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HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

HONDA VT-600 Front Wheel Adapter kit Installation Instructions

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

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1. Using a 6mm Allen wrench, loosen the 2 front axle pinch bolts on the right side of the lower fork leg. Loosen bolts 4 or 5 turns. 2. Using a 17mm Allen wrench, slightly loosen the front axle from the right side of the bike. Having the front wheel on the ground will help you in loosening the axle. Do not remove the axle at this time! 3. Loosen and remove the speedometer cable from the back of the speedometer on your handlebars. Pull the speedometer cable all the way out of the front fork. Remove the cable from the speedometer drive on your front wheel (note the position of the connection as it will be similar on your new drive installation). This speedometer cable or speedometer drive will not be needed on your new wheel installation. 4. Block the back wheel to prevent the bike from rolling backwards, and raise the motorcycle’s front wheel off of the ground, so the wheel spins freely. You can do this with a motorcycle lift placed under the front portion of the motorcycle frame. Contact Scootworks to purchase a lift if you don’t have access to one. Ensure the bike is stable and will not fall before proceeding further! Scootworks, Inc. 3 5. Using the 17mm Allen wrench, finish loosening the front axle until it is completely free from the left side of the lower fork. Hold onto the front wheel and slowly remove the axle from the front fork. Be careful not to let the wheel drop. Having a helper hold the wheel for you as you remove the axle will ease the removal. Slide the brake rotor out of the calipers. NOTE: be careful not to operate the front brake controls with the brake rotor removed from the calipers. 6. With the wheel removed from the front forks, lay the wheel on a padded or cushioned surface with the brake rotor facing upwards. Using a 6mm Allen wrench, remove the 5 Allen bolts from the brake rotor. (The bolts are sometimes installed with loctite, and may require heating with a small torch to loosen the loctite). Remove the brake rotor from the wheel. Place the wheel to the side. Clean up the bolts as you will reuse them later. 7. Take your new custom wheel that you will be installing on your bike and place it on a cushioned or padded surface to prevent scratching. Turn it so that the side where the brake rotor attaches is facing upward. 8. Ensure the brake rotor mounting holes on the wheel are clean and free of oil or grease. Clean with alcohol if needed, then let dry. Place your new brake rotor adapter plate onto the wheel with the flat side against the wheel. Apply a small amount of medium strength (blue) loctite on each of the 5/16″ Allen bolts supplied with your kit and install through the new rotor adapter plate and into the wheel. Tighten with a 3/16″ Allen wrench until snug. When all bolts are installed, tighten in a star pattern, and torque to 25-30 ft. lbs. 9. Install your brake rotor onto the new brake rotor adapter using the original bolts you removed in step 6. Apply a small amount of medium strength loctite to each bolt and install through the brake rotor into the new brake rotor adapter. Tighten in a star pattern, and torque to 25-30 ft. lbs. 10. It is now time to install your new wheel/rotor adapter onto your bike. It is easiest to accomplish this with a helper, as it takes some coordination to get the wheel, brake rotor and spacers into place. Apply a thin coat of grease to the axle. Lift the front wheel into place between the front forks, aligning the brake rotor into the caliper. The caliper floats from left to right and can be moved into the proper position. If the caliper is closed, pry the brake pads apart so that the rotor will slide into the caliper.

HARLEY DAVIDSON BLADE FRONT WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. 2. See Figure 2. Install valve stem assembly (L) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. • For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. • For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. • For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08: • Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side. • For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. 4. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. 5. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that they 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

HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY 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) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY 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) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

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

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INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

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