HONDA HT1500 GOLD WING CONVERSION KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Honda) by admin on 25-11-2011

download
Cut-off the saddlebag support tubes where the vertical tube meets the angled tube in the front and back. All you want left is the tour pack support. Loosen tour pack support at bottom bolts, remove top bolts, and then lift up a little. This allows the body to go under the support. If you have the fuel tank: Secure the two black control boxes, facing each other, one on top of the other. Secure to frame using the green ground wire hole at center of frame. Use the 2 ¼”
spacer tube and long screw provided to hold them together. If no fuel tank: leave rear half of fender in place Install machined studs in the swing arm pivot hole with some blue Locktite on them. This provides a 5/8” stud on the side of the frame for the suspension side plates. Screw in until flush with frame. Remove the 6mm bolts from the exhaust heat shield on the outside of the frame rail. nInstall the shock replacement bars on the top shock stud and re-install bolts, leave bars hanging loose for now. Install air-compressor relocation bracket (1 ½” x 4″ w/ 3 holes) and remount compressor. After
mounting, secure the compressor to the bracket with a wire tie.

HARLEY DAVIDSON SIGNATURE SERIES PILLION KIT INSTALLATION MANUAL

0

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

download
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 WINDSHIELD MOUNTING HARDWARE KIT INSTALLATION MANUAL

0

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

download
This kit contains the following items: ITEMDESCRIPTION/ QUANTITY PART NO. 1 Stud, double ended, 5/16-18 (4) 3265A 2 Bushing (4) 67621-94 3 Acorn nut, keps, 5/16-18 (Chrome) (4) 7992 Installation 1. Using a T-40 TORX drive head, remove the upper left- side chrome button-head fork screw and chrome flat washer and discard. 2. See Figure 1. Obtain a double-ended stud (1) and chrome acorn nut (3) from the kit. Thread the nut onto the NON lock patch side of the stud and hand tighten. NOTE Position the clamp so the clutch cable is to the rear of the stud. 3. Slide the clutch cable clamp (4), along with the cable, into position on the stud as shown. Assemble a bushing (2) from the kit onto the stud threads. 4. Insert the lock patch side of the stud through the headlamp nacelle and into the upper fork bracket. Tighten the acorn nut and stud to 15-20 ft – lbs (20-27 Nm). 5. Continue, one at a time, replacing the three remaining chrome button-head fork screws and flat washers with the studs, bushings and chrome acorn nuts from the kit. Tighten to 15-20 ft – lbs (20-27 Nm)

HARLEY DAVIDSON FLSTC & FLSTS DOCKING HARDWARE WITH SADDLEBAG SUP- PORTS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 30-03-2011

download
The rear docking points in kit part number 90366-03 provide the rear mounting points for the Solo Rack. The rear mounting points from this kit ( 53931-03A ) will need to be installed to provide the clearance for the Solo Rack to be mounted. Table 2. Turn Signal Relocation Kit Requirement Turn Signal Relocation Kit Required Accessory Part Number 2003 and later FLSTC Not required 53815-00 Detachable Sideplates Not required 53066-00A Detachable Tour Pak Rack REMOVAL FLSTS Saddlebag Assembly Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Repeat steps 1 – 2 on the other side of the vehicle. FLSTC Saddlebag and Fixed Mount Sissybar Removal 1. See Figure 15. Remove a saddlebag by removing the acorn nut and washer on the lower support and the two flange locknuts inside the bag. Discard the flange locknuts, but retain the acorn nut and washer. 2. See Figure 1. Remove the saddlebag support studs and their mounting hardware. 3. Remove and discard fixed mount sideplates. Retain sissy bar for use with detachable sideplates. 4. Repeat steps 1 – 3 on the other side of the vehicle. 1 is06914 1. Saddlebag support studs Figure 1. Original Equipment Hardware (FLSTS model shown) INSTALLATION Docking Hardware Installation – For Detachable Sideplates or Tour-Pak Rack NOTE See Figure 15. The rear docking point (8) is wider than the front docking point (2). -J02425 1 of 5 1. Place front docking point (2) on front stud (1), with countersunk end of docking point facing fender support. 2. Place spacer (6) for side plates or mid docking point (for detachable sideplate kit) on rear stud (1). 3. Place rear docking point (8) on bolt (7), with countersunk end facing fender support. 4. Insert front stud (1) through front docking point (2), fender support and into bracket underneath fender as shown. 5. Insert rear stud (1) through fender support and into bracket underneath fender as shown. 6. Install bolt (7) through fender support and into bracket underneath fender as shown. 7. Tighten front and rear studs (1) and bolt (7) to 27 ft-lbs (37 Nm) . 8. Repeat steps 1-7 on the other side of the vehicle.

Incoming search terms:

ARLEY DAVIDSON FXDL INSTRUMENT CONSOLE INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 28-03-2011

download
Installation CONSOLE REMOVAL 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 and disconnect battery, negative cable first. 2. Remove fuel tank mounting bolts. Lift fuel tank far enough to remove the speedometer sensor cable from the mounting clips under the tank. 3. See Figure 1. The 3-place speedometer sensor connector is located on the frame beneath the seat. Remove from t-stud and disconnect the connector. Cut the cable strap that holds sensor wires to right rear frame tube. 4. Remove instrument console mounting screws and lift console from tank. SPEEDOMETER REMOVAL 1. See Figure 2. Disconnect 8-place connector under console. Remove assembly from tank. 2. Cut remaining cable straps holding wires to instrument mounting bracket. Remove screws holding bracket to back of instruments. Remove bracket. 3. See Figure 3. Remove nuts and washers from terminal studs (1, 2 and 3). Remove wires from studs. 4. Unscrew the rubber function switch cover that protrudes from the left side of the console. Remove the function switch (3). 5. Gently push on bottom of speedometer and remove speedometer from top side of console. Remove gasket from speedometer. TACHOMETER REMOVAL 1. See Figure 3. Remove nuts and washers from terminal studs (3, 4 and 5). Remove wires from studs. 1 WARNING 1 WARNING

HARLEY DAVIDSON BASEPLATE KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 09-03-2011

download
51138-07 2007 VRSCAW, VRSCX, and VRSCDX 51220-07 2007 VRSCD 51120-07 Kit Contents See Figure 9 and Table 2. INSTALLATION 2 1 3 is02795 1. Seat tether 2. Hex nut 3. Seat post nut Figure 1. Remove Pillion 1. See Figure 1. Open rider’s seat and remove tether (1) from pillion base. 2. Remove and save seat post nut (3) and hex nut (2) from the pillion base for reinstallation. Lift pillion tabs off frame studs and push the pillion forward to release bottom of the pillion from pillion post on fender. Lift the pillion away from the motorcycle and temporarily set aside. 1 is02786 1. Electronics Caddy Figure 2. Remove Electronics Caddy 3. See Figure 2. Make note of electronics caddy location and wiring routes under pillion base. Press on the caddy’s retaining tabs and remove the caddy from the fender. Move the caddy and wiring to the side. 2 1 2 is02787 1. Pillion post 2. Screws and washers Figure 3. Remove Fender Support Screws and Washers 4. See Figure 3. Remove the four fender support screws and washers (2). Discard screws, but save three washers for re-installation. From under the fender use an allen wrench to hold the lower pillion screw while removing the upper pillion post (1). Save the pillion post and lower washer for reinstallation. 5. Thoroughly clean fender at pillion mounting area of all dirt and debris

Incoming search terms:

HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

0

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

download
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 ULTRA TOUR-PAK BRAKE LAMP CHROME ACCENT COVERS INSTALLATION MANUAL

0

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

download
Installation- Corner Brake Lamp Trim 1. Carefully cut out brake lamp trim template (1) attached to this instruction sheet. 2. Position template (1) on plastic brake housing (2) as shown in Figure 2. 3. Using a punch, score two points indicated on template to mark mounting hole locations (3) on plastic brake housing (2). 4. Using a 1/8 in. drill bit, drill a pilot hole in plastic housing. 5. Use a 7/32 in. drill bit to drill through housing and fiberglass Tour-Pak. 6. See Figure 3. Insert studs on chrome brake lamp trim piece through holes drilled in plastic housing and Tour- Pak. Using two flatwashers (1), two lockwashers (2) and two acorn nuts (3) from kit, secure trim piece to Tour- Pak. Tighten finger tight. 7. See Figure 3. Locate brake lamp retaining clip (4) on inside of Tour-Pak and remove. Save clip (4) for later reinstallation. 8. Form chrome trim around corner of Tour-Pak, so that it is positioned around plastic housing evenly. While holding chrome trim in position, mark forward mounting hole position on Tour-Pak using a punch

HARLEY DAVIDSON SIGNATURE SERIES SOLO SEAT KIT REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 19-02-2011

download
REMOVAL NOTE Refer to owner’s manual or service manual for seat removal instructions for your model. 1. Remove right and left saddlebags according to the instructions in the service manual. Save saddlebag mounting brackets and hardware. 2. Remove passenger seat strap. Discard passenger seat strap. 3. Remove existing seat from vehicle. 4. See Figure 1. Remove and discard stock nuts (2) from studs (1) on rear fender (3). INSTALLATION Install Rider Seat 1. Push front seat on frame with mounting bracket at rear. 2. Firmly push front of seat downward and rearward until frame tongue engages slot in seat. 3. Push seat forward until studs are centered in slots of mounting bracket. 4. See Figure 4. Install two nuts (4) on studs to secure rear seat mounting bracket to rear fender. Alternately tighten nuts to 60-96 in-lbs (6.8-10.9 Nm). 5. If installing a new passenger seat, refer to the instructions included with the kit. 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) 6. If installing passenger seat, install passenger seat strap following the instructions in the service manual. 7. Install right and left side saddlebags following the instructions in the service manual. 1 2 3 2 1 is04121 1. Stud (2) 2. Nut (2) 3. Rear fender Figure 1. Rear Fender Install Rider Backrest NOTE Flaps shown removed for clarity of illustration. 1. See Figure 2. Turn backrest assembly (1) at a 45 degree angle clockwise to the seat. Slide the backrest shaft (2) through the flaps and into the receptacle in the seat. 2. While pushing down on the backrest assembly, twist the backrest counterclockwise until the shaft hits the stop. 3. Verify that the backrest assembly is locked in place by pulling up in the backrest pad

HARLEY DAVIDSON SPLIT VISION MIRROR KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 18-02-2011

download
These kits are designed to fit all 1982 and later Harley- Davidson motorcycles. Kit Contents See Figure 1 and Table 1. INSTALLATION 1. Remove and discard the existing mirror. Discard any lockwashers and acorn nuts used to mount the original mirror. 2. For motorcycles with turn signals mounted to the underside of the hand lever housings except 2004 and later XL models: See Figure 1. Secure the left side mirror using only the flat washer (3) and the acorn nut (5) from the kit. 3. Secure the right side mirror with the flat washer (3) and acorn nut (5) from the kit and the turn signal retainer only. Do not use washer (4) on either side. For 2004 and later XL models use only the lockwasher (4), and acorn nut (5) on each side. 4. For motorcycles with turn signals mounted away from the hand lever housings: Insert the mirror studs into the holes in the hand lever housings, and secure the mirrors with the flat washers (3), lockwashers (4) and acorn nuts (5) from the kit. 5. Adjust the mirrors for proper field of vision and tighten the acorn nut to 12 ft-lbs (16 Nm). Check mirror adjustment and reposition if necessary