harley touring 4 point docking installation instructions

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HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.

HARLEY DAVIDSON DYNA DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION Installing the Front Docking Point To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Remove the seat and disconnect the negative (-) battery cable. NOTE To keep the fender aligned, complete ALL the following procedures on one side of the motorcycle before starting the other side. 2. See Figure 1. Remove the stock fender support bracket. Position new rear fender mounting bracket from kit (5) into position. 3. Apply Loctite 243 (Blue) to button head bolt (2) prior to installation. Place the tapered side of front docking point (1) against the strut cover. Insert button head bolt (2) through the docking point, fender support and fender. Tighten to 12-18 ft-lbs (16.3-24.4 Nm) . 4. If used without saddlebags, install rear docking point (3) and recess cover (4) according to instructions in Part Number 53968-06C, Directional Relocation Kit. If used with saddlebags, mount rear docking point according to instructions with saddlebag kit. MAINTENANCE NOTE In time, the docking points may wear causing the mating luggage rack or sideplates to become loose. The fit may be tightened using the following procedure. If any fasteners with Loctite are loosened, then the fasteners must be removed, cleaned of existing Loctite and re-installed with new Loctite. 1. Loosen the docking hardware. 2. Rotate the docking points clockwise approximately 45°. 3. Tighten the docking hardware to the appropriate torque values as indicated in the installation procedures. This procedure can be repeated up to 3 times before replacement of the docking points is recommended.

HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

2004 Harley Davidson Micro Tach Tachometer Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-03-2012

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Tachometer Installation Instructions for 2004+ Harley Davidson Sportster Custom Look for other model instructions online at www.speedwayinstruments.com Introduction: Installation of the Speedway Instruments microTach+ TM tachometer Tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. These instructions utilize a 2004 Harley Davidson XL1200C motorcycle as basis for the all descriptions and pictures. Variations in location, color and procedure may be required for different year and make. Please refer to the Service manual to confirm the proper color and location of wires. Please make sure you have the proper service manual and tools before starting the installation. 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservior b. Top handle bar clamp

HARLEY DAVIDSON STEERING HEAD WASHER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 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. 1. See Figure 1. Remove the fork stem cap (1). Bend the lockwasher (2) tab away from the steering stem nut (3) and remove the fork stem nut and lockwasher. Discard the lockwasher. NOTE Always tighten the steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm) before measuring fall away. Lubricate threads of nut with a small amount of clean engine oil. Avoid applying oil to the mating surfaces of the steering stem nut (3) and the new hardened washer from the kit. 2. Install the new hardened washer from the kit (2) and steering stem nut (3). Tighten steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm). 3. Check fall away following the instructions in STEERING HEAD BEARINGS BEARING ADJUSTMENT (FALLAWAY) in an appropriate Service Manual, however, tighten the steering stem nut (3) to 70 – 80 ft-lbs . Adjust adjusting nut (5), if necessary per instructions. 4. Install fork stem cap (1).

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