2007 Harley Davidson Sportster 1200 Installation Manual

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Filed Under (Harley Davidson) by admin on 11-04-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Remove the ECM from the tray and remove the tray from the fender. You can reach underneath the fender to gain access to the release tabs for the tray. 4 Install the Dynojet tray into the rear fender . Make sure that all 3 location tabs are underneath the fender. 5 Lay the PCIII in the tray (Fig. B). 6 Install the stock ECM on top of the PCIII making sure that it is secured by the tray locking tabs. 7 Plug the GREYconnector from the PCIII into the ECM. 8 Route the PCIII harness on top of the GREY connector (Fig. C) and route towards the front of the bike. Fig. A Fig. B Fig. C 2007 Harley Davidson Sport ster 1200 – PCIII USB – 2 i817-51 1 www .powercommander .com Unplug Tray 9 Plug the BLACK connector from the PCIII into the stock wiring harness. Secure this connection with one of the supplied zip ties (Fig. D). 10 Run a zip tie behind the wiring harness (Fig. E). 11 Route the stock wiring harness as shown in Fig. E. Due to the lack of room on this bike this step needs to be exact or the install will not fit properly . Make sure that the harness coming from the GREYconnector is flush against the battery box. Acouple inches of this harness will be tucked underneath the frame

HARLEY DAVIDSON SIGNATURE SERIES PILLION KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Install the grab strap (4) with the seat mounting studs (A) through the inner grab strap holes (F). 2. Refer to solo seat instruction sheet for installation of rider seat (C) and backrest (D). 3. Install the mounting nuts (E). 4. Tighten nuts snugly. 5. Slide slots on leading edge of passenger pillion (1) onto seat mounting studs (A) while sliding the pillion through the grab strap. 6. Install mounting screw (B) from stock seat through the mounting tab and tighten to 36-60 in-lbs (4-7 Nm) . After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 7. Pull on seat and pillion to verify they are securely installed. SERVICE PARTS C E 1 B 2 D 4 A F is05690a Figure 1. Service Parts: Pillion Kit Table 1. Service Parts Table Part Number Description (Quantity) Item Not Sold Separately Pillion 1 51652-97A Mounting tab 2 3588 Mounting tab screw (2) (not shown) 3 51863-09 Grab strap 4 Items mentioned in text, but not included in kit: Mounting stud (2) A 2952A Stock screw B 51700-09 Signature Series Solo Seat Kit (purchased separately) includes Items C-E Seat C Backrest D 3638 Mounting nut (2) E Inner grab strap mounting holes

HARLEY DAVIDSON DYNA PASSENGER PILLION SEAT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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REMOVE SEAT NOTE When performing the following installation procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove screw to detach rear seat mounting bracket from fender. 2. Remove two capscrews that attach seat mounting bracket to bottom of stock seat. 3. Remove the existing seat from the motorcycle. Save the seat bracket and mounting screws for installation of the new seat. 4. If motorcycle has a grabstrap installed, remove nut and washer that holds passenger strap in place and remove strap. 5. See Figure 1. Remove the plastic cap from rearmost fender hole (3). 6. Remove the seat retention nut and washer from the solo seat mounting hole. 7. See Figure 2. A cable strap may be used as an installation aid to remove and reinstall the retention nut and washer. Place the retention nut (1) over the cable strap (3) so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the rearmost fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. 8. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear. This will lock the retention nut in place. Remove the cable strap. 2 5 1 2 1 3 6 7 4 is00363 1. Retention nut and washer (2-up seat positon) 2. Retention nut and washer (solo seat position) 3. Rear-most fender hole 4. Middle fender hole 5. Grabstrap mounting hole 6. Flange screw 7. Plastic retention nut

HARLEY DAVIDSON FXD SOLO SADDLE REMOVAL AND INSTALLATION MANUAL

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

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Removal of Stock Seat 1. Remove screw (6) to detach rear seat mounting bracket (9) from fender. 1996 models will have a nylon washer under the bracket that should also be saved for installation of new seat. 2. Slide seat rearward to unhook front of seat from frame, then pull seat forward out of passenger strap. 3. Remove two capscrews (10) that attach seat mounting bracket to bottom of stock seat. Install original seat mounting bracket to bottom of new solo saddle with original capscrews. Tighten capscrews securely. 4. Remove nut (7) and washer (8) that hold passenger strap (11) in place and remove strap. Installation of Kit Seat This seat is for solo driver use only. Do not attempt to carry a passenger with this solo seat installed. Use of a luggage rack, fender, or tail section as an additional seat may result in death or serious injury. NOTE When a solo seat is installed without a passenger seat, the passenger footpegs or footboards and the passenger grabstrap must be removed. For 1996 models: 1. Slide seat into position until front seat tab engages frame, then place original nylon washer under hole in rear seat mounting bracket and secure bracket to fender with screw (6). NOTE For 1997 models, a retention nut and washer must be installed into the fender hole, covered with a plastic cap, where the rear seat bracket will be attached. A cable strap is included to aid in this installation. For 1997 models: 1. Remove plastic cap from hole in fender where the rear seat bracket will be attached. 2. Place retention nut (3) over cable strap (2) so wide end of nut rests on eye of cable strap. Thread cable strap up under fender and through fender hole. Pull up on cable strap to hold nut snug against underside of fender. 3. With rib on retention nut seated into notch in fender hole, slide retention washer (4) into place from the rear. This will lock the retention nut in place. 4. Slide seat into position until front seat tab engages frame, then secure rear seat bracket to fender with screw (6). Install chrome cap (5) in rear retention nut

HARLEY DAVIDSON SOFTAIL SEAT KITS INSTALLATION MANUAL

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

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INSTALLATION FXST, FXSTS, and FXSTB models NOTE When performing the following installation procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove existing seat from motorcycle by unscrewing seat at rear bracket and unhooking front seat tab. 2. See Figure 4. Remove and discard existing grabstrap and save fastening hardware from the motorcycle. 3. See Figure 4. Install the grabstrap (7) from kit with the hardware saved in Step 2. Install the grabstrap according to Figure 1. Kit Number: 51470-06A, 51397-06A Grabstrap Number: 51184-00 Kit Number: 51468-06A, 51469-06A, and 51801-07 Grabstrap Number: 51176-96B is00420 Figure 1. Grabstrap installment information 4. See Figure 4. Slide the back of the seat through grabstrap and hook front tab of seat (1) into frame. Secure seat bracket to fender with screw (8). After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 2007 and later FXSTC models NOTE Refer to the Owner’s, or Service Manual instructions for removal of the stock seat, and mounting hardware. 1. Remove, and discard the existing grabstrap, and mounting hardware. 2. Remove, and discard the plug in the rear mounting position on the fender. 3. See Figure 2. Using the retaining nut (1), washer (2), and cable strap from the kit; Install the nut, and washer in the rear hole location on the fender (Note: A cable strap can be used as an installation aid)

HARLEY DAVIDSON CHROME SEAT POST REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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REMOVE 2 1 is00000 1. Seat Post 2. Screw Figure 2. Lower Seat Post 1. Refer to Owners Manual to remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery negative cable. 3. On motorcycles equipped with oxygen sensors, disconnect the rear sensor connector. 4. See Figure 2. Remove screw (2) and washer from the lower seat post (1) and discard. -J04294 1 of 2 5. Disconnect spark plug wires and primary wire from ignition coil. 6. See Figure 3. Loosen the bracket screws (1). Remove seat post screw (2) and seat post with ignition coil and cover. 7. See Figure 4. Remove coil cover screw (5) and cover (4) from stock seat post (1). 8. Remove ignition coil screws (3) and coil (2) from seat post. 2 1 is04241 1. Bracket Screws 2. Upper Seat Post Screw Figure 3. Upper Seat Post Fasteners 2 5 1 3 4 is04337 1. Seat Post 2. Ignition Coil 3. Coil Screw 4. Coil Cover 5. Coil Cover Screw Figure 4. Install Ignition Coil to Seat Post INSTALL 1. See Figure 4. Install ignition coil (2) to new seat post using screws (3). Tighten ignition coil screws to 10-15 ft-lbs (13.6-20.3 Nm) . 2. Install coil cover (4) to seat post with screw (5) and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 3. See Figure 1. Place seat post (1) in position and attach lower post with screw (2), washers (3) and dome nut (4). Tighten screw (2) to 10-15 ft-lbs (13.6-20.3 Nm) . 4. See Figure 3. Attach upper seat post with screw (2). Tighten screw (2) to 12-15 ft-lbs (16.2-20.3 Nm) . Tighten bracket screws (1) to 12-15 (16.2-20.3 Nm) . 5. Connect primary wire to ignition coil. 6. Connect spark plug wires to ignition coil. The rear cylinder plug wire attaches to the top coil post. Ensure that spark plug wire boots are fastened securely. 7. Connect rear oxygen sensor connector, if equipped. 8. Reconnect battery negative cable

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY DAVIDSON DYNA SEAT WITH ADJUSTABLE RIDER BACKREST INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION Seat Installation NOTE When performing the following procedures, be careful not to scratch painted surfaces (fender, tank, etc.) with the metal tabs on the seat. 1. Remove the existing seat and passenger grab strap following the instructions in the appropriate Service Manual. Discard the grab strap and retain all other hardware for later use. 2. See Figure 9. Remove the seat bracket from the stock seat. 3. For all except FXDWG: Install the stock seat bracket onto the new seat with the stock screws. For FXDWG: Install new seat bracket 52152-97 onto the new seat with the stock screws. For models equipped with original or accessory two- up seating: Proceed to Step 6. 4. On models equipped with an accessory Solo Seat: Remove the plastic plug from the hole in the rear fender where the rear seat bracket will be attached. 5. See Figure 9. Slide the retention nut (9) onto the cable strap (11) so the wide end of the nut rests on the eye of the strap. Thread the cable strap up under the fender and through the fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. Seat the rib of the retention nut in the notch in the fender hole and slide the retention washer (10) into place from the rear. This will lock the retention nut in place. 6. See Figure 1. Place the black bracket (1) from the kit onto the frame as shown. 7. See Figure 9. Install the new grab strap (8) in the original location with the hardware saved in Step 1. Tighten the nut to 96 in-lbs (10.85 Nm) . 8. See Figure 1. Install the screw (2) in the hole on the forward edge of the bracket. Attach the locknut (3) and washer (4) from under the frame. Tighten to 96 in-lbs (10.85 Nm)

HARLEY DAVIDSON BADLANDER XL CUSTOM SEAT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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Removal of Stock Seat 1. Remove screw (8) to detach rear seat mounting bracket from fender. 2. Slide seat rearward to unhook front of seat from frame, then remove seat. 3. If equipped with a grab strap, remove hardware that holds it in place and remove strap. Installation of Kit Seat For 1996 and earlier models: Make certain you select the correct kit screw in step 1. Attempting to install a coarse threaded screw in a fine threaded hole, or vice versa, will damage threads. 1. Secure grab strap (2) to fender using washer (7) and appropriate screw (6) below: On 1995 and earlier models use 1/4-28 (fine) screw. On 1996 – 2003 models use 1/4-20 (coarse) screw. 2. Slide seat into position until front of seat engages frame, then secure bracket to fender with screw (8) using guide washer (3) between bracket and fender with the small washer diameter facing upwards. The guide washer will center the screw in the bracket hole and serve as a washer to protect the fender. NOTE For 1997 883 models, a retention nut and washer must be installed into the fender hole, covered with a plastic cap, where the rear seat bracket will be attached. A cable strap is included to aid in this installation. For 1997 – 2003 models: 1. Install grab strap (see step 1 for 1996 and earlier models). 2. Remove plastic cap from hole in fender where the rear seat bracket will be attached. 3. Place retention nut (5) over cable strap (9) so wide end of nut rests on eye of cable strap. Thread cable strap up under fender and through fender hole. Pull up on cable strap to hold nut snug against underside of fender. 4. With rib on retention nut seated into notch in fender hole, slide retention washer (4) into place from the rear. This will lock the retention nut in place. 5. Slide seat into position untilang=en

HONDA VTX 1800R AND VTX 1300R SOLO RACK INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Remove the stock passenger seat. And “U” shaped mounting bracket from the rear fender. 2. Install the 2 “L” brackets provided (NOTE: there is a left and a right) onto the rear fender using the bolts from the stock bracket. Snug the bolts just enough to still allow them to slide. 3. Using the 3 knobs provided re-install the stock seat using the knob with the long stud in the rear hole. Center the slot in the seat and tighten the knob. Install the 2 knobs with the short threaded studs through the front seat mounting holes and into the new brackets. Center the bracket holes to the seat holes and snug the knobs. This will align the forward brackets. Carefully remove all three knobs and the seat. Tighten the forward bracket securely. 4. Install the solo rack starting with the 2 short knobs at the front then the long knob at the rear with the black spacer between the rack and the fender. Tighten all 3 knobs securely, as tight as you can by hand. Lost knobs are not a warrantable item. Now you can switch from your new cool solo rack look back to your stock passenger seat in seconds without any tools. NOTE: when using the stock seat, place the black spacer on the long rear knob and install them over the stock rear seat bracket. This keeps the long stud from extending below the inside of the fender and possibly contacting the rear tire if the rear shocks should bottom out

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