harley davidson CRUISE CONTROL KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 23-02-2012

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See Figure 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 5. Refer to the service manual, and follow the instructions to loosen the brake hand lever/master cylinder assembly and remove the right-side upper and lower switch housing sub-assemblies from the handlebar. It is not necessary to remove the throttle control grip. For FLHR models: Refer to the service manual. Disconnect the left-side handlebar MOLEX socket housing from the gray eight-way main harness pin housing [24B] inside the headlamp nacelle. Refer to the service manual to remove the clutch hand lever and left-side upper and lower switch housing subassemblies from the handlebar. 6. For ALL models: See Figure 2. The friction shoe (1) is a loose fit on the end of the tension adjuster screw (2). Make sure the shoe has been removed with the switch housing sub-assemblies, and is not lodged in the groove of the throttle control grip (4). 3 4 1 2 is06318 1. Friction shoe 2. Tension adjuster screw 3. Right-side lower switch housing 4. Throttle control grip Figure 2. Throttle Tension Adjuster Screw and Friction Shoe 7. See Figure 1. Verify that the 5/32-inch (4 mm) thick insert is in place between the brake lever and the lever bracket. Obtain the new right-side handlebar switch housing assembly (Item 4 or 5, depending on model) from the kit. Separate the upper and lower halves of the housing assembly. Refer to the service manual, and follow the instructions to install the switch housing assembly and brake hand lever/master cylinder assembly to the handlebar. 8. Route the right-side switch harness along the same path as the original harness (along the right handlebar). Connect the pin housing to the black socket housing disconnected in Step 3. 9. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Continue at Step 11. For FLHR models: Obtain the new left-side switch housing assembly (6) from the kit. Separate the upper and lower halves of the switch housing assembly. Refer to the service manual, and follow the instructions to install the left-side switch housing assembly and clutch hand lever assembly to the handlebar. 10. Route the left-side hand control harness along the same path as the original harness (along the left handlebar). Connect the pin housing to the gray socket housing disconnected in Step 5

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

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HARLEY DAVIDSON HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL See the service manual for removal procedures. INSTALLATION See the service manual and follow the wiring procedures. NOTE For Non-FXDF Models Only: See Figure 1. Cut the mesh tubing from the kit into two equal length pieces. Slide the switch wire bundles through mesh conduit. Position conduit into switch control housing. Tie each end of conduit with cable tie from kit. Handlebar Installation See the service manual and follow the installation procedures. SAFETY CHECK Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) •Be sure wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops. 1. Verify that the ignition/light key switch is turned to the OFF position. Install the main fuse. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 2. Turn the ignition/light key switch to IGNITION, but do not start the engine. Test each handlebar switch for proper operation. Before starting engine, be sure thr ottle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or serious injury. (00390a) SERVICE PARTS

POLINI XP 65 R USE AND MAINTENANCE MANUAL

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Filed Under (Polini) by admin on 24-11-2010

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The following instructions give the most practical order for assembling the various parts of your motorcycle. 1- Remove the motorcycle from the crate (photo 1). 2- Remove all the parts needed to reassemble the motorcycle from the crate and check them thoroughly (photo 2). WASHER 6X18X1 No. 4 PLASTIC TIE No. 1 FRONT WHEEL SPINDLE No. 1 WHEEL SPINDLE SPACER No. 1 M12 WHEEL SPINDLE NUT No. 1 FOOTREST SPRING No. 2 TCEI SCREW M8X40 No. 2 TB SCREW M6X16 No. 4 TBEI SCREW M6X40 No. 1 NUMBER PLATE No. 1 NUMBER PLATE SPACER No. 1 RIGHT FOOTREST No. 1 LEFT FOOT REST No. 1 M8 SELF-LOCKING NUT No. 2 TCEI SCREW M8X75 No. 4 HANDLEBAR CLAMP No. 2 HANDLEBAR CLAMP SPACER No. 4 HANDLEBAR WITH FOAM ROLLNo. 1 FRONT WHEEL WITH DISK No. 1 FRONT MUDGUARD No. 1 3- Fit the rear shock-absorber, using the M10 hexagonal head screw and the two washers with the M10 nut. Fit one of the washers at the bolt side and the other at the nut side. The nut, bolt, spacers and washers have been pre-fitted in their seats on the swinging arm (photos 3). 4- Open the front brake disk pads. 5- Fit the front wheel using the special spindle; fit the spacer on the disk side of the wheel 6- Insert the spindle and the nut and tighten with a torque wrench (See section 6.2 ) (photo n.4). 1 2 3 XP65R_instructions.qxd 5-09-2007 10:45 Pagina 3
7- Tighten the spindle locking bolt with a torque wrench (See section 6.2 ) (photo 5). 8- Inflate the front and rear tyres (See section 4.12 ). 9- Fit the front mudguard with the provided 4 screws and the TBM6X16 washers (photo 6). 10- Cut the transport tie securing the front brake master cylinder. Fit the handlebar and fix it to the top fork with the two handlebar clamps and the four Allen bolts M8X75 (See section 6.2 ) (photo 7). 11- Regulate the front fork height as per photo No. 8 (see section 6.2 for tightening torque) ATTENTION! For safety reasons the front fork must be extracted within notch No. 4 (minimum) and No. 5 (maximum) (photo No. 8). 12- Remove the throttle control cover and fit the cable as shown in photo 9. Re-fit the cover. (See section 4.9 ). 13- Fit the front brake lever and secure the clamp with the provided screws 14- Fit the engine stop button and fix it to the handlebar with its mounting clamp 15- Fit the clutch lever and adjust the travel of the lever as you prefer using the regulator (photo 10) (See section 4.11 ). Fit the number plate fixing it with the related spacers and screw TBEI M6X40 and insert the front brake cable in the slide. 16- Fit the footrests (photo 11) 17- Fill the engine coolant circuit (See sections 4.5 and 4.6 ) (photo 12)

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2002 URAL Classic Motorcycles BC-75 (Bavarian Classic) LC-75 (Luxury Cruiser) Tourist, Adirondac & Patro Owner's Manual

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Filed Under (Ural) by admin on 02-11-2010

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Front brake control lever (Fig.1, #5). When the lever is squeezed, the front wheel brake is actuated. The front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal lamps are switched on. Kick lever (Fig.1, #11) is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Note: this is a backup to the electric starter. Gear shift foot pedal (Fig.1, #12) is a two-arm type. When the front arm is pressed, shifting from high to lower gears takes place. When the rear arm is pressed, shifting from low to higher gears takes place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift up if you rotate the heel of your left foot in towards the rear arm before stepping on it with your heel. The neutral position is fixed between the I and II gears. Speedometer is on the dash board, with trip (Note..BC-75 has no trip odometer) and total odometer. The trip odometer is reset to zero by rotating push-button (Fig.1, # 3) counterclockwise. Note that the odometer reads in kilometers not miles. Ignition Switch (Fig.1, # 19) has three fixed positions of the key. The position and switching diagram of the ignition locks are shown above.
18 The indicator lamps are mounted on the instrument board: (Fig. 1, # 2) — turn indicator pilot lamp, (orange) (Fig. 1, # 4) — gearbox neutral and reverse gear engagement, (green) (Fig. 1, # 18) — head lamp high beam indicator, (dark blue) (Fig. 1, # 20) — alternator fault indicator lamp, (red) Note: If the red alternator fault light stays on continuously during normal operation above approximately 1500 RPM, there is a problem with the charging system or battery. Throttle Control (Fig.1, # 6) is on the right handlebar. Turning the twist grip counterclockwise increases engine speed. Ignition Cutoff Switch (Fig.1, # 7) has two positions, ignition off (up), and ignition on (down). Low and High Beam Light Switch (Fig.1, # 15), turn indicator switch (Fig.1, #13) and horn push-button (Fig.1, # 14) are combined in one unit on the left-hand handle bar control housing. Master Battery Switch (Fig.1, # 21) is under the seat. Electric Start Button (Fig. 1, # 8) is located on the right-hand twist grip, below the kill switch. The Steering Damper absorbs lateral kicks on the front wheel. Turning tightening bolt (Fig.1, # 17) clockwise increases friction. This can be used while riding over bad roads

2001 URAL Classic Motorcycles Owner's Manual

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Filed Under (Ural) by admin on 02-11-2010

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Front brake control lever (Fig.1, #5). When the lever is squeezed, the front wheel brake is actuated. The front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal lamps are switched on. Kick lever (Fig.1, #11) is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Note: this is a backup to the electric starter. Gear shift foot pedal (Fig.1, #12) is a two-arm type. When the front arm is pressed, shifting from high to lower gears takes place. When the rear arm is pressed, shifting from low to higher gears takes place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift up if you rotate the heel of your left foot in towards the rear arm before stepping on it with your heel. The neutral position is fixed between the I and II gears. Throttle Control (Fig.1, # 6) is on the right handlebar. Turning the twist grip counterclockwise increases engine speed. Engine cutoff switch (Fig.1, # 7) has two positions, ignition off (up), and ignition on (down). Low and high beam light switch (Fig.1, # 15), turn indicator switch (Fig.1, #13) and horn push-button (Fig.1, # 14) are combined in one unit on the left-hand handle bar control housing. Master battery switch (Fig.1, # 21) is under the seat. Electric Start Button (Fig. 1, # 8) is located on the right-hand twist grip, below the kill switch. The steering damper absorbs lateral kicks on the front wheel. Turning tightening bolt (Fig.1, # 17) clockwise increases friction. This can be used while riding over bad roads. WARNING: DO NOT TIGHTEN THE DAMPER TO THE POINT WHERE THE STEERING BECOMES STIFF . DOING SO WILL ADVERSELY AFFECT HANDLING QUALITIES . Parking brake (Fig. 1, # 22) is located on the right side of the motorcycle next to the foot peg. It is engaged by applying the foot brake pedal fully and turning the handle and pushing it down to hold the foot brake lever in the applied position. Always disengage the parking brake before moving the motorcycle