REMOVAL or REAR WHEEL: REMOVAL in the Service Manual, and follow the instructions to remove the wheel from the motorcycle. Use a TORX® drive head to remove the screws retaining the currently installed brake disc to the wheel. The brake disc and screws can be discarded. 3. Inspect the wheel bearings per the PRELIMINARY INSPECTION instructions in the appropriate WHEEL section. Follow the DISASSEMBLY and CLEANING AND INSPECTION instructions as necessary to properly service the wheel. Reassembly and Installation Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 4. Refer to WHEEL: ASSEMBLY in the Service Manual, and follow the instructions to install the new brake disc to the wheel, using the new TORX screws from the kit. Complete the ASSEMBLY instructions as necessary to service the wheel. 5. Refer to WHEEL: INSTALLATION in the Service Manual, and follow the instructions to re-install the wheel to the motorcycle. Return to Service 6. Verify that the Ignition/Light Key Switch is turned to the OFF position. 7. Models WITH maxi-fuse: Refer to the Service Manual and follow the instructions given to re-install the maxi-fuse

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