diagram of harley davidson rear master cylinder

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HARLEY DAVIDSON CHROME MASTER CYLINDER AND CLUTCH BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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MASTER CYLINDER REMOVAL See Figure 1. Master cylinders designed for dual disc (two caliper) operation have an 11/16 inch (17.5 mm) bore, while those that are designed for single disc (one caliper) operation have a 9/16 inch (14.3 mm) bore. The bore size is stamped (1) on the master cylinder assembly inboard of the handlebar clamp bracket. NOTE Do not use an 9/16 inch bore master cylinder assembly on dual disc (two caliper) models or dual disc 11/16 inch bore master cylinder assembly on single disc (one caliper) models. These master cylinder assemblies are not interchangeable. Using the wrong assembly can adversely affect braking efficiency or result in brake failure which could result in death or serious injury. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1 is 01230 1. Bore stamp size location Figure 1. Verify Correct Master Cylinder Bore Size 1. Open bleeder nipple caps on front brake caliper. Install end of a length of clear plastic tubing over caliper bleeder valves, while placing free end in a suitable container. Open bleeder valves about 1/2-turn. Pump brake hand lever to drain brake fluid. Close bleeder valve. Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) 2. Remove bolt and two steel/rubber washers to disconnect fitting of hydraulic brake line from master cylinder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 3. See Figure 2. Place the cardboard insert between the brake lever and lever bracket

HARLEY DAVIDSON 80-SPOKE REAR WHEEL KIT INSTALLATION MANUAL

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

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Additional Parts Required This kit includes the custom wheel only. Proper installation of this kit requires the separate purchase of the following parts which are available at a Harley-Davidson dealer: •Wheel Bearing Remover and Installer (HD-44060) •Wheel Installation Kit (See Service Parts Tables for part number) The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning: •Harley® Bright™ Chrome Cleaner (94683-99) •Harley® Glaze™ Polish and Sealant (99701-84) •Harley®Wheel and Spoke Brush (43078-99) •Harley-Davidson®Wheel and Tire Cleaner (94658-98) The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. 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. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See the Service Parts section for kit contents. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. NOTE Remove the rear brake caliper before removing the wheel. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. Install the tube and tire on wheel. Refer to REAR WHEEL 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) NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. 4. Install rear wheel (1), stock axle and stock axle nut. Refer to REAR WHEEL in Service Manual

HARLEY DAVIDSON CHROME FRONT BRAKE MASTER CYLINDER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. See Figure 2. Drain the brake fluid. a. Open bleeder nipple cap on front brake caliper. b. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. c. Open bleeder valve about 1/2-turn. d. Pump brake hand lever to drain brake fluid. e. Remove cover. f. Close bleeder valve. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 2. Remove bolt and 2 steel/rubber washers to disconnect fitting of hydraulic brake line from master cylinder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 3. 5/32 in. (4 mm) Cardboard Insert 3. See Figure 3. Place the cardboard insert between the brake lever and lever bracket. 4. Using T27 TORX® drive head, remove the 2 screws with flat washers securing the handlebar clamp to the master cylinder housing. Remove the brake lever/master cylinder assembly and clamp from the handlebar. 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) 5. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. 6. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE New master cylinder comes with all internal components preassembled. It is not necessary to remove the components from the bore of the old master cylinder. See Figure 9. Use denatured alcohol to clean clutch system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause clutch failure, which could result in death or serious injury. (00296a) 7. With denatured alcohol, clean and inspect all parts that will be reused. Replace as necessary and wipe dry with a clean lint free cloth

HARLEY DAVIDSON THROWOVER SADDLEBAGS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Installation 1. Place the saddlebags on the vehicle so the straps are positioned over the top of the passenger seat. 2. Lace saddlebags together. 3. Adjust the leather straps so the saddlebags ride high and fit snugly and evenly against the side of the seat. Top of saddlebags may be replaced to achieve snug fit. NOTE On some models, the rear turn signal lights may interfere with mounting of saddlebags. To correct this, a new directional set-back kit is available under part number 90504-82. This kit allows the rear signal lights to be mounted in the rear positions on the fender support, on 1982 and later FXR and XL models. Contact your Harley- Davidson Dealer to obtain this kit. If rear turn signal lights interfere with saddlebags, see your Harley-Davidson Dealer for a turn signal set-back kit. Proper turn signal operation and visibility is a major concern for motorcyclists. Failure to have visible, operational rear turn signals may result in death or serious injury. 4. The front securing straps must be fastened to a point on the motorcycle which is forward of the saddlebags, such as the upper shock mount or fender brace. Be certain the straps so not interfere with any moving parts. Improper positioning or fastening of these saddlebags could cause them to interfere with the operation of the vehicle, possibly causing a hazardous condition. The fastening straps and the saddlebags must be clear of the rear wheel, drive chain or belt, sprocket and rear brake components. Location of the saddlebags should not interfere with the operation of the swingarm and rear shocks and the turn signals should remain clearly visible from the rear and side of the vehicle. Improperly positioned or fastened saddlebags could interfere with the operation of the motorcycle, which could result in death or serious injury. 5. The rear securing straps must be fastened to a point which is rearward of the saddlebags such as the rear turn signal light support. 6. Check that saddlebags are mounted with ample clearance between the bags and the brake caliper and disc so they do not contact each other, even when the swingarm deflects under full load. 7. Once both saddlebags are mounted correctly, check all securing straps to be certain they are not interfering with or exposed to any moving parts. Tuck the tails of the leather straps underneath the portion of the straps that connect the two saddlebags. NOTE On some motorcycles, it will be necessary to mount the saddlebags over the outside surface of the rear shock. This is acceptable if all CAUTIONS and WARNINGS are observed

HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. 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) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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