How to Replace a Harley Throttle Cable

Harleys with carbureted engines utilize a dual push-pull system for their throttles.

Harley-Davidson motorcycles with carbureted engines utilize a dual push-pull system for their throttles. One throttle cable pulls the throttle cable bracket to provide acceleration, while the other cable helps to push the bracket back into place. Harley recommends replacing both of these cables should one of them become broken or excessively worn. The length of time to complete this replacement should be between 45 minutes and an hour, depending on your skill level.

Difficulty:

Moderate

Instructions

Things You'll Need

• Cross-tip screwdriver
• New throttle cables
• SAE wrench set

1. Removing the Cable

   • 1

     Remove the two screws securing the handle bar housing with a cross-tip screwdriver. Separate the housing components.

   • 2

     Disconnect the two throttle cable ferrules from the throttle grip. Pull the cables out of the housing.

   • 3

     Pull both throttle cables out of the throttle bracket on the carburetor. Withdraw the cables from the engine area, observing their correct installation position as you do so.

   Installing the Cable

   • 1

     Insert two new throttle cables into correct position through the engine area.

   • 2

     Connect the two cables to the throttle cable bracket on the carburetor. On the opposite ends, insert both cables through the handlebar housing. Insert the metallic ferrules into the ends of the cables and connect them to the throttle.

   • 3

     Reconnect the housing components together and secure with their screws.

   • 4

     Adjust the throttle cable adjuster nut with a wrench with the throttle wide open, making sure the throttle cam touches the cam stop. Release the throttle.

   • 5

     Adjust the idle cable adjuster nut with a wrench, making sure the cable housing touches the spring located on the throttle cable bracket of the carburetor.

Why Do You Break in a New Harley Davidson?

Breaking in a Harley's engine properly has long-term benefits.

Breaking in your new Harley Davidson motorcycle is an important step that ultimately affects your bike's performance in the long run. There are several ways to do it, depending on whom you ask.

1. Ring Seating

   • One of the biggest reasons for breaking in a new Harley engine is ring seating. The rings on the pistons need to achieve compatibility with the cylinder wall, and breaking in your engine will help do so.

   Horsepower

   • If the rings aren't properly set, your engine won't achieve its maximum horsepower, as blow by will regularly occur. Blow by is the escaping of gases into the engine's crankcase, which will in turn cause it to burn oil.

   Head Gaskets

   • The first start up of the engine is important for the care of the head gaskets. The motor needs to run for about a minute at 1,200 rpm with no extra stress applied at first.

How to Charge the Motorcycle Battery for an Electrical Harley

The batteries on an electric Harley Davidson motorcycle need to be fully charged before each ride. Both batteries are located under the seat in the same compartment. One battery powers the engine and the other battery powers all other components on the bike. You can buy the battery charger at any Harley dealership. The charging process will take about 24 hours for the engine's battery and three hours for the other battery.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Ratchet set
• Harley battery charger

1. • 1

     Park the electric Harley on a clean flat surface. Allow the engine to completely cool before proceeding.

   • 2

     Remove the bolts that secure the seat to the frame using the ratchet set. The bolt placement will be different between models but they will be along the edge of the seat in clear view.

   • 3

     Pull the seat off the frame and pull the plastic cover from the top of the battery. Plug the battery charger into an output and turn the power on.

   • 4

     Connect the red clamp to the red connector on the battery. Connect the black clamp to the black connector.

   • 5

     Turn the knob on the charger to the charge position. Allow the battey to charge over night.

How to Measure Harley Shocks

The shock absorbers are the metal piston and spring mechanism on the back of this bike.

The simplest job you can do on a Harley is measure the shock absorbers. Depending on the year and model of your motorcycle, replacement shock absorbers can be found in lengths from about 11 inches to about 14 inches. Commonly, aftermarket shocks are sold in pairs that are described either as stock or as some measurement, up to 1 1/2 inches, "under" standard length. Standard length of the shocks on most recent Sportsters, for example, is 13.5 inches. So a 12.5-inch-long Sportster shock absorber would be sold as a "one under." Aftermarket manufacturers do not always agree with Harley-Davidson on how shocks should be measured; this is how Harley says to do it.

Difficulty:

Easy

Instructions

Things You'll Need

• Steel ruler at least 18 inches long

1. • 1
     Shock absorbers connect the frame to the swingarm.

     Unload the motorcycle. Unload the saddlebags.

   • 2

     Bounce the rear of the motorcycle up and down several times. Ensure the suspension is free and not binding.

   • 3

     Measure the distance from the center of the upper shock bolt to the center of the lower shock bolt with a steel ruler.

How to Service 1991 Harley Front Forks

The forks are the long tubes on the front of this V-Rod.

In 1991, Harley-Davidson shipped motorcycles with two radically different styles of forks. Springer Softail models shipped with "springer" forks, or what old-timers call "new style springer" forks. The ones Harley shipped include two exposed coil springs and a shock absorber. Most of the motorcycles Harley shipped in 1991, though, had telescoping tube forks of several widths and tube diameters. These forks are hydraulic shock absorbers, and the only service Harley recommends is that you change the fork oil every 20,000 miles. There are a half dozen methods for changing fork oil in these forks; this is a method of which Harley-Davidson approves.

Difficulty:

Easy

Instructions

Things You'll Need

• 1-3/8 inch open end or adjustable wrench
• Phillips head screwdriver
• Drain pan
• Teflon paste
• Fork oil
• Pint measuring cup
• Funnel

1. • 1

     Loosen the fork cap on top of the left fork with a 1-3/8 inch open-end wrench or a large adjustable wrench. Remove the fork cap, washer and O-ring.

   • 2

     Remove the drain plug on the bottom, side or back of the fork slider assembly with a Phillips head screwdriver. Drain the fork oil into a pan.

   • 3

     Coat the drain plug threads with Teflon paste. Replace the plug into the drain hole and tighten with a Phillips head screwdriver.

   • 4

     Measure the correct weight and amount of fork oil, as specified in the owner's manual or shop manual, for your motorcycle into a pint measuring cup. Most 1991 Harleys will use about 11 ounces of 10-weight oil.

   • 5

     Stick a funnel into the top of the fork; pour the measured amount of oil into the funnel.

   • 6

     Reinstall the O-ring, washer and fork cap. Tighten the cap wrench securely with a 1-/38 inch open-end or adjustable wrench.

   • 7

     Repeat all these steps for the right fork.

Harley Davidson Fatboy History

Harley Davidson, an American motorcycle company, has a history of paying homage to the American Armed Forces. According to Kevin Lang, parts manager at New Roc Harley Davidson and life-long Harley Davidson enthusiast, the company named the Fat Boy after Little Boy and Fat Man, the two atomic bombs that were dropped on Hiroshima and Nagasaki, respectively.

1. Family

   • The Fat Boy belongs to the Softail family, a line of motorcycles known for its hardtail look with hidden rear suspension that Harley Davidson first introduced in 1984. As of 2009, all members of the Softail family, unless otherwise noted, have a rigid mountain twin-cam 96B engine, 6-speed cruise drive transmission, horseshoe-style gas tank with chrome external oil lines, a 5.0-gallon fuel tank and a Rockertail, Bobtail or FL-style rear fender.

   Original Model

   • The Harley Davidson Motor Company unveiled the Fat Boy in 1990. Inspiration for this bike came from the B-29 bombers that the American armed forces used during World War II. This original Fat Boy model featured the patented Evolution engine, silver grey color (the only color option available), solid-cast aluminum wheels, a wide-bodied fuel tank and a wide front fork.

   Customization

   • Each year, beginning in 1999, the Harley Davidson Motor Company releases a customized version of a few select motorcycles. Available only for one year, these bikes, known as Custom Vehicle Operations (CVOs), have custom paint options, custom wheels, added accessories and the patented Screamin' Eagle engine. In 2005, the Fat Boy joined the CVO program to commemorate its 15th anniversary and featured a lower suspension than the original model, as well as a solo seat called the steel pan.

   Additional Model

   • In 2010, the Harley Davidson company introduced another Fat Boy model: the Fat Boy Lo. This motorcycle sports a very low suspension, an inch-and-a-quarter lower than the original Fat boy and the lowest of any Harley-brand motorcycle. Other details that separate the Fat Boy Lo from the original model include a narrower seat, narrow handle bars and a new tank panel with a Harley Davidson medallion.

   Fun Facts

   • In the movie "Terminator 2: Judgment Day," Arnold Schwarzenegger rides around Los Angeles on the original Fat Boy model. Universal Studios in Hollywood, California, created an attraction based on this film, which features a custom-built Fat Boy similar to the one used in the film. Other films that feature the Fat Boy include "Wild Hogs," "Bulworth" and "Renegade."

How to Install Harley Oil Pumps

Harley Davidson oil pumps are two-sided, gear-type, positive-displacement pumps. The oil pump drive shaft is driven by the cam gear-train which passes through the case and into the back of the oil pump body. Two sets of gears are keyed to the drive shaft: a thick set and a thin set. The thin set supplies high-volume, low-pressure oil to the engine's oil system. The thick set, or return set, draws oil that is collected by the breather valve and forces it through the oil filter and back into the oil tank.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Standard socket set
• 3/8-inch ratchet
• New hose clamps
• Hose clamp crimper
• Fresh engine oil
• Pump gasket kit
• 3/8-inch torque wrench
• New oil pump keys (2)

1. Installing Harley Oil Pumps

   • 1

     Locate the drive key slot in the drive shaft close to where it exits the case. Insert a key into the slot and insure that it nests fully in the groove evenly without cocking. Slide the thin drive gear onto this shaft and engage the drive gear key into its slot on the gear.

   • 2

     Place the thin driven gear onto its mounting stud on the backside of the pump body and hold it in place. Place the new inner pump gasket onto the locating studs on the case and slide the pump body onto the drive shaft. Rotate the driven gear until the drive and driven gears nest together, allowing the pump body to slide up tightly against the case.

   • 3

     Insert a key into the drive shaft where it exits the front of the pump body. Slide the thick drive gear onto the shaft and engage the drive gear key onto its slot on the gear. Slide the thick driven gear onto its mounting stud and rotate the gear until it nests with the thick drive gear.

   • 4

     Place the pump cover gasket onto the locating studs. Slide the pump cover onto the locating studs and install the cover bolts finger-tight. Tighten the cover bolts to factory spec and in the approved pattern set by the manufacturer. Install the oil return line onto the spigot on top of the pump and install a new clamp with the factory crimping tool.

How to Pull Harley Rocker Boxes

The popularity of the motorcycle counterculture is currently reaching an all-time high. But while the fun and adventure of motorcycle travel may be undeniable, the hidden cost of motorcycle maintenance can become prohibitive. That's where a good mechanic's tool set and a can-do attitude will go a long way. Fixing a leaky gasket at home rather than at the local Harley dealership can save the rider loads of cash better spent elsewhere. Pulling the rocker box covers from a Harley is necessary to access the heads, replace worn parts and stop rocker box leaks.

Difficulty:

Moderately Challenging

Instructions

Things You'll Need

• Mechanic's tool set
• Torque wrench
• Replacement gaskets
• Harley-Davidson factory manual for your make and model

1. • 1

     Drain the gas from the tank. Loosen all gas tank retaining bolts and remove the tank itself. Place the tank in a safe, out-of-the-way place.

   • 2

     Remove the four bolts and seals from the top of each rocker box cover with an Allen wrench. Remove the upper and middle rocker box covers from each cylinder. Dispose of the old gaskets.

   • 3

     Remove the bolts retaining the rocker arms with a standard wrench. Start with the bolts closest to the push rods. Mark the rocker arm shafts and rocker arms so that they are each installed in their original positions, and then remove them.

   • 4

     Remove all remaining fasteners holding the lower rocker box to the cylinder head using the appropriate wrench. You may now remove the lower rocker box.

   • 5

     Replace old gaskets on each cylinder head and reinstall all removed parts in reverse order. Tighten each fastener down to the specified amount of torque. Before tightening the final fasteners, make sure that the middle section and gasket of the rocker boxes is equally spaced on all sides. Torque the final bolts in a crisscross pattern to help lock down the gasket. Reinstall the gas tank and hoses with all associated hardware.

Tips & Warnings

• Gas tanks vary greatly among Harleys. The method of draining and removing will depend greatly upon the model of Harley-Davidson upon which you are working.

• A word on torque values for fasteners: Harley placed these values in their official factory repair manuals for a reason, so use them. A good torque wrench for the reassembly process is a must. It can prevent you from having to the same job over again down the road.

Harley Davidson Scrapbook Page Ideas

1. • Harley-Davidson shipped 112,720 motorcycles in the first six months of 2010, according to the company's public financial statement.

     Harley-Davidson owners are a proud bunch who love their bikes. Ever since four young men played around with internal combustion engines in 1903, the Harley-Davidson company has grown steadily, according to its website. Possibly, Evel Knievel's famous 1975 Wembley Stadium jump had something to do with it. Or maybe it was the Easy Rider movie craze of 1969 that brought the Harley-Davidson name to be synonymous with coolness. No matter the cause, Harley-Davidson is here to stay. Celebrating your love (or your loved one's love) of a Harley-Davidson is easily done through scrapbooking.

   Scrapbooks as Photo Pages

   • Using a scrapbook as a photo album makes sense. Unlike old photo albums where there was a little plastic sleeve for each photo and room for nothing else, scrapbooks today open a world of possibilities. Paste photographs of yourself and/or your friends on the pages along with silly or profound captions. You can find quotes about motorcycles online, print them out and paste them in strategic places around your photos.

   Scrapbooks as Journals

   • Use your scrapbook to journal your journeys with your Harley-Davidson. Using the company colors of black, orange and white as the background pages, chronicle the exploits you've experienced on your Harley on typewritten pages and paste them on the scrapbook pages. Experiment with different fonts and colors. Use orange, yellow and black font colors against a white background, pasted onto an orange, black or white scrapbook page. Don't forget photos, postcards and little souvenirs, such as event tickets and matchbooks.

   Scrapbooks as a Collector's Display Case

   • Collectors of Harley-Davidson embroidered patches will want a clever and original place to display them. Harley-Davidson patches come in a variety of colors, shapes and sizes. Everything from the company logo to fiery embellishment and eagles with golden wings are depicted on patches along with the Harley-Davidson logo. In addition to patches, this artwork is available as stickers and decals. A scrapbook is the right place to sort and display these tiny masterpieces, along with a caption as to where the patch was acquired and under what circumstances. Use hot glue or double-sided tape to fasten the patches to the heavy scrapbook paper.

References

How to Change a Harley's Transmission Oil

Don't over tighten the drain plug.

While most motorcyclists are well-versed in the proper method to replace their machine's motor oil, Harley-Davidson riders must also replace a separate fluid that lubricates their motorcycle's transmission. This can cause some confusion for newer owners of Milwaukee's finest motorcycles, since most manufacturers consolidate their motor and transmission into one single unit. Luckily, changing the transmission fluid is a simple task that doesn't require special knowledge.

Difficulty:

Moderate

Instructions

Things You'll Need

• Oil pan
• Socket wrench and sockets
• Drain plug O-ring
• Shop towels
• 1 quart transmission fluid

1. • 1

     Unscrew the filler cap from the right side of the transmission. Locate the drain plug on the bottom of the transmission and place an oil pan directly beneath it.

   • 2

     Unscrew the drain plug using a socket wrench and allow the transmission fluid to drain completely.

   • 3

     Remove the O-ring from the drain plug and wipe away any debris or buildup with a shop towel. Slip a new O-ring onto the drain plug. Insert the drain plug into the transmission and tighten it with a socket wrench. Wipe away any remaining fluid from the bottom of the transmission with a shop towel.

   • 4

     Insert a funnel into the filler neck on the right side of the transmission. Add up to one quart of fresh transmission fluid. Remove the funnel and wipe away any transmission fluid that may have spilled with a shop towel. Screw the filler cap onto the filler neck.

Tips & Warnings

• Warm the transmission fluid first to speed up the process. Start the motorcycle and let it idle for five minutes to warm the fluids, then stop the motor. Be careful when removing the drain plug since the motor, transmission, and exhaust pipes may be hot.

• Don't over tighten the drain plug. The threads that secure the drain plug to the transmission can be damaged easily by excessive torque

Harley-Davidson Mechanic Training

Harley-Davidson V-twin engine

Harley-Davidson mechanic training is offered at various public and private technical training institutions. According to Harley-Davidson.com, Harley-Davidson dealerships require technical training to be hired as a mechanic. Some schools that offer the technical training are Motorcycle Mechanics Institute in Phoenix and Orlando, Florida, (offers a complete education aligned with Harley-Davidson University), Fort Scott Community College in Kansas, Central Carolina Community College in North Carolina and Lake Washington Technical College in Washington.

1. Training Time Frame

   • Early model Harley-Davidson V-twin engine

     At Motorcycle Mechanics Institute, you will start with a 30-week training that focuses on service, repair and maintenance of motorcycles. After the 30 weeks you then move on to Harley-Davidson Technology. Motorcycle Mechanics Institute offers an early and/or late model Harley-Davidson program. You will also become certified through online courses with Harley-Davidson Motor Company. Fort Scott Community College offers a two-year program eligible to graduate with a Associate of Applied Science degree in motorcycle service technology. Central Carolina Community College offers a diploma and a certification course. The diploma course is a total of 46 credit hours and the certification course is a total of 12 credit hours. Lake Washington Technical College offers an Associate of Applied Science degree that consists of 113 credits in six quarters.

   Specialized Training

   • Potentially your next customers

     Harley-Davidson specialized training includes Electrical Diagnostics, Crash Estimating, Chassis Service, Screamin Eagle, Buell, V-Rod, Big Twin Power-train, Vehicle Maintenance and the Harley-Davidson 45-inch engine.

   Benefits

   • Learn to become a safe and knowledgeable technician.

     Becoming a Harley-Davidson Technician opens the door to many different job opportunities. You can work in a Harley-Davidson dealership, V-twin custom shop, Harley-Davidson Race Team, a shop that restores older Harley-Davidson motorcycles, or go into business for yourself.

   Misconceptions

   • Keeping your customers safe on the road is the first priority.

     One misconception about someone who works on motorcycles is that he is covered in grease and works in a dungeon-like garage. Harley-Davidson no longer uses the title "mechanic," instead referring to Harley-Davidson technicians. The days of smelly dirty garages are over. Now the technicians work in state-of-the-art facilities that house the best tools and machinery available.

   Take it Seriously

   • Harley Davidson since 1903

     Remember that you are about to enter a career that places peoples lives in your hands daily. Becoming a certified motorcycle technician is not something you do for fun. This is a very technical and serious career that should never be taken lightly. Harley-Davidson is the most well-known motorcycle in the world, and Harley-Davidson owners expect expertise.

Harley-Davidson Screamin Eagle Exhaust Tips

1. • Harley-Davidson is a leader in the industry when it comes to motorcycles. The Screamin Eagle exhaust system is a muffler setup in the exhaust of a motorbike that allows it to imitate the aggressive sound output produced by Harley-Davidson's professional racing exhaust system for its motorcycles.

   The Sound

   • A motorcycle fitted with a Screamin Eagle exhaust can sound like a bike on the racing circuit even when it is not in motion. The good news about these exhausts is that they are road-legal. Most performance enhancements have the disadvantage of not being road-legal despite the high performance they offer. The Screamin Eagle exhaust combines a large internal volume with maximum flow baffles to achieve the perfect balance needed for usable performance.

   Specifications

   • The tips of the Screaming Eagle exhaust are made of the highest quality steel that is chrome-plated to give them a dazzling finish that will attract a lot of attention. The pipes for this system are unique from the stock pipes because of their larger size and come in a variety of shapes and curves, with some of them having fins that mimic those of a fish. These types of exhaust can fit otherwise ordinary motorcycles, improving their aesthetic appeal and giving them the exhaust note of a powerful racing machine.

   Installation

   • These slip-on muffler kits normally require the use of additional muffler clamps. To install the muffler, the old muffler should be removed. The Screamin Eagle muffler slides onto the exhaust pipe and is clamped it into place.

Harley Davidson Decorating Ideas

A Harley Davidson decorating theme can turn any room into a memorabilia showcase. Here are some tips for decorating with Harley Davidson accessories, and bringing some of the carefree feelings of a day on the bike into your home or garage.

1. Harley Davidson Painting

   • Whenever you decorate, your paint job makes the most impact. The dominant colors for a Harley Davidson room should be orange, black and white. Use painter's tape to mark off sections of the wall for striping.

   Harley Davidson Mural

   • If you have a projector, try painting a mural by projecting the Harley Davidson logo or other related emblem onto the wall. Trace it with a pencil and then paint it with latex wall paint.

   Harley Davidsom Memorabilia

   • You can collect memorabilia and display it in your room. Chrome garage shelving can be used to make a tough-looking display case. Hats and T-shirts can be encased to make them look special. Try framing calendars and other items for a classy look.

   Harley Davidson Home Decor

   • Harley Davidson has licensed its logo for appearance on towels, rugs, blankets, lamps, fabric for curtains and slipcovers ... even baby bedding. You can even get an adhesive kit to deck out your KitchenAid mixer with Harley Davidson flames and logo.

How to Change a Harley Exhaust

Harley Davidson exhaust systems dampen engine exhaust noise and provide a precisely metered amount of back-pressure to the system. The back-pressure created at the muffler is an important part of the air/fuel circuit and has a strong impact on maintaining the air/fuel charges entering the cylinders. Harley motorcycles employ a two-part exhaust system consisting of an exhaust pipe leading from each cylinder head and terminating close to the rear of the vehicle. Slip-on mufflers are clamped onto each pipe and then mounted to a bracket at the rear of the bike. The pipes also incorporate a crossover tube to assist the backpressure and aid in exhaust gas scavenging in the heads.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Standard socket set
• 3/8-inch drive ratchet
• 3/8-inch torque wrench
• New slip-on mufflers
• Brake cleaner
• Shop rags

1. • 1

     Loosen the clamp where the exhaust pipe enters the muffler, with a socket. Slide the clamp forward and allow it to rest on the exhaust pipes.

   • 2

     Loosen with a socket and remove nuts on the muffler T-bolts where they enter the rubber mounted exhaust bracket. Lower the muffler away from the frame and wiggle it gently to loosen the slotted muffler sleeve at the pipe. Support the exhaust pipe with one hand and pull the muffler off the pipe with the other to avoid stressing the exhaust pipe gasket. Remove the T-bolts from the muffler and insert them in the muffler mount slot.

   • 3

     Push the new muffler onto the exhaust pipe. Support the pipe with one hand and the muffler with the other. The muffler may have to be wiggled on in order to spread the slotted clamp sleeve enough to fit onto the pipe. Slip the pipe in about two inches.

   • 4

     Rotate the muffler until the T-bolts are lined up with the exhaust support bracket. Insert the T-bolts in the bracket and tighten the nuts hand-tight.

   • 5

     Slide the exhaust clamps back onto the slotted clamp sleeve and torque them to factory specifications with a torque wrench and socket. Torque the T-bolt nuts to factory specifications with a torque wrench and socket.

   • 6

     Use brake cleaner and a clean shop rag to remove all fingerprints and oils from the muffler and the exhaust pipes. Any oily spots will permanently discolor the chrome components once the pipes heat up to operating temperature.

Tips & Warnings

• This procedure describes how you change from one factory style, full restriction muffler to another. This is not the same as changing to a low restriction, high performance exhaust. Adding low-restriction mufflers, such as Screaming Eagle slip-ons, without adjusting the air cleaner and carburetor will de-tune the engine and degrade performance. This three-part process is commonly called a Stage-1 upgrade and is better left to a certified technician at a factory authorized dealer/service department.

How to Identify Harley Gas Tanks

To identify a Harley gas tank without badges requires a closer look.

Harley-Davidson motorcycles are some of the most popular bikes to customize and restore. Often, those who wish to restore an older Harley to its original condition will want only Harley-Davidson parts on the bike so that it is as close to factory-shape as possible. In order to know what to look for to identify a Harley gas tank, you will need to be able to see around the tank and inspect it.

Difficulty:

Moderately Easy

Instructions

1. • 1

     Look to see if one or two tanks are above the motor. If two are above the motor, then the motorcycle was built before 1936. Check inside the right tank. It should have gas only in it, while the left one held gas and oil.

   • 2

     Look for a large bubble shape on the frame side of the tank. If it has one, and it has a matching cavity on the oil tank adjacent to it, it is a 45 model engine and was produced between 1937 and 1973.

   • 3

     If it has no bubble, but has a recess to match the frame, this indicates a Big Twin SV. If both the right and left tanks have deep recesses in the bottom to clear the heads, as well as recesses for the frame, then it is an OHV motor. These motors have been used in a variety of model years since 1937.

Tips & Warnings

• If the emblem mounting strips are still on the tank, they can help identify the year of the tank. To further identify the bike, use the vehicle identification number (VIN). One easy rule of thumb is that if a VIN is on the bike frame, it was built after 1968.

How to Add Transmission Fluid to a Harley Sportster

A casing on the backside of the engine houses the Harley-Davidson (H-D) Sportster transmission. The primary chaincase holds the lubricant shared with the clutch components and the primary drive chain. Normal vehicle service includes changing the lubricant, and should be performed at 1,000 miles and at each 10,000-mile service after that.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Shop rag
• Ratchet
• Allen driver set
• Transmission lube (Harley-Davidson part number 98851-05)
• 1/4-inch torque wrench
• 3/8-inch torque wrench

1. • 1

     Ride the bike until the engine reaches full operating temperature. Park the bike on firm, level ground.

   • 2

     Cover the rear master cylinder with a shop rag. Grasp the left side-cover and pull it away from the plastic mounting clips on the frame.

   • 3

     Compress the locking tabs on the main fuse by hand. Pull the main fuse connector off the fuse terminals.

   • 4

     Raise the bike off the jiffy stand to the vertical position. Hold it for three minutes to allow the oil to settle in all of the passages before proceeding. Have someone continue to hold the bike up throughout the rest of the process.

   • 5

     Remove the left rider footrest bolts from the frame with a ratchet and Allen driver. Remove the footrest from the bike.

   • 6

     Remove the six clutch inspection cover mounting screws with a ratchet and Allen driver. Pull the cover from its recess, and inspect the rubber seal for damage or wear. Replace if necessary.

   • 7

     Pour the H-D lubricant into the clutch inspection hole until the fluid level reaches the bottom edge of the clutch diaphragm spring.

   • 8

     Install the clutch inspection cover screws. Torque the screws to between 84 and 108 inch-pounds, using a 1/4-inch torque wrench.

   • 9

     Install the rider footrest and mounting bolts. Torque the bolts to between 45 and 50 foot-pounds, using a 3/8-inch torque wrench and Allen driver.

   • 10

     Push the main fuse connector onto the fuse terminal until the locking tabs snap into position. Position the left side-panel and snap it into the plastic mounting tabs in the frame by hand.

Types of Harley Davidson Motorcycles

1. • Saddlebags are one option when building your dream motorcycle.

     The Harley Davidson Company has been building motorcycles since the two founders created the first one in their wooden shed in 1903. Since then the line of motorcycles has expanded and today there are several different models of Harley Davidson motorcycles, each with features that make it distinctively a Harley.

   Softail Deluxe

   • The Softail Deluxe has what Harley Davidson call a "nostalgic chrome tank console" and a narrow seat. The weight of this bike is 726 pounds when running and is 94.7 inches in length. The seat height when you are riding is 25.9 inches. Other features include full length floor boards, a tombstone taillight and a seven-inch ball headlamp. Other accessories such as rear end components, windshields and luggage rack can be added to the motorcycle to customize it as you wish.

   Sportster

   • The Sportster is a lighter weight model with a running weight of 589 pounds and is just over 90 inches in length. Some of the main features of this motorcycle include passenger pegs, low-rise handlebars and a bullet style headlight. The standard seat height is 28 inches without a rider and 26.5 inches when you are seated. Build it your way and add things like their Brawler seat or back rest for the passenger seat, decorative decals, enhanced foot controls and hand controls. The Harley Davidson Screamin' Eagle trademark is available on things like air cleaners, mufflers and carburetor covers.

   Road King Classic

   • The Road King Classic is one of the Touring models and is equipped with standard features such as a redesigned rear fender, rubber-mounted twin cam engine, leather saddlebags and LED indicator lights. An optional feature for this bike is a sidecar. Accessories to be added to your motorcycle include items such as chrome hand controls, custom mirrors and a windshield. This bike has a running weight of 810 pounds, measures out at 94 inches in length and a seat height of up to 29.5 inches. Color packages are available for you to tailor your bike to your personal style.

   Street Glide Trike

   • If you prefer to ride on three wheels there is the Street Glide Trike. It comes with a thin seat and a trunk that can hold up to 50 pounds. The steering has been made more functional by expanding the front forks to make it easier to control on the road. This bike is heavier with a running weight of 1,110 pounds and a length measurement of 105 inches. The seat height when you are seated is 28.4 inches. Accessories include a back rest, windshield, a cover, seat pads and seat rain cover.

How to Calculate a Harley's Horsepower

Harley-Davidson engines are known to be the "Kings of Torque".

Horsepower is the work produced that maintains movement. One horsepower is defined as producing 33,000 foot-pounds of work in one minute. An engine can continue to make more horsepower as long as RPM is increasing faster than torque is falling. Torque and horsepower are the result of frictional losses, volumetric efficiency, engine displacement, BMEP (Brake Mean Effective Pressure) limitations and RPM. As RPM rises, there is less time to fill the cylinder and torque begins to fall off. When torque is measured over time, it becomes horsepower. If you know the horsepower you can calculate the torque.

Difficulty:

Easy

Instructions

Things You'll Need

• Calculator

1. • 1

     Multiply torque by RPM.

   • 2

     Divide your answer by 5252. For example, a TC88 engine produces 84 foot-pounds of torque at 3,500 RPM. The horsepower would be 55.97.

   • 3

     Multiply horsepower by 5252.

   • 4

     Divide answer by RPM. Example: A TC88 engine records a maximum of 78 horsepower at 5,500 RPM. The engine torque would be 74.48.

How to Change a Battery on a 2005 Harley Sportster 883

Change a Battery on a 2005 Harley Sportster 883

The Harley-Davidson Sportster 883 is equipped with a battery designed to require little in the way of maintenance or service until it fails. When the battery in your Sportster 883 dies, buy a 12-volt battery from a Harley-Davidson dealership, auto parts store or motorsports specialist. Change the battery at home in minutes with a Phillips screwdriver and save the expense of a technician.

Difficulty:

Easy

Instructions

Things You'll Need

• Phillips screwdriver

1. • 1

     Loosen the screw securing the back of the seat using a Phillips screwdriver. Lift the seat up and pull it toward the rear of the motorcycle to remove it.

   • 2

     Lift the cover off the battery compartment and set it aside. Remove the screw on the retaining strap with a Phillips screwdriver. Lift the strap off the battery.

   • 3

     Disconnect the negative battery cable with a Phillips screwdriver. Repeat the process for the positive cable. Lift the battery out of the compartment. Position the new battery in the battery tray.

   • 4

     Connect the positive battery cable and tighten it with a Phillips screwdriver. Repeat this for the negative cable. Replace the retaining strap and secure the screw with a Phillips screwdriver. Place the cover on the compartment.

   • 5

     Reposition the motorcycle seat. Tighten the retaining screw with a Phillips screwdriver.

How to Increase the Horsepower of a 2007 Harley Sportster 1200

How to Increase the Horsepower of a 2007 Harley Sportster 1200
How to Increase the Horsepower of a 2007 Harley Sportster 1200thumbnail The twin cylinder engine has potential for much more power.

Increasing the horsepower of your Harley Sportster 1200 involves trade-offs between performance and potential problems. Modifications bring no guarantee of usable additional performance. Harleys are fast bikes when they come from the factory, so the added expense and complexity may not be worthwhile. Despite these concerns, such modifications remain popular. Harley dealers sell many kinds of accessories along with mechanical services to install and tune the upgrades. Besides many after-market vendors, Harley-Davidson itself offers branded accessories designed to enhance the performance, look and sound of its products.

Difficulty:
Challenging

Instructions

1
A new exhaust can add power and sound great.

Replace the exhaust system. By adding a higher flow exhaust system, any engine will experience improved performance. If the engine has to work less to push the exhaust gas out, it has more power to drive the rear wheel. Do your research and find an exhaust system that has been proven to increase your power.
2
Custom air filters can look great.

Replace the air filter with one that has more free flow. More air into the engine along with more gasoline will make for more horsepower. Make sure that the air filter you purchase meets the warranty requirements of Harley-Davidson. Too much flow can mean grit or water in your engine.
3

Adjust the fuel injection. With the change to the air filter and the exhaust system and the increased air flow, some changes to the fuel system will be required. Careful adjustment can yield benefits in additional power.
4
Performance tires are much softer than stock.

Swap out the tires. A stickier tire means better traction. Stock motorcycle tires are a compromise; a harder compound means they will last longer, but they will tend to slip more when the throttle is applied.

Tips & Warnings

This article has concentrated on changes that can be made without altering the interior of the motor. If done properly, they can add power to your bike. More-drastic changes could include boring the cylinders out, replacing the heads or the cams, or adding a turbocharger. But these changes are expensive, may make the bike less comfortable to ride, and will certainly invalidate the warranty.

When making changes to a drive train, it is always best to find a combination of parts that someone has tried and found to work. If you are not an experienced mechanic, the changes that are suggested here may be best left to a licensed Harley-Davidson mechanic.

How to Install Harley Switch Covers

Stock switch covers.

To customize your Harley-Davidson motorcycle, you can do many things, including a custom paint job and changing the handle bars, throttle cables and switch covers. Changing switch covers is an easy way to customize your bike. While the process of changing out the switch covers is pretty easy, it will take some time to install them correctly.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Harley-Davidson chrome ignition switch cover kit, number 71527-04
• Harley-Davidson neutral switch cover kit, number 33919-00

1. Chrome Ingnition Switch Cover Installation

   • 1

     Remove the ignition-switch-face nut.

   • 2

     Remove the front mounting bolt on the fuel tank.

   • 3

     Remove the ignition cover mounting screw; then remove and discard the original ignition switch cover.

   • 4

     Place the chrome ignition-switch cover in position and install the original mounting screw. Tighten the screw.

   • 5

     Reinstall the front fuel tank mounting bolt. Tighten the bolt.

   • 6

     Install the face nut to secure the switch to the cover and tighten.

   Installing Neutral Switch Cover Kit

   • 1

     Disconnect the battery cables, negative cable first.

   • 2

     Unplug the neutral switch wires from the switch.

   • 3

     Loosely start the set screws into the mounting bracket.

   • 4

     Install the mounting bracket over the switch hex. The bracket surface should rest against the transmission top cover with threaded holes facing up toward the rear cylinder.

   • 5

     Tighten the set screws. Do not tighten one all the way and then do the other; snug one screw then snug the other screw. Tighten the rest of the way.

   • 6

     Plug in the switch wires.

   • 7

     Install the cover over the mounting bracket, using the washer and the 8/32-inch button-head screw, using the provided wrench. Do not pinch the wires.

   • 8

     Reconnect the battery cables, positive first.

How Do I Fill the Harley Davidson Primary With Oil?

Primary cover on a Harley-Davidson big twin

Checking and maintaining the proper level of fluids in your Harley-Davidson is important. In addition to the engine and transmission, the primary case requires fluid to lubricate the primary chain and clutch plates.

1. Inspection Cover

   • You check your primary fluid level through the inspection cover, which is the oval cover in the middle of the primary cover. You'll need a T25 Torx wrench to remove the bolts. Have a new inspection cover gasket in case you need it.

   Adding Fluid

   • Add the fluid through the inspection cover. You can use any kind of oil -- petroleum or synthetic -- as long as it does not contain friction modifiers.

   Closing the Inspection Cover

   • Replace the gasket on the inspection cover if needed. Tighten bolts finger tight; then tighten the bolts at 10 foot-pounds. Start with the top bolt and then tighten the bottom bolt. The third bolt is the right one, and the left bolt is last.

References

How to Replace a Brake Line on a Harley

The brake system may be the most important safety feature on a motorcycle.

One of the first customizations many riders make to their Harley-Davidson motorcycle is changing the handlebars. It sounds pretty simple at first--unbolt the old ones, then transfer over the old parts to the new one. However, if the brake line is too short, it impedes your range of motion and becomes a safety hazard. If it is too long, it may scratch and damage your motorcycle. Fortunately, replacing the brake line is fairly easy and can be completed just about anywhere with some simple tools.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Shop towels
• Clean bucket
• Length of tube
• Adjustable wrench
• Phillips screwdriver
• Allen wrench
• Socket wrench
• 12-point 1/2" socket
• Replacement gaskets (consult owner's manual for size and quantity)
• DOT 4 or DOT 5 Brake Fluid (consult owner's manual for correct fluid)

1. • 1

     Move your motorcycle to a clean, level surface. Place your motorcycle in first gear to prevent accidental movement. Place the run/off switch to "off." Consult your owner's manual and follow the instructions to disconnect your negative battery terminal.

   • 2

     Drain the fluid from your front brakes. First, cover your painted surfaces with shop towels to prevent damage from brake fluid or loose parts. Connect tubing to the bleeder valve located on your brake caliper. Run the tubing to a clean bucket. Using the adjustable wrench, open the bleeder valve--only one half to one turn should be enough. With the motorcycle upright, use the Phillips screwdriver to unscrew the master cylinder cover on your front brakes. Pump the brake lever and fluid should begin to flow. When the fluid stops flowing loosely, disconnect the tubing and move out of the way. Reinstall the master cylinder cover. Clean up any spilled fluid with shop towels.

   • 3

     Note the routing of the current brake line to ensure reinstallation follows the same pattern. Also, note the order of the mounting hardware where the brake line fits to the caliper and master cylinder. Using an Allen wrench, remove the brake line mounting clamps from the motorcycle. With the socket and socket wrench, remove the brake line from the master cylinder and caliper.

   • 4

     Replace the gaskets and connect the brake line fitting of the new brake line to the master cylinder. Replace the gaskets and connect the brake line fitting to the caliper. Consult your notes to ensure the line and fitting are at the proper angle and that the hardware was installed in the proper order.

   • 5

     Run the brake line through the mounting clamps and reinstall them on the motorcycle. Consult your notes to ensure the line is properly routed. Check the range of motion of your new brake line.

   • 6

     Reconnect the tubing and bucket to the caliper drain valve (it still should be open). Remove the master cylinder cover. Slowly add brake fluid until it begins to flow into the bucket. At this time, close the drain valve. Pump the front brakes several times and slowly add more fluid. Open the bleeder valve one half turn and bleed out any air in the line. Repeat until the master cylinder is full and no air bubbles are in the line. Replace the master cylinder cover. Dispose of used fluid in accordance with local laws.

Tips & Warnings

• These instructions were based on a 2006 Harley Softail front brakes. Other models and years may vary slightly, but will have similar procedures and tools.

• Using incorrect brake fluid can damage your braking system and could result in death or serious injury.

• Even if the brakes have been properly bled, full braking power may not be available after initially replacing brake lines. Carefully test your brakes at low speed with plenty of stopping room until you know your brakes are functioning properly. Be prepared to use rear brakes if the front brakes do not function as expected.

• Brake fluid is toxic and may damage skin and motorcycle surfaces. Read and follow all cautions on the brake fluid container.