2012 heritage softail classic recall

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saddlebag locks for Heritage Softail INSTALLATION GUIDE

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1. Center the top support channel on the inside top of the bag lid so that it is centered. Leave a gap so that the lid will close completely when overlapping the bag body. 2. Prior to drilling any holes, check that the support bar is positioned so that it will fit inside the bag when closed. Align the support bar and drill only the eight (8) holes shown in black to mount the top support rail. Mount the rail using the blind button cover screws with the closed end to the outside of the bag. Use a drop of thread lock on each screw. 3. Position the ratchet bar assembly as shown so that the rachet bar is directly over the existing bag emblem and aligned with the existing bag buttons. The center position of the bar leaves two holes exposed on either side of the

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HARLEY DAVIDSON HERITAGE SOFTAIL WIND DEFLECTORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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This kit is designed for 1986 and later FLSTC, FLST, FLSTF and FLSTN model motorcycles equipped with a windshield and/or passing lamps. If your FLST, FLSTC, FLSTF or FLSTN is equipped with a windshield but not a passing lamp assembly, you will need two washers 5/16 x 1 x 1/8 in. (HD Part Number 6645). These washers will be used as spacers for the bottom of the deflector. This kit is also designed to fit with accessory five gallon Fat Bob Gas Tanks. Installation 1. See Figures 1 and 2. On Rigid Mount Windshields, remove the bolts (1), lockwashers (2), and flat washers (3) securing one side of the windshield support bracket. Save all hardware for reinstallation. NOTE On Rigid Mount Windshields, be sure the large spacer (4) between the tip of the windshield support bracket and the fork stays in position. On Detachable Windshields, remove the bolts (1) and flat washers (2) securing one side of the windshield support bracket. Save all hardware for reinstallation. 2. Place the wind deflector in position and install the hardware removed in Step 1. Do not tighten the bolt at this time. NOTE On Rigid Mount Windshields, be sure you install the large spacer between the windshield support bracket and the fork. NOTE On 2000 and later models, be sure the wind deflector is outside of the windshield docking points. 3. Position the wind deflector parallel with the fork leg and install the other flat washers, lockwashers and bolts. Do not tighten the bolts at this time. NOTE If you have a motorcycle equipped with a windshield, but no passing lamps assembly, use the washer (6645) to space the deflector away from the fork leg. 4. Position the wind deflector so it does not touch the bottom of the windshield or the turn signal. The deflector bolt holes are slotted for th is purpose. 5. When the deflector is correctly positioned, tighten the bolts to 17 ft-lbs (23 Nm). 6. Repeat steps 1-5 for the opposite side of the vehicle

2002 URAL Classic Motorcycles BC-75 (Bavarian Classic) LC-75 (Luxury Cruiser) Tourist, Adirondac & Patro Owner's Manual

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Filed Under (Ural) by admin on 02-11-2010

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Front brake control lever (Fig.1, #5). When the lever is squeezed, the front wheel brake is actuated. The front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal lamps are switched on. Kick lever (Fig.1, #11) is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Note: this is a backup to the electric starter. Gear shift foot pedal (Fig.1, #12) is a two-arm type. When the front arm is pressed, shifting from high to lower gears takes place. When the rear arm is pressed, shifting from low to higher gears takes place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift up if you rotate the heel of your left foot in towards the rear arm before stepping on it with your heel. The neutral position is fixed between the I and II gears. Speedometer is on the dash board, with trip (Note..BC-75 has no trip odometer) and total odometer. The trip odometer is reset to zero by rotating push-button (Fig.1, # 3) counterclockwise. Note that the odometer reads in kilometers not miles. Ignition Switch (Fig.1, # 19) has three fixed positions of the key. The position and switching diagram of the ignition locks are shown above.
18 The indicator lamps are mounted on the instrument board: (Fig. 1, # 2) — turn indicator pilot lamp, (orange) (Fig. 1, # 4) — gearbox neutral and reverse gear engagement, (green) (Fig. 1, # 18) — head lamp high beam indicator, (dark blue) (Fig. 1, # 20) — alternator fault indicator lamp, (red) Note: If the red alternator fault light stays on continuously during normal operation above approximately 1500 RPM, there is a problem with the charging system or battery. Throttle Control (Fig.1, # 6) is on the right handlebar. Turning the twist grip counterclockwise increases engine speed. Ignition Cutoff Switch (Fig.1, # 7) has two positions, ignition off (up), and ignition on (down). Low and High Beam Light Switch (Fig.1, # 15), turn indicator switch (Fig.1, #13) and horn push-button (Fig.1, # 14) are combined in one unit on the left-hand handle bar control housing. Master Battery Switch (Fig.1, # 21) is under the seat. Electric Start Button (Fig. 1, # 8) is located on the right-hand twist grip, below the kill switch. The Steering Damper absorbs lateral kicks on the front wheel. Turning tightening bolt (Fig.1, # 17) clockwise increases friction. This can be used while riding over bad roads

HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

HARLEY DAVIDSON SOFTAIL DETACHABLE SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Detachable Saddlebag Configurations Table 1 provides a short description of the detachable saddlebag configurations. Table 1. Softail Detachable Saddlebag Configurations Accessory Configuration (Long Description) Short Descrip- tion Kit 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Other Detachable Accessories FL Outer 88237-07 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) Without Other Detachable Accessories FL Inner 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Rigid-Mounted Accessories FL Rigid 2006-Later FX Models (Except FXSTD) With Other Detachable Accessories FX Outer 88238-07 2006-Later FX Models (Except FXSTD) Without Other Detachable Accessories FX Inner 2006-Later FX Models (Except FXSTD) With Rigid-Mounted Accessories FX Rigid 2007-Later FXSTC Models With Stock Passenger Upright FXSTC Stock NOTE Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Install Turn Signal Relocation Kit Refer to instructions included with Turn Signal Relocation Kit 69857-07. Install Docking Hardware Kit(s) Without Other Detachable Accessories: Refer to instructions included with Docking Hardware Kit 53932-03. With Other Detachable Accessories: Refer to instructions included with Docking Hardware Kits 53932-03 and 88256-07. Install Rear Docking Adapter NOTE This procedure only applies to models without detachable accessories. 1. See Figure 1. Insert rear docking adapter (1) into holes in saddlebag bracket and hold in place. 2. Install rear docking adapter using screw (2) and nut (3). Tighten snugly.

2000 Harley-Davidson FLHRCI Road King Classic

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

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the Road King® Classic is a motorcycle with enough traditional styling to drop jaws throughout the continent. The Road King® Classic boasts laced wheels, fat white-walls and gorgeous leather saddlebags with hard inserts so they keep their shape across the long miles. Slightly narrower new handlebars provide improved ergonomics. Fender tips, tank and seat valance all boast a metal emblem. The model is available with a fuel-injected, chrome-and-black Harley- Davidson® Twin Cam 88 engine. Specifications: Engine Type: 1449 cc, 4-Stroke, Air Cooled, V-Twin Engine Bore and Stroke: 95.3 mm x 101.6 mm Valves 2 valves/cylinder Claimed Horsepower: 67 hp (50 kW) @ 5200 rpm Maximum Torque: 110 Nm (81.1 ft. lbs) @ 3100 rpm Transmission type: 5 speed Final Drive: Belt Tire – Front: 130/90-16 Tire – Rear: 130/90-16 Brakes – Front: dual 292 mm discs with 4-piston calipers Brakes – Rear: single 292 mm disc with 4-piston calipers

Harley Davidson Softail Motorcycles EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Softail EZ-Steer Instruction Supplement Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Harley Davidson Softail Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Installation Notes • Note the torque specifications for the items listed below. Item # Description (Qty) Torque Spec. (Lb.Ft.) N/A OEM Steering Stem Bolt (1) 35 7 7/16-20 x 1.5 Socket Head Cap Screw (2) 45 • The supplied fork tube extensions (Item #2) must be used with the Champion EZ-Steer system. • Do not torque the steering stem bolt until fork tubes have been installed to the assembly. • Remove O-rings from OEM fork tube ends and install to Champion fork tube extensions (Item #2) prior to installation onto fork tubes. • The supplied fork tube covers (Item #9) must be installed to lower triple clamp prior to installation of fork tubes. WARNING: If the Champion EZ-Steer system is installed on a motorcycle / sidecar combination and the sidecar is removed, the motorcycle is not safe to ride, and OEM triple clamps should be replaced.

HARLEY DAVIDSON SOFTAIL REAR SADDLEBAG GUARDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION 1. Remove saddlebag, if equipped, from motorcycle. 2. Remove passenger footpeg or passenger footboard assembly (including footboard mount) from vehicle. 3. See Figure 1. Remove nut (1), seat strap bracket (if equipped) and 3/8 inch diameter bolt (2) from indicated position on rear fender support (immediately to the rear of the front seat) Discard the bolt, but save the nut for reinstallation. This location is where the upper part of the saddlebag guard will mount. 2 1 is03883 1. Rear fender support nut 2. Rear fender support screw Figure 1. Hardware Removal 4. See Figure 2. Install saddlebag guard (4) top flange (5) against fender support (3). Install 3/8-16 x 1-3/4 inch button head bolt with the seat strap bracket (if equipped) and hardware removed in Step 3 (if equipped) and nut in same direction as bolt removed in Step 3. Finger tighten only. 5. Position bottom flange (6) of saddlebag guard (4) against inboard surface of motorcycle frame (7) at location where passenger footpeg (2) (or passenger footboard bolt) attaches. If Heritage-Style Saddlebag relocation kit, Part Number 90238-00 is to be installed, the bracket should be positioned between the saddlebag guard flange and the motorcycle frame member. Follow installation instructions included with that kit. 6. See Figure 3. Determine your model application and follow the applicable installation procedure below: On models with passenger footpeg, but without saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support (B). Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Install lower saddlebag guard flange over bolt protruding from inboard surface of frame member. Install 3/8-16 lock nut to end of bolt. Tighten to 35-45 ft-lbs (47-61 Nm). Install footpeg (C) according to Service Manual instructions. On models with passenger footpeg and saddlebag relocation bracket: Install 3/8-16 x 2-3/4 inch socket head cap screw (6) (For 2007 FLSTC Models, use the 3.5 inch long socket head cap screw (7) from kit) through footpeg support. Install support to frame. Tighten support bolt to 35-45 ft-lbs (47-61 Nm). Position saddlebag relocation

Dazon Raider Classic 150 (Oil-cooled & Internal Gearbox): Service Manual (single/ double-seat)

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Filed Under (Dazon) by admin on 30-11-2010

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1.2.1 Fuel Please use the gasoline of SAE 90# or above. Also we recommend you to use the unleaded gasoline. 1.2.2 Engine Oil Please use the high-quality engine oil of SAE 10w/30SF. 1.3 Break-in Procedure For your first 2 hours of riding, don’t exceed 2/3 throttles. Vary the engine speed for the first 5 hours. Never hold the engine at full throttle for long periods of time. Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 5 1.4 Specifications DIMENSIONS SINGLE-SEAT / DOUBLE-SEAT Overall Length 2330mm / 2300mm Overall Width 1310mm / 1460mm Overall Height 1425mm / 1425mm Wheelbase 1475mm / 1520mm Ground Clearance 200mm VIN Accord with GMVR A01-01 Statutory Plate& Safety Labels Accord with GB 7258-1997 ENGINE Model DZ1P57QMJ Type Oil-cooled, single cylinder, 4-Stroke Engine Capacity 150cc Displacement 149.6ml Bore X Stroke 57.4mm X 57.8mm Max Power 7.0kw or 7000r/m Max Torque 10.0N.m or 6500 r/m Idle Speed 1700 ± 100 r/m CO Emission 7.0g/km HC Emission 1.0g/km Fuel Type SAE 90# or above (unleaded) Lubricate Oil Type SAE 10W/30SF Lubrication Force & Splash Cooling Oil-cooled Ignition C. D. I. Starting Electric Spark Plug C7HSA (NGK) Spark Plug Gap 0.6~0.7mm Transmission Chain Transmission Gearbox Transmission Ratio F.:7.8:1 ; B.:11.297:1 Compression Ratio 9.5 ± 0.1 : 1 Carburetor MIKUNI BS 24-1005 Absorber Normal (in 10 5 times of experiments) CAPACITIES Front/ Rear Tire Load Coefficient 36 Front/ Rear Tire Speed Level L Fuel Tank 7.0L, 130kpa (no leakage in experiments) Engine Oil 1000ml Gear Oil 200ml Starting Time ≤15s Climbing ≥20%

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