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HARLEY DAVIDSON QUICK RELEASE DETACHABLE WINDSHIELD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation The rider’s safety depends upon the correct installation of this kit. 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. (00308a) NOTE Cover the front fender, headlamp and the front of the fuel tank with clean shop towels to prevent scratching. Make sure the windshield assembly does not contact chrome or painted parts. Damage to the finish could result. Turn Signal Relocation Relocate the turn signals according to instructions included in the Turn Signal Relocation Kit, item 20. Assemble the Clamps to the Windshield 1. See Figure 1. Remove the windshield sub-assembly from the packaging and place face down on a clean, soft surface with the mount brackets facing upward. 2. See the Service Parts illustration. Remove both the clamp and hardware kits from the packaging, and separate similar parts in preparation for assembly. Note that upper and lower clamps are exactly alike. 3. See Figure 2. Assemble the clamp assemblies and hardware stacks. The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce the windshield’s ability to break away in a collision, which could result in death or serious injury. 4. See Figure 2. One clamp at a time, with the clamp facing upward and inboard of the windshield bracket (2), tighten the shoulder bolts (1) enough to hold the clamp orientation to the windshield during mounting of the windshield to the bike. The bolts will be fully tightened later. Install the Windshield NOTE Keep front wheel straight to prevent brackets from scratching fuel tank. 1. Make sure all four clamps are in the “open” position, then bring the windshield (with the clamp side away from you) to the front of the bike. 1 WARNING 1 WARNING ® Kit Numbers 58779-05, 57160-05 1 of 3 Figure 1. Windshield Mounting Brackets i07503 Figure 2. Windshield MountingClamp i07504 1 Shoulder bolt 2 Right windshield bracket 3 Cup washer 4 Belleville washers (cupped sides face each other with windshield bracket between)

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DETACHABLE KING SIZE WINDSHIELD FOR SOFTAIL MODELS WITH CHROME HEADLAMP NACELLE OR STREET STALKER HEADLAMP NACELLE (WITHOUT PASSING LAMPS)

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

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Installation 1. Remove upper screws that attach the chrome headlamp nacelle to the front forks. 2. See Service Parts illustration. Attach the upper docking bushings (22) using washer (21) and mushroom head screws (20) Use Loctite 242 (blue) on screw threads. Torque screws to 19 ft-lbs (25.8 Nm). 3. Remove lower screws that attach the chrome headlamp nacelle to the front forks. 4a. For vehicles equipped with the Chrome Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (23). 4b. For vehicles equipped with the Street Stalker Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (24). Installing/Removing Windshield 1. Carefully lock bottom windshield assembly jaws into grooves of the lower rubber docking bushings. 2. Hook the top windshield assembly jaws into grooves of the upper rubber docking bushings. 3. Firmly press the windshield into place until seated on docking bushings. 4. To remove windshield, grab windshield edges on each side of center brace and firmly pull windshield loose from docking bushings. 1 WARNING Carefully inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. Restricted movement could affect handling, resulting in personal injury. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. 1 CAUTION Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of either or both. 1 CAUTION Do not clean Lexan®polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result. Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan®. Lexan®is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. • Do not use liquid windshield “protectors” on your windshield. Although they may work well on automobile safety glass, Harley-Davidson cannot ensure the results when used on Lexan®Harley- Davidson windshields. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant®. • Do not use benzine, paint thinner, gasoline, or other types of harsh cleaning agents on windshield. They will damage the windshield surface. • Do not use benzine, paint thinner, gasoline, lubricants (including Armorall), or other cleaning agents on the rubber bushings. They will damage the bushing surfaces

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HARLEY DAVIDSON FLHR/ FLHP WINDSHIELD KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Remove stock windshield. 2. Remove all hardware that secures the mounting brackets to the windshield. The nine screws that must be removed require a T-27 TORX® screwdriver. Save all hardware and brackets for installing the new windshield. 3. Remove all old tape from the brackets. Apply tape from kit to areas of the new windshield that had tape on the stock windshield. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets and tighten all screws and acorn nuts to 23-27 in-lbs (2.6-3.0 Nm) . 5. Install windshield on motorcycle. 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) NOTE Inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. NOTE Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of components. CARE AND CLEANING NOTE Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections

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 FLST REPLACEMENT WINDSHIELD KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. See Figure 1. Remove stock windshield. 2. Remove all hardware that secures mounting brackets to windshield. The nine screws must be removed with a T- 27 TORX® screwdriver. Save all hardware and brackets for installing new windshield. 3. Remove all old tape from brackets and apply new tape (1, 2) from kit onto brackets. Align holes in tape with holes in brackets. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets. Tighten all screws and acorn nuts to 48-60 in-lbs (5.4 to 6.8 Nm) . 5. Install windshield (3) on motorcycle CARE AND CLEANING Polycarbonate windscreens/windshields require proper attention and care to maintain. Failure to maintain polycarbonate properly can result in damage to the windscreen/windshield. (00483d) •Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windscreen/windshield. Doing so will damage the surface. •Do not clean Lexan® polycarbonate in hot sun or high temperature. •Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. •Never scrape the windshield with a razor blade or other sharp instruments, as permanent damage will result. •Sunlight reflections off of the inside curvature of a windscreen/windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windscreen/windshield to avoid reflections. •Do not use benzene, paint thinner, gasoline or any other cleaning agents on the rubber bushings. Doing so will damage the bushing surfaces. Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant (00231a) NOTES Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier. Harley-Davidson Windshield Water Repellent Treatment Part Number 99841-01 is approved for use on Harley-Davidson Lexan windshields

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HARLEY DAVIDSON SPORT WIND DEFLECTOR AND WINDSHIELD KITS INSTALLATION MANUAL

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

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HEADLAMP VISOR INSTALLATION (2004 ONLY) 1 2 is 01467 1. Headlamp 2. Headlamp bracket mounting screws Figure 1. Remove Headlamp Mounting Screws (Left Side Shown) 1. See Figure 1. While holding the headlamp (1), remove the left and right headlamp bracket mounting screws (2). 2. See Figure 5. Obtain the headlamp visor (2) from the kit. 3. See Figure 2. Orient the headlamp visor (1) between the headlamp and headlamp mounting bracket (2) and reinstall the headlamp bracket mounting screws (3) securing the visor and headlamp to the headlamp mounting bracket. 4. Refer to the Service Manual and adjust the headlamp for the correct angle. 2 1 3 is01468 1. Headlamp visor 2. Headlamp mounting bracket 3. Headlamp mounting bracket screw Figure 2. Install Visor Between Headlamp and Mounting Bracket (Left Side Shown) 1 2 3 is03212 1. “RT” or “LFT” marking 2. Hinge-pin head faces up 3. Clamp post socket faces outward Figure 3. Fork Tube Clamp and Post Identification (Right-Side Clamp Shown) WINDSHIELD INSTALLATION 1. See Figure 5. Obtain one of the lower mount kits from the windshield kit carton. Identify the fork tube clamp for right- side (RT) or left-side (LFT) installation as indicated in Figure 3. NOTE The lower grommets (4) have been pre-installed into the Lexan® windshield. 2. Insert the rounded end of the post into the socket in the fork-tube clamp, oriented as shown in Figure 5. Lining up the hole in the end of the post with the hole in the clamp. With a 3 mm hex key, fasten the post to the clamp with the flat-head screw (16) from the kit, and tighten to 6.8 Nm (60 in-lbs ). 3. Place the clamp around the correct-side fork tube with the hinge-pin head facing up. Insert the two longer screws (15) from the lower mount kit through the counterbored holes in the outboard side of the clamp, and thread the screws part-way into the tapped holes in the inboard half. 4. Position the clamp so the top surface is approximately 6 to 13 mm (1/4 to 1/2 inch) below the upper triple-tree, and the hinge pin is straight forward. With a 4 mm hex key, tighten the screws just enough to hold the clamp in posi- tion. 5. Obtain the remaining lower mount kit and repeat Steps 2 through 4 to install the clamp to the opposite fork tube. 6. Obtain the upper mount kit from the windshield kit carton. NOTE The upper grommets (4), socket assemblies (3), windshield mount caps (6) and 5 mm screws (9) have been pre-installed into the windshield. 7. Place one of the handlebar clamps (5) onto one side of the handlebar, in the straight section between the riser and the handlebar controls, oriented as shown in Figure 4. NOTE Temporarily disengage the switch harness retainer from the handlebar to allow installation of the clamp.

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Kawasaki Teryx 750 Roof / Windshield Kit Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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2. Installation iii) Adhere high density foam gasket to top portion of hood using marker line as centerline guide to ensure windshield panel will sit squarely onto foam after installation. If desired, install small edge trim to side edges of windshield panel and cut to suit. (Steps not shown) iv) Re-install windshield panel onto vehicle. Fasten panel with (6) #10-32 x 3/4″ Lg. screws and nyloc nuts (Fig.4) ensuring windshield panel sits firmly onto foam strip. v) Install and position roof panel onto vehicle allowing for equal spacing on either side of widshield panel edges. Once centered, carefully transfer upper windshield panel holes onto roof panel using a ¼” drill bit. (Fig. 5) NOTE: To prevent excessive rattling noise during operation, install foam strips between roof and rollcage contact points at this time. vi) Fasten roof panel to windshield panel using (6) ¼-20 x 5/8″ screws, washers and nyloc nuts (Fig.6).

HARLEY DAVIDSON WINDSHIELD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL 1. Remove all hardware securing windshield. 2. Remove windshield. INSTALLATION 1. See Figure 1. Remove rubber trim strip from the original windshield and install on the replacement windshield. 2. Put the windshield into position. At each wellnut location use a scribe, or similar pointed tool, to make a pilot hole through the windshield tape where the mounting screw (4) goes into the wellnut (3). Install the mounting screws (4), with the nylon washers (5) and on 2004 models, the rubber washers (6) positioned as shown into the wellnuts (3). 3. Tighten mounting screws from the center to the outside edge on both sides. Tighten screws to 6-13 in-lbs (0.7- 1.5 Nm) . Well-nuts will expand to grip fairing CARE AND CLEANING NOTE Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan. Lexan is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. Failure to maintain Lexan properly can result in damage to the windshield. (00230a) Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant (00231a)

2009 TRIUMPH DAYTONA 675 Triumph/ Arrow Race Rearsets

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Filed Under (Triumph) by admin on 12-11-2010

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race harness kit, air funnel kit, racing oil pump gearing kit, adjustable camshaft sprocket kit, manual camshaft tensioner and blade kit, a reusable engine cover gasket set and racing cylinder head gaskets. Here’s a closer look at the new racing parts and their associated performance improvements: TRACS – Triumph Race Calibration Software TRACS ( T riumph Ra ce C alibration S oftware) is a new computer program that allows racers to tune Triumph’s programmable race ECU from a laptop PC. Developed by one of Triumph’s most experienced EFI calibration engineers, the programmable ECU and software was created for the growing number of competitors that are riding Triumph motorcycles at the track. The new software provides racers with quick access to a wide range of adjustments that can be downloaded to the race ECU in about 35 seconds for tuning during testing, practice and qualifying sessions. Features include: Fully programmable fuel mapping (500rpm increments, for individual cylinders). Fully programmable ignition mapping. Switchable wet and dry maps. Adjustable pit lane speed limiter and speedo calibration. Adjustable quickshifter cut duration (adjustable at low, mid and high RPM) Adjustable rev limiter up to 15,000rpm. New software strategies to improve throttle progression. Optimized software to run faster to cater for the higher RPMs involved in a race environment. Ability to save multiple maps within the memory of the PC. Ability to update an existing 2007/2008 Race ECU to 2009 specification and functionality.* (*Not all features will be available if using the 2007/08 Race harness.) Exhaust – Triumph/Arrow Titanium “Stage 3″ System Triumph has continued to collaborate with Italian race exhaust specialists Arrow Special Parts to develop a new, full titanium racing exhaust system. This system complies with current FIM regulations, works as part of the factory race kit, and offers a significant weight reduction and considerable power gains.

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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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