Harley-Davidson CUSTOM FIT SADDLEBAG INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 24-04-2012

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INSTALLATION INSTRUCTIONS 1. It is anticipated that the smooth back side of the bags will be drilled to facilitate mounting, and that you will fabricate mounting brackets, spacers or supports. Mounting bolts with then pass thru the bags and, using the supplied fender washers, be secured to either your fabricated brackets, fender or fender struts. Most installations utilize the fender struts and their fender mounting locations for connecting the saddlebags to the motorcycle. Other locations can also include turn signal or top shock mounting points. Mount points should be as far apart as possible and use the fender washers supplied to provide a stable mount base and spread the mounting load and stress over the largest area possible. The bags can also be mounted utilizing aftermarket saddlebag support brackets and securely attaching the saddlebags to these brackets. 2. The saddlebags must be securely mounted to the motorcycle so that they can support any load that you intend to carry (less than 10 pounds per side) and so the bags clear all moving or suspension components thru the full suspension travel, even when the bags are fully loaded. Be expecially careful that the cantilevered bottom inside edge of the bag, and all other surfaces, clear all components such as shocks, swingarm, brake calipers, brake rods and lines, chain guard, etc. after installation. 3. Inspect the bags immediately after first use to determine that the bags are not interfereing with moving components. Inspect weekly thereafter to be certain that the bags are not contacting moving parts and that the bags are not developing cracks as a result of inadequate mounting support. 4. If the installed bags obstruct the original factory supplied side reflectors, please contact Saddlemen to purchase self-adhesive reflectors, which must be installed where they are clearly visible from the side of the motorcycle. LOCKABLE BUCKLES FEATUREDrifter and Desperado models feature leather straps with hidden lockable buckles. Once locked, bags cannot be opened. Cruis’n models feature lockable twistlocks, with small padlocks included.

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HARLEY DAVIDSON ADJURE'S BIG CITY LED LIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 20-04-2012

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ADJURE OFFERS DOT COMPLIANT LED REPLACEMENT TURN SIGNALS TO FIT BOTH THE FLAT AND FOOTBALL HARLEY DAVIDSON TURN SIGNAL HOUSINGS. STOCK HARLEY DAVIDSON HAS 3-WIRE AMBER (RUN/TURN) IN FRONT AND 2-WIRE AMBER (TURN ONLY) IN THE REAR. IF YOU WANT TO CHANGE YOUR REAR TURN SIGNALS INTO RUN/TURN/BRAKE, YOU MUST CHANGE THE LENS COLOR TO RED AND THE BEST WAY TO DO THIS IS TO ALSO ORDER AND INSTALL OUR P/N# K48590 (RUN/TURN/BRAKE CONTROLLER). NOTE: WHEN USING LED’S AS A TURN SIGNAL YOU MUST ALLWAYS USE A “LOAD EQUALIZER” P/N#K48100 TO MAKE THEM WORK PROPERLY. INSTALLATION: COVERS BOTH FLAT AND FOOTBALL HOUSINGS 1) REMOVE THE LENSES FROM YOUR STOCK TURN SIGNALS BY REMOVING THE 2 SCREWS ON EACH SIDE OF THE LENS. 2) REMOVE THE BULB BY PUSHING IN AND TURNING COUNTER CLOCKWISE. 3) INSERT INTO THE LIGHT SOCKET THE PLUG ON YOU NEW LED’S BY PUSHING IT IN AND TURNING IT CLOCKWISE. 4) SET THE LENS ON THE HOUSING AND REPLACE THE SCREWS. TO CONNECT THE LOAD EQUALIZER: 1) THERE ARE 3 WIRES CONNECT THE BLACK TO A GOOD GROUND AND ONE OF THE WIRES TO ANYWHERE IN THE LEFT SIDE TURN SIGNAL SYSTEM AND THE OTHER WIRE TO ANYWHERE IN THE RIGHT SIDE TURN SIGNAL SYSTEM.

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Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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Filed Under (Harley Davidson) by admin on 16-04-2012

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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FLH Harley-Davidson Bikes/ Trikes Steering Damper Installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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First, we’re going to install the upper Bracket. (#8 in Fig. 1) Start by placing a clean towel or other protective material over your front fender to protect it from falling objects. Remove the 5/16-18 Allen head bolt and washer holding the top of the crash bar to the frame. Use a ¼” Allen wrench. Access is easier if you crank the forks over to one side. Line up the hole in the new bracket with the crash bar, orienting the bracket to the crash bar as shown in Fig. 1, and re-install the bolt with a drop of blue loc-tite. Torque the bolt to 15-20 ft. lb. If you don’t have a torque wrench, well, you should have one, but if not, 15-20 ft. lb. is a bit tighter than a spark plug torque, which is 12-18 ft. lb. If you are not sure, snug it down tight, but don’t try to break it. Note than on a couple of these, I had to slightly elongate the hole in the bracket to re-install the upper crash bar bolt. (Side mount bracket installation) Next, the side bracket install. (#6 in Fig. 1) You’ll need a #35 Torx driver to remove the two screws holding the LEFT passing lamp/turn signal bar to the bike/trike. Carefully remove the upper and lower screws, holding the bar to prevent it from falling, possibly jerking the attached wiring. Once you have removed the screws, you can let the bar hang, while you orient the side bracket as per Fig. 1. Re-install the two screws you just removed, capturing the damper side bracket under the light bar. Use a drop of blue loc- tite here as well. Hand tighten the two screws, aligning the lamp bar and damper side bracket. Using your torque wrench, (you did find one didn’t you?) Tighten the two screws to 15-20 ft. lb. Ok the easy part is out of the way.

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HARLEY-DAVIDSON TURN SIGNAL MIRRORS WITH CONVEX GLASS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 03-04-2012

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STEP 1 Remove the stock mirrors. LEFT SIDE: STEP 2 Choose the longest Allen bolt from the hardware kit that passes through the hand control, a split lock washer, an internal tooth star washer, the turn signal mount (if applicable), and still provides maximum thread engagement in the mirror stem without bottoming out. Mount the mirror with the hardware listed above. (Place the star washer between the mirror stem and the hand control). RIGHT SIDE: STEP 3 If the turn signals are not mounted under the mirror, proceed in the same manner as the left side. STEP 4 If the turn signal is mounted under the mirror proceed as follows: Apply Red loctite to the short threaded end of the special mounting stud. Screw this end securely into the mirror stem. -cont.- 1432-22HD-0105 TURN SIGNAL MIRRORS WITH CONVEX GLASS 1432 INSTALLATION Illiana CUSTOMER SERVICE 877.370.3604 (toll free) INSTALLATION QUESTIONS techsupport@kuryakyn.com or call 715.247.2983 WARRANTY Küryakyn™warrants that any Küryakyn product sold hereunder, if properly installed, maintained and operated under normal conditions, shall be free from any defects in materials and workmanship for a period of one (1) year from the date the Küryakyn products are sold to the customer. CONSEQUENTIAL DAMAGES: Küryakyn shall not be liable for any consequential or incidental damages. ABOUTOURCA TA LOG You’ll find all our innovations for H-D, GL and Metric Cruisers in our annual catalogs. Order online today-select the “CATALOGS” icon. Each Küryakyn™ product comes with a Proof-of-Purchase good for a complimentary catalog. Details in packaging. Be sure to ask your local dealer about other Küryakynproducts, the motorcycle parts and accessories designed for riders by riders. ©2004 Küryakyn USA™All Rights reserved.
STEP 5 Remove the turn signal assembly from the stock mirror. Pay close attention to how the stock turn signal ball joint assembly comes apart as this will aid in re-assembly. STEP 6 Place a star washer over the mounting stud and insert the mirror and stud assembly into the hand control. Re-assemble the turn signal ball joint being sure the turn signal light is aimed to your liking. You may wish to consult your H-D shop manual when re-assembling this ball joint. WIRING: STEP 7 Determine where you wish to splice into the H-D turn signal wiring harness. Cut the harness or strip back an appropriate amount to vinyl wire covering and prepare the wires for splicing. Make the wire connections as follows: Wires from Turn Signal Mirror H-D Turn Signal Wire Colors Black – (Ground) Black (Ground) Red – (Running Light) Blue (Running Light) White (Turn Signal) Violet (Turn Signal) If a more pronounced flash is desired, one may eliminate the running light function and wire as follows: Black Black Red and White together Violet If these turn signal mirrors are to be used in conjunction with stock front turn signals, no load equalizer will be required. If the turn signal mirrors are REPLACING stock front turn signals, in most cases, a load equalizer is required. For easiest access we suggest installing the load equalizer under the seat; tapping into the main wiring harness that leads to the tail lights and rear turn signals.

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HARLEY-DAVIDSON SPORTSTER MODEL'S 215 and S 215 INSTALLATION and CLEANING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 16-03-2012

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1. Refer to Figures 1 & 2. 2. Remove taillight and remove seat. SAFETY: DISCONNECT BATTERY PRIOR TO ALL WIRING MODIFICATIONS 3. Disconnect Right turn signal connector inside taillight. Pull wire from the underside of fender. Cut the wire approximately 2 inches from the connector, 02/16/09 save for reinstallation. Ensure the wires are loose from all retaining clips under fender. 4. Remove nut located behind fender holding the turn signal. 5. On the right side only, Remove the two torx bolts from fender strut, carefully pull and rotate fender strut cover to remove. Pull turn signal wire completely out. Remove bolt holding turn signal to the fender strut cover. SADDLEBAG INSTALLATION 6. Reinstall the fender strut cover using the 1 7/8″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the front hole and the 1 1/2″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the rear hole. Refer to view “B”. Insert the chrome caps into the existing turn signal holes. Bend tabs over to ensure a snug fit. 7. Repeat disassembly and installation on opposite side. TURN SIGNAL RELOCATION 8. Install turn signal bracket between license plate and license plate bracket with ears of bracket facing the front of the motorcycle, using 1/4 – 20 x 3/4 Hex cap screws, 1/4 flat washers, and 1/4 – 20 locknuts. 9. Mount turn signals directly to bracket using 5/16 – 18 x 3/4 hex cap screws with a Black Plastic Spacer, and 5/16 star washer. For a clean installation slide rubber grommet over the wire and secure into hole in turn signal, remove top center mounting bolt on license plate bracket and run wires through this hole. Splice the connector back on the wire, and reconnect to wire harness. Ensure all wires are secure under fender. Reinstall taillight. 10. Connect battery and test turn signals for function. Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points. 11. Mount saddlebags over spools on fender strut and secure with clips retained inside bags. 12. Inspect each clip to verify each clip is properly seated in retaining groove. See View “A”

2007 KTM EXC LED Taillight and Turn Signal Kit Installation Instructions

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Filed Under (KTM) by admin on 31-01-2012

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Remove the seat & fuel tank. Photo 1 Unplug 2. Unplug the two three-pin connectors that mate the taillight & turn signal power leads to the stock wiring harness on top of the airbox. See Photo 1. 3. Unbolt and remove the stock taillight & rear turn signal assembly from the rear fender. The wires & connectors will pull through the gap in the fender/airbox plastic with a little finesse. 4. Unplug the two small white plastic connectors near the upper edge of the stock taillight lens and separate the wire extension from the taillight. See Photo 2. Photo 2 Unplug these two connectors and remove wire extension Photo 3 Remove 5. Using a sharp blade or cut-off wheel, remove the two molded mounting bosses on the bottom of the fender. See Photo 3. 6. Attach the new LED taillight to the fender as shown using the provided countersunk mounting hardware. Use the two longer bolts for the front mounts. The LED cluster should not protrude beyond the edge of the fender

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Honda GL1500 Gold Wing Motorcycles Trike Conversion Installation Guide

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Filed Under (Honda) by admin on 19-12-2011

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Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Left and right side-covers (to be re-installed with minor modification). • Seat (to be re-installed without modification). • Trunk. • Left and right passenger foot rests (to be re-installed without modification). • Left and right side-covers above passenger foot rests. • Battery and holder (to be re-installed without modification). • Left and right saddle bags (retain side cover mounting grommets for re-use). • Left and right mufflers. • Rear wheel. • Rear brake line to master cylinder.** • Reverse resistor assembly (to be relocated). • Swing Arm (Drive shaft boot will not be used). • Bank angle sensor. • Shocks. Air shock (non coil-over) to be reused. ** Thoroughly vacuum drain rear brake system, including feed line to left front caliper Modification to Trunk / Luggage Stay Removal from vehicle frame is not necessary. a. Cut the down tubes of the trunk stay and remove the lower section as shown in Figures 1 & 2 b. Trim rear upper tube-end rounded corners just outboard of welded nut. Trim line should be parallel with center line of vehicle. This will provide clearance for body when installed. Figure 2 (Inset) c. Remove the Hazard and Turn Signal relays from the center holder; bend Relay Holder Tab up 90°. Relays will be relocated to left and right sides. Figure 3

HONDA 2005 CBR 600 RR FULL S/S EXHAUST HEADER INSTALLATION

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Filed Under (Honda) by admin on 01-12-2011

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Place the motorcycle in a vise or on it’s kick stand and make sure it is safe and secure. NOTE: If reusing the stock midpipe and muffler, skip ahead to step #5. 2) Remove the rider and passenger seats. Unplug the tail light, license plate light, and turn signals wires inside the tail section. 3) Remove the four bolts that secure the tail section to the subframe. Carefully remove the tail section from the subframe. 4) Remove the four bolts that secure the license plate/turn signal mount to the subframe. Remove the mount from the motorcycle. 5) Remove the upper and lower front fairing pieces. 6) Remove the two bolts that attach the right side footpeg assembly to the motorcycle. Disconnect the rear brake light switch and swing the footpeg assembly out of the way. Remove the outer plastic foot guard. Remove the aluminum heat shield from the motorcycle. 7) If equipped, remove the o2 sensor from the stock midpipe assembly.
NOTE: If reusing the stock midpipe and muffler, loosen the midpipe mounting bolts, and loosen the clamp securing the headpipe to midpipe connection. Skip ahead to step #9 8) Remove the midpipe mounting bolt, located on the right side of the subframe. Remove the
muffler mounting bolts. Lower the muffler and remove the rear exhaust section from the midpipe. 9) Remove the eight hex flange nuts securing the header flanges to the cylinder. 10)Remove the bottom header mounting bolt from the midpipe assembly. Remove the complete header from the motorcycle. 11)Remove the hat washer and rubber grommet from the stock midpipe assembly. Install the rubber grommet and hat washer into the hole provided on the Jardine midpipe assembly. 12)Slide the four headpipes into the new collectors. The headpipes are numbered from #1 thru #4, with #1 being the furthest toward the left side of the motorcycle, then work your way to the right. Do not install the provided springs at this time

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Honda CBR 600 F4i 2004 – 2005 Bestem USA Fiberglass F13 Installation Guide

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Filed Under (Honda) by admin on 20-11-2011

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We highly recommend having a professional install this undertail. A dremel tool or nsimilar is what we found the best to cut plastics. Place bike on a rear wheel center stand. Remove passenger seat and hardware which secure stock undertail section Unplug the harness that connects tail light and remove the stock undertail. Position Bestem undertail close to the bike and determine the amount of plastic needs to be cut out. Use a dremel tool to carefully trim off plastics (glove boxes etc). This is the most time consuming part of the installation but your patience will be paid off. 5) Once the new undertail is slide in, determine holes need to be drilled (only on
certain models). Reuse the hardware for the stock undertail to secure the new undertail. 6) The wiring color codes from two round tail lights are Black Wire – Ground, connects to Ground wire. Red Wire – Brake Light, connects to brake light. Blue Wire – Running Light, connect directly to the running light. Orange Wire – Turn Signal, connect them to your L/R turn signal wires We highly suggest you solder the connections and use heat shrink wrap to seal the connections. Test your lights before going out for a ride, also make sure your new undertail is securely installed on the bike. Now it’s time to go out for a spin!

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