HARLEY DAVIDSON FLHRS SADDLEBAG LOCK SET KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Lay a clean pad or blanket on the work surface to protect the saddlebag leather surfaces. 2. Open the saddlebag lid. Remove the saddlebag from the motorcycle, leaving the lid open. See SADDLEBAG REMOVAL in the Service Manual. Lay the saddlebag flat on the pad or blanket with the inboard side facing up and the lid furthest from you. 3. See . Obtain the templates (10) from the kit. Lay the correct (left or right) template in the upper rear corner of the hard plastic inboard face of the saddlebag. Fit the template around the rear of the lid hinge and against the curve of the raised surface in the middle of the saddlebag, and tape it into place. is03044 Figure 1. Template Placement (Left Side Shown) 4. Drill four 3/16 (0.19)-inch holes in the saddlebag inboard face where indicated on the template. 5. Drill four 5/32 (0.15)-inch holes in the saddlebag inboard face as indicated on the template. 6. Remove the template. Cut out the area in between the four smaller holes to create a rectangular opening for the lock arm. Stand the saddlebag upright, with the cover open. 7. See the Figure 2. Obtain one lockset (1) and two screws (5) from the kit. Position the lockset to the saddlebag as shown, with the actuator rod protruding through the rectangular opening cut in step 6. Insert the screws through the lockset mounting holes and into the saddlebag. 8. Position a backing plate (3) over the screw threads inside the saddlebag. Fasten the lockset and backing plate to the saddlebag with two lockwashers (6) and hex nuts (7) from the kit. 9. Using a 3/16-in. hex wrench, remove the two screws holding the inside cover over the existing pushbutton lid release. Remove the cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 10. Remove the retaining ring fastening the lid release cable to the pushbutton. Unhook the cable from the pushbutton lever, and pull the cable sheath out of the retaining channel on the inboard wall of the saddlebag. Remove the flat washer from the cable end. Do not discard the retaining ring and washer. 11. Trim about one inch (25 mm) from the rearmost part of the retaining channel, and re-insert the cable into the channel so the free end is at the rear of the saddlebag. 12. Insert the cable end through the hole in the backing plate, and slip the washer over the end of the cable fitting. Insert the cable into the slot in the lockset actuator rod so the ball on the end of the cable fits into the depression.

HARLEY DAVIDSON ILLUMINATED CHROME COVER KIT FOR FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION Preparation Models with main fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. Models with main circuit breaker: 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. Installation NOTE Cover the work surface with an H-D Service Cover or clean shop towels to prevent scratching the finish of the outer fairing. 1. Remove the outer fairing per the instructions in the service manual. Lay the fairing face down on a sturdy work sur- face. 2. See Figure 2. Remove the mirrors (2), flange nuts (3) and plastic backing plates (4) securing the mirrors to each side of the inner fairing (1), and retain all items 3. Measure one inch (25 mm) straight down (5) from the large mirror stud hole in the inner fairing, and make a mark. 4. Drill a 1/4 inch (6 mm) diameter hole (6) through the inner fairing at the mark. 5. See Figure 1. Obtain a chrome wire collar (3) from the kit, and press it into the new hole from the outside of the inner fairing. Gently tap into place with a soft-faced hammer. 6. Repeat Steps 3 through 5 on the opposite side of the inner fairing. NOTE Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the mirror cover to the mirror. 7. Clean the back surface of the mirrors with the alcohol pad (7) provided. Allow to dry thoroughly. 8. Obtain the primer tube (8) from the kit, and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back surface of one mirror. 3 6 2 1 4 5 is06091 1. Inner fairing 2. Fairing mount mirror 3. Flange nut (2) 4. Plastic backing plate (2) 5. Measure one inch (25 mm) down 6. Drill 1/4 inch (6 mm) hole (2) Figure 2. Fairing Drill for Illuminated Mirror NOTE The Illuminated Chrome Mirror Covers are side-specific. The covers install with the wire harness exiting from the bottom. 9. Obtain the correct mirror cover from the kit. Rub the liners on the three pads on the back surface of the mirror cover to activate the adhesive, then remove the liners. 10. Place the mirror cover over the back surface of the mirror and press into place for a minimum of 60 seconds. 11. Repeat Steps 8 through 10 for the remaining mirror and cover. NOTE The plastic backing plates (removed earlier) are identified with a letter “L” (left) or “R” (right) stamped on the post. The mirrors are marked with a letter “L” or “R” stamped on the swivel block. Use the correct backing plate for each mirror by matching the letters. 12. Position the mirror on the outer face of the inner fairing, with the rounded side of the mirror outboard and the Bar & Shield logo upright. a. Insert the mirror cover wiring harness through the chrome wire collar installed in Step 5. b. Insert the mirror post through the original mirror mounting hole. c. Place the correct plastic backing plate against the inner face of the inner fairing, engaging the two holes in the backing plate with the threaded stud and index pin on the mirror swivel block. d. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . e. Repeat for the remaining mirror on the other side of the fairing