HARLEY DAVIDSON CHROME INNER PRIMARY COVERS INSTALLATION MANUAL

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

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INSTALLATION 1 2 3 is06139 Figure 1. Remove Three Original Equipment Screws As Shown 1. See Figure 1. Remove the stock fasteners as shown in Figure 1. Save screw (3) for reuse. 2. Install the stock fastener in the rear inner cover. Place a locating washer over the fastener with the rounded side facing toward the hole in the primary chain case. 3. Slide the rear inner cover into place and loosely secure it with the stock fastener. 1 is06416 1. Acorn nut Figure 2. Fasten Front And Rear Inner Primary Covers Together 4. See Figure 2. Position the front inner cover over the rear inner cover and make sure that the hole in the front cover fits over the threaded stud in the rear cover. Secure the covers together with the acorn nut installed finger tight. 5. See Figure 3 and Table 1. Place the new 4.25 inch (5) and 1-1/2 inch (4) screws in the front inner primary cover. Place locating washers (6) over the fasteners with the rounded side of the washer facing toward the hole in the primary chain case. 6. Tighten all three screws to 108-120 in-lbs (12.2-13.6 Nm) . 7. Tighten the acorn nut. 8. Push the Allen hole plugs (7) into the four exposed screw heads

HARLEY DAVIDSON TIMER COVER KITS INSTALLATION MANUAL

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

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INSTALLATION 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) NOTE For kits 32972-04A, 32924-04A, 32675-04A, and 32923-04A, refer to step 1 and 2 for installation instructions. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. See Figure 2. Remove and discard the original screws and timer cover. 2. Place new timer cover (1) in position and secure with chrome screws (2). NOTE For kits 32584-88TA, 32668-98A, and 32571-98A, refer to steps 3 through 8. 3. Use a 3/8 in. drill bit and drill the heads off the original timer cover rivets. Remove original timer cover. NOTE If the inner timer cover has been riveted in place and access to the cam position sensor is required, use a left hand drill and carefully remove the rivet heads. If a right hand drill is used, the sensor plate screw heads could break off when trying to remove the rivet. NOTE To make the cam position sensor tamper proof, follow steps 4 through 6. If the cam position sensor is not required to be tamper proof, skip steps 4 through 6. 4. Remove and discard inner cover retaining screws. Leave gasket (if used) and inner cover in position. 5. See Figure 1. Place washers (4) over rivets (3) and place rivets into inner cover holes so the backs of the rivets go into the sensor plate screws’ tapped holes. 6. Use a standard rivet tool and install rivets, securing inner cover to sensor plate screws. 7. Use the self-tapping screw (5) to cut threads into the remaining inner cover holes. Discard screw after use. 8. Place new timer cover (1) in position over inner cover (A) and secure with chrome screws (2). NOTE For kit 32581-90TB, refer to steps 9 and 10. 9. Use 3/8 in. drill bit and drill the heads off the timer cover rivets. Remove original timer cover. 10. Place new timer cover in position and secure with chrome screws (Part Number 9462) from kit

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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

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HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON CHROME SPROCKET HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION For 1991 through 1996 XL with Laced Wheels For 1993 through 1996 Softail with Laced Wheels For 1993 through 1997 Dyna with Laced Wheels 1. Remove the rear wheel. Refer to REAR WHEEL REMOVAL in the Service Manual. 2. Remove all stock sprocket mounting screws, washers and locknuts. 3. Place a new chrome washer onto the threads of each new chrome screw from the kit. Install the sprocket onto the wheel. 4. See Figure 1. Obtain new original equipment locknuts and install on the screws. See Figure 2. Tighten all screws in the sequence shown to 45-55 ft-lbs (61-75 Nm). 5. Install the rear wheel. See REAR WHEEL INSTALLATION in the service manual. Verify the correct axle alignment and check belt deflection per service manual instructions INSTALLATION For 1997 and Later XL with Laced Wheels For 1997 through 1999 Softail with Laced Wheels For 1998 through 1999 Dyna with Laced Wheels For ALL Models with Cast Wheels 1. Remove the rear wheel. Refer to REAR WHEEL REMOVAL in the Service Manual. 2. Remove all stock sprocket mounting screws and washers. 3. Place a new chrome washer onto the threads of each new chrome screw from the kit. Apply 2-3 drops of Loctite 262 (red) to the screw threads, and install the sprocket onto the wheel. Tighten all sprocket screws finger-tight. 4. See Figure 3. Tighten the bolts in the sequence shown to 23 ft-lbs (31.2 Nm). NOTE If 23 ft-lbs (31.2 Nm) is reached before screw is fully seated, remove screw and examine screw and wheel for thread damage. Replace screw or wheel if threads are damaged. 5. After all screws have been tightened to 23 ft-lbs (31.2 Nm), mark a straight line, with a grease pencil, on all sprocket screw heads continuing the line over onto the sprocket. 1 4 2 5 3 30 is04009 Figure 3. Tightening Sequence (Later Laced Wheels and All Cast Wheels) 6. Mark a second line at 30° clockwise from the lines on the sprocket at each screw. NOTE For best results, use Snap-on Torque Angle Gauge TA360 or equivalent. 7. Using the marks as a guide, and using the tightening sequence shown in Figure 3+, turn each screw an additional 1/12 turn or 30° clockwise. 8. Install the rear wheel. See REAR WHEEL INSTALLATION in the service manual. Verify the correct axle alignment and check belt deflection per service manual instructions

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HARLEY DAVIDSON FL ADJUSTABLE RIDER BACKREST MOUNTING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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REMOVAL 1. Remove existing seat and grab strap (if equipped) following instructions in the service manual. 2. Refer to the service manual and remove the left side cover and battery. 3. See Figure 5. Pull plastic spark plug wire clip out of the hole in the frame plate at the location where the adjustment handle bracket is going to mount. Discard plastic hose clip. 4. Remove the mid-frame air deflector upper left mounting bolt and washer. Save for installation. 5. If equipped with a grab rail: See Figure 1. Remove grab rail screws (1) and discard. 6. Remove wire harness retention clip located above the bank angle sensor. Discard clip. 7. Remove screws (3) holding the bank angle sensor (4). 1 3 2 4 is06104 1. Grab rail screw (2) 2. Grab rail 3. Bank angle sensor screw (2) 4. Bank angle sensor Figure 1. Remove Bank Angle Sensor Screws INSTALLATION 1. See Figure 2. Install clip nut (1) in mounting hole (2). Align the clip nut hole with alignment hole (3). Follow the instructions included with the Mid-Frame Air Deflector Kit to install the four self-clinching special nuts. 2. Move the electrical connector so that the backrest mounting base does not interfere with it. 3. See Figure 3. Install mounting bracket (8) to mounting base (4) with screw (6) and flange nut (7). Tighten screw to 72-96 in-lbs (8-11 Nm) . NOTE Only use the specified screw to install the mounting bracket to the bank angle sensor. 4. Secure the mounting bracket (8) to the bank angle sensor bracket with 1/4-20 x 5/8 inch screws (5). 5. If installing grab strap (9), install backrest mounting base and grab strap with screws (1) and washers (2). If grab rail is installed, install backrest mounting base with screws (1) and washers (2)

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HARLEY DAVIDSON CHROME BELT SPROCKET COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation 1. Remove rear wheel. Refer to the applicable Service Manual for the proper removal procedure. 2. Remove bolts and washers from sprocket. •If you intend to install Acorn Nut and Stud Kit (Part No. 91734-85), refer to that Instruction Sheet at this time (please note that this Acorn Nut and Stud Kit does not fit Sportster (XL) models). •If you do not intend to install Acorn Nut and Stud Kit (Part No. 91734-85), retain bolts and washers for reassembly. Proceed to Step 3. 3. Position sprocket cover so that its mounting holes align with the holes in the sprocket. NOTE There is only one position which allows each hole in the cover to align with a hole in the sprocket. If replacement bolts, washers, or nuts are required, use only genuine Harley-Davidson parts specified for your particular model. Aftermarket fasteners can adversely affect performance, which could result in death or serious injury. NOTE • See Harley-Davidson service manual for proper torque val- ues; •Aftermarket fasteners may not have the specific property requirements to perform properly. 4. Install bolts with washers through holes in sprocket cover and sprocket, and into threaded holes in wheel hub. Depending on the tensile strength grade of the bolts in your particular application, tighten bolts in a crosswise pattern to one of the torque values listed in the following table: 5. Refer to the applicable Service Manual for the proper procedure and perform the following: •Install axle. •Align belt. •Adjust belt tension. •Tighten rear axle nut to 60 – 65 ft-lbs torque. 6. Check sprocket for radial runout (eccentricity). If runout is visible, mark outer edge of sprocket at the location of runout. Loosen sprocket bolts and tap the marked location with a rubber mallet. Tighten sprocket bolts in a crosswise pattern to the applicable torque specified in Step 4.

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HARLEY DAVIDSON SOFTAIL DETACHABLE WINDSHIELD INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION NOTES To prevent scratches, cover the headlamp and the front of the fuel tank with a clean cloth and be sure the windshield assembly does not contact chrome or painted parts when removing or installing it. 1. Remove the original equipment windshield, if equipped. Discard the windshield and attaching hardware. 2. See Figure 1. Remove and discard screws and washers securing trim strip (6) to the front and rear trim pieces. 3. Peel protective cover from adhesive side of clear tape. Center tape over front panel trim piece, attach tape to trim piece, wrap tape edges around trim piece and attach to back of trim piece. Leave the protective tape on the trim pieces after kit installation. 4. Install a flat washer (2), bushing (3) and thick washer (4) onto mushroom screw (1), then install the screw into the upper hole of the trim strip (6) and front and rear trim pieces. Do not tighten screw. 6 1 4 2 3 5 4 2 3 is02411a 1. Mushroom head screw (2) 2. Flat washer from kit (4) 3. Docking point bushing (4) 4. Washer, thick (4) 5. Button head screw (2) 6. Front panel trim strip Figure 1. Front Panel Trim Strip and Windshield Dock Installation 5. Install a flat washer (2), bushing (3) and thick washer (4) onto button screw (5), then install the screw into the lower hole of the trim strip (6) and front and rear trim pieces. Tighten screws to 96 in-lbs (10.8 Nm) . 6. Repeat procedures 2 – 5 on the opposite side. 7. Lock the bottom windshield assembly jaws into the grooves of the lower rubber docking bushings on each side of the front fork assembly. 8. Hook the top windshield assembly jaws into the grooves of the upper rubber docking bushings. 9. Firmly press the windshield into place until it is seated on the docking bushings. 10. Tighten the upper screws to 96 in-lbs (10.8 Nm) . Improper installation of accessories or loading of cargo can affect motorcycle stability and handling, which could result in death or serious injury. (00455b) Failure to provide adequate clearance between stationary and moving parts can cause loss of control, which could result in death or serious injury. (00378a)

HARLEY DAVIDSON SOFTAIL SADDLEBAG KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTES Maximum saddlebag weight capacity is 7 lbs (3.18 kg) for each bag. Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. 2000-2002 Models with Wide Tire Kit 1. See Figure 1. Remove and discard stock screws (1) and washers (2) from fender support. Button head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b) 2. See Table 3. Determine appropriate screw from wide tire kit. 3. See Figure 2. Install saddlebag using screw (from wide tire kit) (1), washer (2) and nut (3). The screws are installed from inside to outside of fender. NOTE If you do not have the appropriate screw from the wide tire kit, it can be purchased from a Harley-Davidson dealer. Table 3. Wide Tire Kit Screws (3/8-16) Wide Tire Kit 44490-00, Hardware Kit 43763-00 Wide Tire Kit 44490-00, Hardware Kit 43761-00 Part Number and Length X X 4030 – 2-1/2 inch X X 4225 – 3-1/2 inch X X 4224 – 1-1/2 inch X X 4044 – 1-1/4 inch X 4215 – 2 inch X 3912 – 2-3/4 inch X X 4228 – 2-1/4 inch X X 4229 – 3-1/4 inch Failure to tighten saddlebag mounting bolts to specified torque could result in damage to saddlebags. (00406c) 4. Tighten all saddlebag hardware to 22 ft-lbs (30 Nm). NOTE Check that front screws have at least one thread exposed beyond the nut after proper torque has been applied. 5. Install reflectors on saddlebag. Refer to Install Reflectors subtopic.

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HARLEY DAVIDSON DASH PAD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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This kit fits 1997 and later FLHT model motorcycles. INSTALLATION 1. Refer to the appropriate Service Manual and remove the outer fairing. NOTE See Figure 1. Place the template in the left side position (as seen facing the forward side of the inner fairing) with the “L” showing. Place the template on the right side with “R” showing. 2. See Figure 1. Using the template supplied in the kit, mark the two hole locations on forward side of the inner fairing. 3. Drill a 1/8 in. pilot hole in each of the hole locations. 4. Drill a 1/2 in. hole in each of the pilot hole locations. 5. Install the dash panel above gauges on inner fairing and secure with screws and washers from kit. Tighten screws to 25-30 in-lbs (2.8-3.4 Nm) . 6. Refer to the appropriate Service Manual and install the outer fairing. L 1 is00488 1. Template Figure 1. Template Placement (Left Side Shown) SERVICE PARTS 1 3 4 2 2 is00486 Figure 2. Service Parts for Dash Pad Kit Table 1. Service Parts Part Number Description (Quantity) Item Not Sold Separately Dash pad, leather wrapped 1 Not Sold Separately Screw (2) 2 Not Sold Separately Washer (2) 3 58318-05 Template 4