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. The perfect tool can now be used in a mobile environment. Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. Upper saddlebag guard screw 3. Discard chrome hub cap 2. The Clymer online manual is excellent for viewing on tablets such as the iPad.
Remove bolt 1 connecting the exhaust system 2 to the support bracket 3. Install modified top center screw 1093 between the cylinders and tighten to 50-90 in-lbs 5. Remove Docking Hardware 1 2 is05320 1. Install the chrome hub cap 2 on the side opposite the brake disc. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available.
Install Saddlebag Guard — Right Side Shown 2005 Models -J04645 2 of 4 2 1 3 4 is05332 1. Detailed easy-to-follow instructions, accompanied by sharp photos and illustrations, guide you through every procedure, from basic maintenance and troubleshooting, all the way to teardown and rebuild. Tighten exhaust shields following the instructions in the appropriate Service Manual. Refer to Service Manual, Page 5-3 7. Lower saddlebag guard screw 2. Spigot Bore and O-Ring Counterbore Dimensions Table 1.
Inspect and clean engine case mating surfaces. Engine Mounts Inspect at 500 miles 800 kilometers and every 5,000 miles 8,000 kilometers thereafter. Do not re-use brake disc screws. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables negative - cable first before proceeding. Failure to complete the required engine maintenance can result in engine damage and an increase in emissions. Keep Your All-Terrain Vehicle Running Smoothly. If swallowed, obtain medical attention.
. Remove brake line components carefully. Every Clymer service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer repair manuals are the cheapest way to keep your four wheeler running properly. Refer to Figure 46 when servicing the change clutch assembly. Remove existing clutch diaphragm spring.
Refer to Service Manual, Page 8-8 2. This Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth small spills or washing with a large quantity of soapy water large spills. Refer to Service Manual, Page 5-14 4. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity.
Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. ~ When service is required, remember that your Honda dealer knows your motorcycle best. With hundreds of pages, it will show you how to distinguish any problem from an oil change to a transmission swap and how to fix it on your own. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. 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. The following table presents the required service schedule for normal operating conditions.
However, when tightening the locknut during clutch assembly, a separate tool is required to hold the clutch so that the clutch locknut can be tightened with a torque wrench. Remove existing air cleaner assembly. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. You will be able to use the search function to browse the manual and print out your needed pages. Remove seat according to the instructions in the service manual.