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1999-2008 FLHT Series Harley- Davidson Trike Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 04-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect negative Battery Terminal. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Save the Passenger Handrail and two nuts. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove five ¼ – 20 HHCS, ¼ – 20 nyloc nuts, and Aluminum Spacers. 13. Remove Tour Pak from Top Support Tube. 14. Loosen Muffler Clamp on both Mufflers and remove 2 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 15. Remove and discard Muffler Support Plates. 16. Remove both ¼ – 20 HHCS and Front Saddle Bag Brackets. 17. Remove the twelve 5/16 – 18 Torx HCS six 5/16 – 18 nuts, and the Left and Right Saddle Bag Guards. 18. Remove the Air Line Junction from the Rear Fender. 19. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip.
6 20. Remove two 5/16 – 18 Phillips head screws. Remove the Left and Right Frame Covers. 21. Remove two 5/16 – 18 Torx HCS. Remove and save the Top Tour Pak Support Tube Top. 22. Remove four 5/16 – 18 Torx HCS. Remove the Left and Right Rear Saddle Bag Guard Support Bracket. 23. Remove four 5/16 – 18 HHCS. Remove and save the Tour Pak Support Tube Bottom. 24. Remove and discard the Air Valve Assembly Bracket. 25. Remove four ½ – 13 HHCS and washers. Remove and discard both Rear Air Shock Absorbers. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. 26. Drain all Brake Fluid from the Rear Brake System. 27. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 28. Remove the 10 – 24 flanged HHCS and Rear Brake Hose Clamp from the Right Rear Fork Bracket. 29. Remove ¼ – 20 SHCS from Rear Stop Lamp Switch Bracket. 30. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 31. Remove the Spring Clip and nut from the Rear Axle. 32. Remove Rear Axle and Rear Wheel Spacers. 33. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 34. Remove Rear Brake Caliper. 35. Slide Rear Wheel Assembly rearward. Remove one 5/16 – 18 Torx HCS from inside the Rear Fender well. 36. Slide Rear Wheel Assembly forward. Remove two 5/16 – 18 Torx HCS. Remove Rear Fender. 37. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate

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GL1800 Goldwing Trike Conversion Kit Installation Instructions

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Filed Under (Honda) by admin on 10-11-2010

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Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh

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2009 – Current Harley Davidson Trike Conversion Kit INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-02-2012

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect and REMOVE battery. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Remove and save the Passenger Handrail and two ¼ – 20 flanged hex head nuts if equipped. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove four ¼ – 20 HHCS. 13. Remove Tour Pak from Top Support Tube. 14. Remove both saddlebag support rails. 15. Loosen Muffler Clamps on both Mufflers and remove two 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 16. Remove right side rear heat shield. 17. Remove and discard Muffler Support Plates. 18. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip. 19. Remove four frame cover fasteners and the Left and Right Frame Covers. 20. Remove four Tour Pak Support fasteners and the Tour Pak Support.
7 21. Remove four rear fender fasteners and rear fender. 22. Remove four ½ – 13 HHCS and washers. Remove and discard Rear Air Shocks, Air lines and Air Valve bracket. 23. NOTE: NOTE: NOTE: NOTE: If motorcycle is A.B.S. Equipped refer to A.B.S. Installation Instructions. WARNING: WARNING: WARNING: WARNING: If A.B.S. Equipped DO NOT drain brake fluid. 24. Drain all Brake Fluid from the Rear Brake System. 25. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 26. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 27. Remove the Spring Clip and nut from the Rear Axle. 28. Remove Rear Axle and Rear Wheel Spacers. 29. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 30. Remove Rear Brake Caliper. 31. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate. 32. Remove Rear Wheel Assembly. 33. Remove two 3/8 – 16 SHCS. Remove Passenger Footboards.

Harley Davidson Softail Drive Side Brake System Installation Manual

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Filed Under (Harley Davidson) by admin on 30-03-2012

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Removing The Stock Components Although the PM Drive Side Brake System can be installed with the swing arm bolted to the frame, we recommend removing it for better access as well as repainting. Begin by removing rear wheel,stock brake components and belt guard from swing arm. Photo #1 Using supplied 3/4 x 2″bolt,position Drive Side BrakeAssembly on swing arm. Slide assembly to center position of tab and axle spans. Making sure brake mounting tabs are flush with swing arm,snug 3/4 x 2″ bolt to hold assembly and mark swing arm area to be ground Photo #2 . Remove entire assembly from swing arm and thoroughly grind paint away from marked areas Photo #3 . Photo #4 Re-mount assembly to swing arm and slide to rear-most position of both axle and brake mounting tabs. Confirm that brake tabs are flush with swing arm and parallel to each other. Snug 3/4 x 2″bolt and 5/16″socket head cap screws in tabs to hold assembly during welding process. Warning Center the motorcycle on the lift so that it will not fall while you are working on it. Photo #6 Photo #5 Photo #7 Photo #9 Welding Tabs to Swing Arm Note PM recommends all welding be done by a certified welder. Photo #5 Tack weld rear of tabs to swing arm. Avoid excessive welding near brake as- sembly as heat can mar finish. Loosen socket head cap screws and 3/4″bolt,Slide entire assembly to forward most position and re tighten bolts Photo #6 (movement should require minimal effort if tabs are aligned properly) and tack front of tabs to swing arm. Remove brake assembly from swing arm. Weld tabs to swing arm.Verify alignment of tabs, as they must remain parallel to each other. Repaint swing arm and re-install on bike to factory torque specs. Installing Brake Assembly Remove primary bracket from tower assembly (this allows bracket to be installed without having to line up caliper on disc) by removing the three 5/16″socket head cap screws (commonly called allen bolts). Photo #7 Mount rear tire and bolt pulley to rear wheel. Place disassembled bracket against pulley using smaller of two supplied spacers between bracket and pulley. Slide wheel/brake assembly into swing arm. Place large spacer on right side and slide axle in. Do not tighten axle at this point . Photo #8 Slide caliper/tower assembly over disc and install 5/16″x 1″socket head cap screw in center hole to position assembly Photo #9 . Snug, but do not tighten bolt at this point.

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Harley-Davidson Softail Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 02-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the fasteners that secure the seat. Remove seat. 6. Disconnect negative Battery Terminal. 7. Remove the Saddle Bags. And their hardware. If equipped. 8. Loosen Muffler Clamp on both Mufflers and other attaching hardware. Remove and discard both Mufflers. 9. Loosen the 4 exhaust stud nuts and save. Remove and discard head pipes and exhaust gaskets. 10. Disconnect the Rear Lamp Wiring Harness. 11. Remove any fasteners from Electrical Box. 12. Remove and discard Rear Fender, Fender Support and fasteners. NOTE: 2008-Current various models. Remove ECM from Fender and save nuts. 13. Drain all Brake Fluid from the Rear Brake System. 14. Un-clamp Rear Brake Line from the frame and Rear Fork. 15. Remove and discard both Banjo Bolts and Crush Washers from the Rear Brake Caliper and the Rear Brake Master Cylinder. 16. Remove Brake Light Switch from the Brake line, Save for reassembly. 17. Remove the Torx screw from the Brake Line bracket, Save the Torx screw for reassembly. 18. Remove and Discard Brake Line. 19. If Lower Controls option. Remove and Discard right and left floorboards/foot pegs, brake pedal, shifter, and shift linkage. Remove and Discard Passenger Foot pegs or Floorboards and their mounts. Then skip to step 24. 20. If Lower Controls Not purchased. Continue. 21. Remove acorn nut from Shift Linkage. 22. Remove 3 fasteners from Drivers Floorboard and remove. 23. Remove and discard Jiffy Stand. 24. Remove the Primary Cover by first removing the top and rear inspection cover screws. 25. Continue by removing remaining fasteners. 14 total. 26. Remove and discard Primary Cover Gasket. 27. Clean residual gasket material from both surfaces. 28. Loosen the Top Center Nut on the Primary Chain Adjuster. Lower the Primary Chain Adjuster until it rests flat on the Inner Primary Cover. 29. Remove the Clutch Lifter Retaining Ring from the Clutch Basket. Remove Clutch Lifter Assembly. 30. Using the Primary Drive Locking Tool. Loosen the Compensating Sprocket Nut. 31. Using the Primary Drive Locking Tool. Loosen the Clutch Hub Main shaft Nut. WARNING: This nut is LEFT HAND threaded. 32. Remove the Primary Drive Locking Tool, Compensating Sprocket Nut, and Clutch Hub Main shaft Nut. 33. Remove the Sprocket cover and Sliding Cam from the Crank Shaft Extension. 34. Remove the Clutch Assembly, Primary Chain, Compensating Sprocket, and Crank Shaft Extension in one assembly.

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1987 to Current Harley Davidson Softail (FLST Only) Motorcycle Trike Conversion removal and Installation Guide

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Seat (to be re-installed without modification). • Left and right saddle bags (if so equipped). • Left and right rear crash bars, saddlebag rails (if so equipped). • Left and right passenger foot rests (to be re-installed without modification) • Complete exhaust system (to be replaced with new system). • Rear wheel NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake caliper is removed • Remove Rear Caliper (disconnect brake line at caliper) NOTE: Cap line to prevent introduction of dust / debris into line. Remove caliper. • Rear Drive Pulley (1987-99 models to be re-installed without modification). • Rear Fender (2000 and newer models, fender mount plates to be reused). • Swing Arm NSTALLING TRIKE CONVERSION KIT 3.1 Sprockets and Drive Belts Specifications See following table for belt installation (1987-99 will use a 4 tooth longer belt) Note : See OEM manual for belt replacement procedure. Year Drive Sprocket OEM Belt New Belt / Sprocket 1987-92 70 T 132 T 136 1993-94 61 T 128 T 132 1995-99 65 T 130 T 136/70TOEM 2000-06 Champion Sprocket, 70 T 135 T Use OEM 2007 Up Champion Sprocket, 66 T Use OEM 3.2 Install Swing Arm É Noting size and location of bolts, remove Cross Assembly from Champion Swing Arm. Do not discard hardware. Figure 1 3.2.1 1987-99 Model Years • Remove bearings from OEM Swing Arm using OEM shop tools and hydraulic press. Note : Although original bearings can be re-used, it is HIGHLY recommended that NEW bearings be installed to Champion Swing Arm a. b. Press bearings into Champion Swing Arm in the same way as the OEM Swing Arm. Using OEM Spacer Tube and supplied washers (four ¾” flat washers), install Champion Swing Arm using OEM bolt, outside washers and nut. Do not torque pivot bolt nut at this time. Figure 2 Note : Insure belt path is over and under Swing Arm pivot. c. d. Replace cross assembly and hardware (previously removed in step 3.2) to Champion Swing Arm. Note that the 2 upper left hand side bolts are countersunk. Torque pivot bolt to OEM specification

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HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

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2002-2004 TRIUMPH BONNEVILLE AMERICA/ SPEEDMASTER CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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A.) REAR WHEEL REMOVAL- PAGE 14-16 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 12 mm bolt from rear seat section—if you have a pillion pad remove it first by removing the 8 mm bolt, slide forward and lift free of seat catch. Take a position where you can see what you are doing or you will scratch your painted surface. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-14 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 side allen head mount bolts and 2 12mm hex head top front mount bolts– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-11 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove the 12mm rear tank-mounting bolt. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface. E.) REMOVE SIDE COVERS PAGE 15-10 and 9-15 Triumph Motorcycle Service Manual 1.) Loosen and remove left side cover screws on the air filter facade— lift slightly to disengage top mounts and remove—set aside in a safe place to prevent damage to painted surface. 2.) On right side cover simply and gently pull bayonet fittings from rubber slip mounts. 3.) Secure these rubber mounts and remove for later re-assembly with the Bonneville Performance brackets.

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Harley-Davidson Twin Cam Engines Performer RPM Gear Drive Camshaft Kit INSTALLATION PROCEDURE

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

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1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 INSTALLATION PROCEDURE 1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 . 7. On pre-2000 models with a cam position sensor, you may want to remove the inspection cover, unplug the wires, and remove the sensor at this time to ease installation later on. 8. Remove the cam housing cover keeping the bolts in a separate cup. ( Note: Oil will run out of the cam housing.) 9. Using the Chain Tensioner Unloader Tool, unload pressure on the outside chain tensioner, and pin it in place with the retaining pin (See Figure 2) .

HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. 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 Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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