HARLEY DAVIDSON EFI INTAKE MANIFOLD COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 1. Remove screw (A) that holds the air cleaner cover (B) and seal (C). 2. Remove three T27 TORX® screws (D) to release the cover bracket (E) from the filter element (F). 3. Remove the filter element, pulling the two breather tubes (G) from hole on the inboard side of element. 4. Remove the two breather tubes (G) from the fittings on the two cylinder head breather bolts (I). 5. Remove the two breather bolts (I) and O-ring seals (K) from the air cleaner backplate (J) with a 7/16 inch deepwell socket. 6. Remove the backplate and gasket (H) from the injection module. 7. Aligning the flat edge of a new cover gasket (2) with the backplate molded tab, install a gasket (2), chrome cover (1) and second gasket, in order, on the air cleaner back- plate. 8. Install the breather bolts through the air cleaner backplate. Re-install O-ring seals onto each breather bolt. Install a washer (3) from the kit on each breather bolt. Apply Loctite 243 to the breather bolts and align holes in the backplate with the holes in the cylinder heads and install the breather bolts. Use a 7/16 inch deepwell socket and alternately tighten the breather bolts to 120-144 in-lbs (13.6-16.3 Nm) . 9. Slide gasket over the sleeve on the inboard side of filter element. 10. Install breather tubes about 1/4 inch (6.4 mm) into holes on inboard side of filter element. 11. Install breather tubes onto fittings of two cylinder head breather bolts. NOTE Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into atmosphere in violation of legal emissions standards. 12. Place the filter element onto backplate, with the flat side down, so that the hole on the inboard side of element fits over the molded boss in the backplate. 13. Align holes in cover bracket with those in filter element and start three screws. Stamp on cover bracket points downwards. Use a T27 TORX drive head, alternately tighten screws to 20-40 in-lbs (2.3-4.5 Nm) . 14. Make sure that the rubber seal is proper seated around perimeter of air cleaner cover and place cover on back- plate. 15. Fit the air cleaner cover onto backplate. Apply Loctite 243 to the threads of air cleaner cover screw. Install screw through cover and tighten to 36-60 in-lbs (4.1-6.8 Nm)

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HARLEY DAVIDSON FL SOFTAIL FOWARD CONTROL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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INSTALLATION Shifter Side, Left Block or jack vehicle under frame in a way that the vehicle will not fall over. Failure to properly block and/or raise the vehicle could result in death or serious injury. (00462c) 1. Block the motorcycle under the frame so that it is upright and level, with the weight off of the jiffy stand. 2. Remove footpeg. 3. Remove jiffy stand, shifter linkage and bracket per applicable Service Manual instructions, retaining hardware. 4. See Figure 5. Obtain the new left side shifter bracket (2), and three TORX® screws (3) from the kit. 5. Place washers previously removed on the screws. Apply LOCTITE® 243 (Blue) to the threads, and install the new bracket assembly to the motorcycle frame. Tighten the screws to 40 ft-lbs (54.2 Nm) . 6. See Figure 5. Install footpeg with spring washer (8), clevis pin (10) and retaining ring (9). If leg stop is incorrectly installed, excessive wear can allow vehicle to fall when rested on jiffy stand, which could result in death or serious injury. (00479b) 7. Install jiffy stand and attach the spring. When properly installed, the hook on the spring side connected to the bracket will face upward. 8. Verify that rubber bumper is in place on prong of jiffy stand. Without the bumper, the stand will make hard contact with the primary drive cover when retracted, which may result in damage to the cover. 9. Extend and retract the jiffy stand leg several times to verify proper operation. The stand should swing freely to the fully extended and fully retracted positions. 10. Refer to applicable Service Manual and re-attach the shifter linkage

HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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

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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) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

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HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. 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) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. 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) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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HARLEY DAVIDSON SADDLEBAG LID COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION NOTE To avoid failure, the fastening tab adhesive must be allowed to cure for 24 hours before installing these Lid Covers. NOTE Lid Cover installation may be easier with the saddlebags removed from the motorcycle. 1. See Figure 1. Open the saddlebag lid. Remove the two T-20 TORX® screws (5) attaching the check strap (3) to the lid. 2 4 2 3 1 6 7 4 4 6 5 is02962 1. Saddlebag lid cover 2. Hook and loop fastener, 1.5 inch 3. Check strap 4. Hook and loop fastener, 4.0 inch 5. Torx screws (2) 6. Hook and loop fastener, 6.0 inch 7. Anchor tab (install first) Figure 1. Saddlebag Lid Cover Installation 2. Wash the entire saddlebag lid, inside and out, with warm, soapy water. Rinse and dry thoroughly. 3. Use the alcohol prep pad provided in the kit to further clean the inside of the lid in the areas where the hook and loop strips will be attached. NOTE The Saddlebag Lid Covers are side-specific. A Bar-and-Shield logo is stitched into the rear face of each cover. NOTE DO NOT fasten the Saddlebag Lid Cover tabs to the hook and loop strips until the adhesive has cured for 24 hours. 4. Place the correct Saddlebag Lid Cover (1) over the saddlebag lid in its proper position. Bring the cover tabs over the edge of the lid to serve as a guide in positioning the hook and loop strips on the inside of the lid. Remove the protective backing from one hook and loop strip at a time. Use the corresponding tab on the cover only as a positioning guide, then fold it back out of the

HARLEY DAVIDSON FOUR-POINT DETACHABLE DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 3. Remove the screw (A) retaining the rear of the chrome cover to the rear frame extension on each side of the vehicle. 2. Place a washer (7) over the threads of each of the larger TORX® head screws (6) from the kit. Apply 2 or 3 drops of Loctite 262 Threadlocker and Sealant – Red to the threads of each screw. Install the screws through the docking plates (1) and fender covers, and into the threaded holes in the frame extensions on each side of the vehicle, and tighten to 17 ft-lbs (23 Nm) . NOTE See Figure 1. The docking points must be attached to the docking plates (2) with the chamfer (1) facing the plate and the flat side facing out. 1 2 is05506a 1. Docking point chamfer (bevel) 2. Mounting plate Figure 1. Docking Point Installation 3. See Figure 3. Slide a spacer (2) onto the longer pin (B) of each docking plate. Install the four docking points (3), chamfer end first, onto the long and short docking plate pins using the washers (5) and smaller TORX screws (4). Tighten to 10.5 ft-lbs (14.2 Nm) . NOTE Protective tape must be installed to the rear saddlebag mounting bracket to prevent damage to the saddlebag finish when the lid is opened. 4. See Figure 2. Apply protective tape (2) to the rear mounting bracket (1) on the saddlebag in the location shown. Repeat for the other side. 2 1 is05533 1. Rear saddlebag bracket (2) 2. Protective tape %lengthT=0

HARLEY DAVIDSON FAIRING BRA INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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This kit is designed for installation on 1996 and later FLHT, FLHTC, FLHTCU AND FLHTCU/I Model Motorcycles. Installation 1. Align each of the sewn-in pockets on the fairing bra with each of the outer edges of the fairing at handlebar level. 2. See Figure 1. Standing in front of the vehicle, remove the three T27 Torx screws (1) with washers securing the windshield along the front of the fairing. NOTE In the following Step, the Chrome Windshield Strip (purchased separately) , will serve as a mounting bracket for the fairing bra 3. Obtain the Chrome Windshield Strip (P/N 59213-96) and screws supplied with strip. While aligning holes in the chrome strip over the bra, install the new screws with washers through the strip and bra, then tighten securely into the windshield. 4. The six straps (three on each side near the bottom) will be captured between the inner and outer fairing. Refer to Figure 1. Remove the four screws (2) from the inner fairing. NOTE: The bottom two screws are below the fairing cap. Save screws for installation. Separate the inner and outer fairings just enough to install the straps into the fairing. Adjust the straps, then reinstall the screws and tighten securely. 5. Remove the Phillips screw located at the bottom of the headlamp trim ring. Save screw for installation 6. See Figure 2. Orient the elastic portion of the bra around the headlamp, however in front of, the retaining ring as shown. 7. Install the bottom elastic strap below the fairing seal under the headlamp. 8. Install the headlamp trim ring using the Phillips screw removed in Step 5.

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

BMW R1150R Roadster CargoRest FitKit Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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Check to determine if the BMW system case mounts have been properly installed and that all fasteners and fittings are properly tightened. Inspect for signs of stress, fracture, bending, or other failure. If found, return the mounts to your dealer for replacement. Do not attempt to mount the BestRest FitKit if the BMW system case saddlebag mounts are damaged, defective, or improperly installed. If the BMW luggage rack is in place, remove it from the system case mounts. Removal is accomplished by removing the 4 torx screws, 2 on each side. Use the torx wrench from your toolkit. Once the stock “luggage” rack is removed, you’ll be mounting the Roadster FitKit using those same 4 holes. You’ll be replacing the stock torx head screws with the longer socket head hex screws found in the parts package. Place a flat washer on the 6mm screws and start the screws into the 4 holes. The 4 screws may need some gentle help to get them thru the holes. Work patiently and do not use brute force! Once the screws have started in the holes, turn them clockwise with a hex wrench to help them pass thru the saddlebag mounts and the FitKit Plate. Place a flat washer and 6mm nylon locknut on the end of each screw and tighten the nuts <<<<>>>>. From the rear, lift up on the FitKit Plate and “wiggle” it up and down <<<>>> a few times to remove any tension between the FitKit Plate and the system case brackets. You’ll find a point where everything feels “neutral” and where the screws are aligned in their holes. Tighten the nuts fully. Use common sense and do not over-tighten. Do not use extensions on the hex wrench. As a final tightening technique, hold the hex wrench stationary while you tighten the nuts another ¼ turn, using the box wrench. From the rear, wiggle the FitKit Plate up and down again. If it’s loose, tighten the screws and nuts again. Repeat until the FitKit Plate is snug and secure between the bag mounts. Place a CargoRest over the top of the FitKit Plate. Installation is the same for all 3 models of CargoRest. Align the 5 holes shown in the photo with the holes in the FitKit Plate.

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