HARLEY DAVIDSON REARTURN SIGNAL RELOCATION BAR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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Installation Prepare the Motorcycle for Service 1. Follow the Service Manual instructions 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 the negative (-) battery cable from the bat- tery. Remove and Disassemble the Turn Signals 1. Remove the taillamp lens from the taillamp base and depress the latches on the left [18] and right [19] turn signal connectors to remove the connectors. 2. Pull connectors out of the taillamp base and the wires out of the clips. 3. See Figure 1. Cut both the black (BK) and violet and brown (V/BN) wire 4 to 6 in. (10.2-15.2 cm) from the connector. Save the cut wire ends with the connector. NOTE The wires are cut to fit through the new turn-signal bar. Remove the black conduit to allow splicing and stagger the cuts so the conduit will fit over sealed connectors after the wires are spliced back together. 4. Follow the Service Manual TURNSIGNALS, REAR HOUSINGREPLACEMENT instructions to remove the housing and support.

HARLEY DAVIDSON V-LOGO TURN SIGNAL INDICATOR FORROAD KING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1. Disconnect battery cables, negative cable first. 2. Following instructions in applicable Service Manual, remove the windshield. 3. Remove the phillips screw at the bottom of the of the headlamp door (chrome ring). Remove the headlamp door. 4. Remove the seven Phillips screws to free the headlamp housing from the headlamp nacelle. 5. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside. 6. See Figure 1. Reaching inside the headlamp nacelle, remove the speed nut to release the chrome strip at the top of the nacelle. 7. Remove the wire form clip holding the halves of the nacelle together at the bottom. 8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate. 9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove). 10. Loosen the two acorn nuts from the left and right side fork studs. 11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle. 12. Carefully align the template over the handlebar shroud cover and tape into place. 13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means. 14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure. 15. Drill one 1/4″ hole and two 5/32″ holes as indicated on the Drill Template (attached)

HARLEY DAVIDSON QUICK RELEASE DETACHABLE WINDSHIELD KIT INSTALLATION MANUAL

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

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Installation The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) NOTE Cover the front fender, headlamp and the front of the fuel tank with clean shop towels to prevent scratching. Make sure the windshield assembly does not contact chrome or painted parts. Damage to the finish could result. Turn Signal Relocation Relocate the turn signals according to instructions included in the Turn Signal Relocation Kit, item 20. Assemble the Clamps to the Windshield 1. See Figure 1. Remove the windshield sub-assembly from the packaging and place face down on a clean, soft surface with the mount brackets facing upward. 2. See the Service Parts illustration. Remove both the clamp and hardware kits from the packaging, and separate similar parts in preparation for assembly. Note that upper and lower clamps are exactly alike. 3. See Figure 2. Assemble the clamp assemblies and hardware stacks. The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce the windshield’s ability to break away in a collision, which could result in death or serious injury. 4. See Figure 2. One clamp at a time, with the clamp facing upward and inboard of the windshield bracket (2), tighten the shoulder bolts (1) enough to hold the clamp orientation to the windshield during mounting of the windshield to the bike. The bolts will be fully tightened later. Install the Windshield NOTE Keep front wheel straight to prevent brackets from scratching fuel tank. 1. Make sure all four clamps are in the “open” position, then bring the windshield (with the clamp side away from you) to the front of the bike. 1 WARNING 1 WARNING ® Kit Numbers 58779-05, 57160-05 1 of 3 Figure 1. Windshield Mounting Brackets i07503 Figure 2. Windshield MountingClamp i07504 1 Shoulder bolt 2 Right windshield bracket 3 Cup washer 4 Belleville washers (cupped sides face each other with windshield bracket between)

HARLEY DAVIDSON FRONT TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Purge the high-pressure fuel line and disconnect the fuel line following the instructions in the appropriate Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse following the instructions in the appropriate Service Manual. 3. Remove the seat following the instructions in the appropriate Service Manual. Save all seat mounting hardware. NOTE When moving the fuel tank back, do not damage the fuel gauge wires clipped to the frame under the left side of the fuel tank. 4. Remove the front and rear fuel tank mounting hardware following the instructions in the appropriate Service Manual. Move the fuel tank back on the frame to gain access to the tabs on the steering head harness shield. 5. See Figure 1. Disengage the tabs (2) from the holes (3) on each side of the frame and remove the shield (1). 6. Pull the wire harness down from inside the frame enough to disconnect the white (left) [31L] and black (right) [31R] 3-place turn signal connectors. Set aside the frame-side connector halves. 7. Remove the socket terminals from the lamp-side connector halves following the instructions in the appropriate Service Manual. Make note of the wire colors installed in the cavities of each connector, which should be: Left side (white connector): a. Black [BK] wire in cavity 1 b. Violet [V] wire in cavity 2 c. Blue [BE] wire (if installed) in cavity 3 Right side (black connector): a. Black [BK] wire in cavity 1 b. Brown [BN] wire in cavity 2 c. Blue wire [BE] (if installed) in cavity

HARLEY DAVIDSON BULLET-STYLE CHROME TRIM TURN SIGNAL LENS KIT INSTALLATION MANUAL

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

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INSTALLATION 1. See Figure 1. Insert a standard screwdriver tip into the pry notch (3) on a stock turn signal lens to pry the lens from the bullet-style turn signal housing (4). 2. Position the chrome trim turn signal lens (1 or 2) over the turn signal housing with the pry tab positioned at the bottom of the lens (shown in top position for clarity). NOTE Press on the outer edges of the lens, not on the chrome trim ring around the lens, until the lens snaps into the housing. 3. Press the lens into the turn signal housing (4). 3 2 4 1 5 is01847 1. Trim ring (2) – Kit No. 69739-01 2. Trim ring with visor (2) – Kit No. 69756-05 3. Pry notch on trim ring 4. Turn signal housing (not part of kit) 5. Amber lens (2) Figure 1. Bullet-Style Turn Signal Lens

HARLEY DAVIDSON SPLIT VISION MIRROR KIT INSTALLATION MANUAL

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

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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

YAMAHA ROADSTAR TRIKE Removal of Clear Taillights and installation of Red Taillights

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Filed Under (Yamaha) by admin on 16-02-2011

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1 Installation of Lights 1.1 Support the trike on jack stands and remove the wheels. 1.2 Remove the clear lights from the inside of the wheel wells by unscrewing the three (3) screws from the light. 1.3 Unplug the wires and remove the lights. 1.4 Remove the chrome bezels and rubber gaskets from the clear lights and install on the red lights (5 screws). 1.5 Re-connect the wire plugs and install the red lights to the trike body using the same three screws. 1.6 Replace the wheels and torque the lug nuts to 75 lb.ft. 2 Wire modification inside trunk 2.1 From the inside of the trunk pull back the carpet on both the left and right hand sides to expose the wire harnesses coming from the wheel wells. 2.2 Locate the resistors in the harness, 2.5″ x 0.5″ x 0.5″, and covered by black shrink wrap. 2.3 Cut the shrink wrap to expose the resistors and cut wire on both side of the resistors. Remove and discard resistors. 2.4 Splice in the supplied 5″ green wires (WITHOUT the diodes) with 2 blue scotchlock connectors per side to reconnect the cut wires. 2.5 Do not glue in carpet until lights are tested. 3 Change to pigtail from Trike to Motorcycle. 3.1 Remove driver’s sear 3.2 Unplug pigtail from motorcycle (MC) wiring and trike body wiring. 3.3 Cut heat shrink on the MC plug side of the pigtail and pull expansion sleeve back to expose the wires. Figure 1 3.4 Cut Green and Yellow turn signal wires and about 3″ from the MC plug and splice in Green and Yellow wires from the supplied resistors with the supplied hest shrink solder connectors (heat to be applied) – (three wires in one connection) Figure 1 3.5 Cut the Red (Brake) and Brown (Running lights) wires and splice in the supplied diodes with the supplied heat shrink solder connectors. Red side of the diode wire facing the Trike plug. Figure 1 3.6 Connect eye lug on the black wire from the resistors to the negative terminal of the battery. Figure 2 3.7 Plug pigtail back into the Trike body and the MC

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HARLEY DAVIDSON AUXILIARY BRAKE/ RUN/ TURN SIGNAL CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) -J03990 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. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 2. See Figure 1. Locate the rear wiring harness coming out of the rear fender in the area underneath the seat. Disconnect the rear fender lighting wiring connector (1) from the main harness connector (2). 3. Obtain the turn signal module from the kit, and mate the module connectors to the male and female rear fender wiring harness connections. Snap into place. NOTE Due to variations between models, there is no single best location to secure the module. When deciding on a location for securing the module, make sure that the connectors and module will not be bound, and that the wiring will not be pinched when the seat is re-installed. Also, be certain to maintain clearance between the wiring harness and the rear wheel underneath the fender. 4. Using cable straps from the kit, secure the module, connector and wiring in the area underneath seat. 1997-1999 FLHR and FLHRCI models: Go to Step 5. All other models: Proceed to Step 6.

HARLEY DAVIDSON CLEAR/SMOKED BULLET STYLE OR VRSC TURN SIGNAL LENS KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson Dealer. 1. See Figure 1. Locate the removal notch on the turn signal lens and carefully pry from housing. Discard lens. Repeat for remaining lenses. 2. Remove bulbs from turn signal assemblies. 3. Obtain new amber bulbs from kit. Install the bulbs marked 1157A (Dual Filament) to the front turn signal assemblies. Install the bulbs marked 1156 (Single Filament) to the rear turn signal assemblies. NOTE See Figure 1. VRSC (V-Rod) Models have unique rear turn signal lenses. The rear lens is identified with a dimple mark in the center of lens. The front has no dimple. 4. Obtain new lens from kit and install by snapping into place. Check turn signals for proper operation. ® Figure 1. “Bullet” and VRSC Turn Signal Lenses Kit Numbers 69303-02, 69304-02, 69309-02 and 69315-02 Service Parts Clear/Smoked “Bullet” and VRSC Lens Kits Date 5/02 Part No. 69303-02 and Others Item Description Part Number Kit Number 69303-02 1 Clear lens, bullet, front and rear (4) 69324-02 Kit Number 69304-02 2 Smoked lens, bullet, front and rear (4) 69325-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear) 69330-02 Item Description Part Number Kit Number 69309-02 1 Clear lens, VRSC, front (2) 69324-02 5 Clear lens, VRSC, rear (2) 69322-02 Kit Number 69315-02 2 Smoked lens, VRSC, front (2) 69325-02 6 Smoked lens, VRSC, rear (2) 69323-02 3 Bulb, amber (front) 69331-02 4 Bulb, amber (rear

HARLEY DAVIDSON CLEAR/ SMOKED DOMED OR FLAT TURN SIGNAL LENS KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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CLEAR/SMOKED DOMED OR FLAT TURN SIGNAL LENS KITS Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson Dealer. 1. See Figure 1. Remove existing turn signal lenses and discard. Retain lens mounting screws for installation. 2. Remove bulbs from turn signal assemblies. 3. Obtain new amber bulbs from kit. Install bulbs marked 1157A (Dual Filament) to the front turn signal assem- blies. Install bulbs marked 1156 (Single Filament) to the rear turn signal assemblies. 4. Refer to Figure 1. Using screws saved during removal, install the new turn signal lenses to front and rear turn signal assemblies. 5. Check turn signals for proper operation