Kamis, 26 Mei 2011

How to Replace a Harley Battery

How to Replace a Harley Battery

Harley-Davidson is a well-known American motorcycle manufacturer. Harley owners tend to take care of their bikes as if they were family. Unfortunately, all battery-powered vehicles will need a replacement battery eventually. Like all electrical devices, not all Harley-Davidson motorcycles use the same kind of battery to run. This makes it very important to pay attention when replacing a Harley-Davidson battery. Fortunately, Harley-Davidson makes it simple to replace the battery in a bike when the old one gives out.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Protective gloves
  • Protective eye wear
  • Wrench or Phillips-head screwdriver
  • Steel wool
  • New battery
  • Battery charger
    • 1

      Protect yourself with gloves and eye protection before beginning. This will protect you from the battery acid you will be dealing with.

    • 2

      Take a look at the battery you want to replace. Make a note of the brand and code number. Use this when searching for a new battery. Not all Harley motorcycles take the same battery. If you're unsure, disconnect the positive (red) and negative (black) terminals from the battery posts using a wrench or Phillips-head (some batteries require different removal methods) and bring the battery with you to the store.

    • 3

      Remove any corrosion on the ends of the wires that connect to the battery. Corrosion causes problems with the flow of electricity. Any corrosion may be sanded down with steel wool.

    • 4

      Purchase the battery that matches your brand and code number. Depending on the type of battery you purchased, you may need to fill the battery yourself with an electrolyte solution. Some batteries are pre-filled. If yours is not, it will come with the chemical solution. To fill it, look for a plastic cap on top of the battery. Remove this cap. Push the bottle of clear or yellowish liquid onto the plastic post on the battery. Put the cap back on.

    • 5

      Charge the battery on a battery charger for 3 to 5 hours (based on what the instructions that came with the battery suggest).

    • 6

      Place the battery back onto it's post. Use a wrench (or screwdriver, whichever is needed) and connect the positive cable (red) to the positive post (+) on the battery. Connect the negative cable (black) to the negative post (-) on the battery.

Tips & Warnings

  • Always charge your battery for the recommended duration. If the battery is not charged fully after you purchase it, it will not function properly.

  • Connecting the wrong terminal (i.e., positive to negative) can cause serious electrical damage to the motorcycle and/or cause the battery to explode.

  • Battery acid contains sulfuric acid which can cause serious damage to the skin and eyes. If battery acid gets on your skin, add a paste of baking soda and water to the acid in order to neutralize the burning.

How to Decode Harley Cylinder Casting Numbers How to Decode Harley Cylinder Casting Numbersthumbnail You will find casting codes on various parts of y

How to Decode Harley Cylinder Casting Numbers

How to Decode Harley Cylinder Casting Numbersthumbnail
You will find casting codes on various parts of your Harley.

Different numbers are stamped in different locations on your Harley Davidson motorcycle. The Vehicle Identification Number is on the swingarm frame and on the crankcase. Numbers are also stamped on the cylinder. Some might think this is the parts number, but the three-part number stands for the casting number. Casting numbers indicate when the part was cast or manufactured. This lets you know how old the part is. It is possible to have parts with different casting numbers.

Difficulty:
Easy

Instructions

    • 1

      Look closely at the casting numbers on your Harley cylinder; find a letter and two numbers. Note the two dashes. One comes after the letter, and one after the first number.

    • 2

      Determine where the letter falls in the alphabet. The letter "B" is the second letter of the alphabet. On a Harley that signifies February, the second month of the year. This is the month the Harley was manufactured.

    • 3

      Look at the first number. It indicates the day of the month the motorcycle was made. The second number indicates the year it was manufactured.

How to Change the Transmission Fluid in a Harley

How to Change the Transmission Fluid in a Harley

As one of the three fluids that are crucial to a Harley-Davidson motorcycle's operation, the transmission fluid lubricates the assembly of gears that transmits the motor's power to the rear wheel. Much like the oil used by the machine's motor, the oil within the transmission will begin to thin over time. If left unchecked, the thinned fluid begins to lose its ability to lubricate and cool the transmission, creating excessive wear that could cause permanent damage. Replacing the transmission fluid regularly can prevent this from happening. In fact, Harley-Davidson recommends changing the fluid every 2,500 miles.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Oil pan
  • 5/8" socket
  • Socket wrench
  • Sealing washer
  • Torque wrench
  • 1 qt. Harley-Davidson transmission fluid
    • 1

      Unscrew the filler cap from the right side of the transmission assembly.

    • 2

      Look under the transmission assembly to find the drain plug. Place an oil pan directly below the plug.

    • 3

      Use a 5/8" socket and a socket wrench to unscrew the drain plug bolt. Drain the transmission fluid into the oil pan.

    • 4

      Pull the sealing washer off of the drain plug and replace it with a new sealing washer. Screw the drain plug into the transmission assembly by hand. Use a toque wrench to tighten drain plug to 21 ft-lbs.

    • 5

      Use a funnel to pour up to a quart of Harley-Davidson transmission fluid into the transmission assembly.

    • 6

      Screw the filler cap onto the transmission assembly.

Tips & Warnings

  • The drain plug is hidden between the rear shock absorbers on a Softail model. Use a socket extension to remove and reinstall the drain plug.

  • Do not overtighten the drain plug. Use a torque wrench to prevent damaging the transmission assembly's threads.

How to Dynojet a Harley

How to Dynojet a Harley

How to Dynojet a Harleythumbnail
Installing a Dynojet system in your Harley will give you increased horse power and a competitive advantage in close-course racing.

Fitting your Harley-Davidson motorcycle with a Dynojet will help you squeeze out extra horsepower, which is crucial in many races. However, be sure that you will use your motorcycle exclusively for racing, as Dynojet aftermarket kits are not designed for day-to-day driving or street use or on vehicles required to meet emissions standards. Installing a Dynojet will require some mechanical familiarity with your motorcycle. You should know where your carburetor is as well as how to remove it and how to adjust fuel flow.

Difficulty:
Challenging

Instructions

Things You'll Need

  • Dynojet kit
  • Work gloves
  • Safety glasses
  • Drill
  • Vise clamp
  • Small hammer (or) rubber mallet
  1. Installation

    • 1

      Select and purchase the Dynojet kit that fits your Harley Davidson model number and options. Read the enclosed manufacturer's instructions carefully. Set aside all parts so that they are within reach.

    • 2

      Secure your Harley-Davidson with the engine off. Put on your work gloves and safety glasses. Remove the carburetor float bowl. Remove any excess gasoline before beginning installation. Remove the main jet holder and replace with the Dynojet emulsion tube. Install the Dynojet main jet by screwing it onto the threads of the emulsion tube. Locate the side lift hole and use the drill bit provided in your Dynojet kit and your drill to enlarge the hole.

    • 3

      Install your Harley's e-clip into the Dynojet needle. Replace your stock slide spring with the Dynojet slide spring. Locate the fuel mixture plug, about 8 inches above the main jet. Turn the fuel mixture screw until it is past 3.5 and then untwist the fuel mixture screw until it is at exactly 3.5.

    • 4

      Replace the carburetor float bowl and reinstall the assembly into your Harley. Haul your motorcycle to a closed track for testing. Check for an increase in acceleration and power but also pay attention to how your Harley handles at regular driving speed. If your Harley struggles to maintain speed, you may need to install a slow jet later to control some of the performance enhancements of your Dynojet.

Tips & Warnings

  • Always wear work gloves and eye protection when working on your motorcycle.

  • Do not smoke or work near an open flame.

  • Remove any gasoline in your carburetor float bowl before attempting to install the Dynojet kit.

  • Always wear a helmet when riding and when racing your Harl

How to Change the Oil on a Harley-Davison

How to Change the Oil on a Harley-Davison

How to Change the Oil on a Harley-Davisonthumbnail
Change the oil in your Harley-Davidson motorcycle approximately every 2,500 miles.

Changing the oil in your Harley-Davidson motorcycle is essential to keeping the engine running smoothly. Check the oil in your engine every time you ride your Harley. Most dealers and independent mechanics can charge as much as $100 to change the oil, but it costs less than $20 to do it at home. These instructions are for a Harley-Davidson Sportster, but they correspond to most modern Harley models.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Oil filter
  • 3 qts. oil (2.8 liters)
  • Medium or small flat-head screwdriver
  • Oil filter wrench
  • Used oil container
  • Clean rags
    • 1

      Remove the oil cap and center the used oil container underneath the filter. Turn the oil filter counterclockwise using the wrench until it's loose enough to turn by hand. Gently remove the filter, angling it up as you pull it off so the oil doesn't spill.

    • 2

      Tilt the filter down and drain the oil into the container, leaving the filter open-side down in the container. Allow all the oil to drain out, wiping the excess off the engine case and the oil-sending unit with a clean rag.

    • 3

      Find the oil drain hose, usually behind the clutch and under the swingarm. Move the used oil container under the hose. Unscrew the clamp on the hose counterclockwise. Pull off the hose, angling it down toward the container to drain the oil inside it. Replace the hose and tighten the clamp clockwise.

    • 4

      Wipe any excess oil off the oil pump. Inspect the new filter for damage. Using one finger, rub a small amount of new oil around the filter's rubber gasket. Pour about four ounces of oil into the filter and hand-tighten it on the oil pump.

    • 5

      Fill the oil tank with oil, just to the bottom of the tank opening, about three quarts (less the earlier four ounces). Replace the oil filler cap.

    • 6

      Loosen the oil drain hose again and let a little bit of the new oil drain out to eliminate any air bubbles in the system. Tighten the hose clamp.

    • 7

      Start your engine. If your oil check light had been on, make sure it's off. Check around the oil filter and drain hose for leaks.

Tips & Warnings

  • Choose natural or synthetic oil for your bike, but once you choose, use it consistently.

  • If you consistently ride your bike at high RPMs, you should change your oil more frequently to help protect your engine.

How to Replace a Harley Driving Light

How to Replace a Harley Driving Light

How to Replace a Harley Driving Lightthumbnail
Driving lights provide additional light to improve safety.

Harley-Davidson equips some motorcycle models with driving lights, or the bikes may have light bars retrofitted. Driving lights generate almost as much light as the headlight, and project it forward and onto the road. The increased light output can contribute to safety, as the road conditions ahead are more visible to the rider, and the bike is more visible to other traffic. Driving lights can fail due to heavy use or vibration. Replacement of the light poses no difficulty and requires no special tools.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Screwdriver Set
    • 1

      Locate the trim bezel screw at the bottom of the light housing. Loosen and remove the trim bezel screw with a screwdriver. Remove the trim bezel from the light housing.

    • 2

      Slowly remove the driving light from the housing a few inches. Loosen the light wiring terminal screws with a screwdriver. Remove the wiring terminals from the light.

    • 3

      Hold the new driving light near the housing. Install the wiring terminals onto the new driving light and tighten the screws securely.

    • 4

      Gently push the new driving lamp into the housing. Install the trim bezel ring over the housing and driving light. Install and tighten the trim bezel screw securely with a screwdriver.

    • 5

      Loosen the trim bezel screw slightly and rotate the driving light to change the aim point of the driving light, if desired.

How to Change the Oil on a Harley Fatboy

How to Change the Oil on a Harley Fatboy

Changing the engine oil and filter is one of the basic maintenance skills every motorcyclist should have under their belt. When done on a regular basis, the lifetime of your Harley-Davidson Fat Boy will be extended by reducing wear caused by contaminated or degraded oil. Although the Fat Boy and most Harley-Davidson motorcycles use three types of oil, replacing the engine oil is a fairly simple task for most motorcyclists and requires only a few tools.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Socket wrench
  • SAE sockets
  • Oil filter wrench
  • 3 qts. 20W50 Engine oil
  • Oil catch basin or container
  • Towels or rags
  • Service manual (optional)
    • 1

      Start the motorcycle and let it warm up for a few minutes. Warm oil will flow better and will help flush out any contaminants that may be present in the oil. Be sure not to let the oil get too hot to prevent burning yourself in the following steps.

    • 2

      Locate the oil drain plug and place your oil catch basin below it. The plug is under the right side of the motor.

    • 3

      Remove the oil drain plug using a socket wrench and inspect the drain plug's O-ring for damage or tears, replacing the O-ring as necessary. Set the drain plug aside.

    • 4

      Remove the oil filter with an oil filter wrench and discard the old filter.

    • 5

      Allow the old oil to drain until the flow has reduced to a minimal trickle. Replace the oil drain plug.

    • 6

      Fill the new oil filter with fresh oil, coating the inner lip of filter lightly with oil to provide a stronger seal before screwing the filter onto the motor. Tighten the filter by hand until it is secure.

    • 7

      Add your engine oil into the oil tank from the oil fill neck (where the dip stick is mounted).

    • 8

      Replace the dip stick and wipe away any spilled oil.

Tips & Warnings

  • If possible, consult a service manual for comprehensive details about this process and oil types and amounts.

  • Be sure that you have the right type of oil filter wrench for both the old and new filters.

  • If you own a 2001 and newer Fat Boy, be sure that the replacement oil filter is capable of filtering down to 10 microns to accommodate the smaller oil passages used by the Twin-Cam 88 motor. Using a standard oil filter will prevent the flow of oil into the motor and will cause serious damage.

  • Remove the oil dip-stick to quicken the draining process.

  • If you do not feel that you can complete this project, have the work done by a qualified technician.

  • Use caution when draining the oil to prevent burns. To prevent the oil from reaching extreme temperatures, only allow the motorcycle to warm up for a few minutes.

  • Do not use tools or excessive force when tightening the oil filter to prevent damage.

  • Double check that the oil filter cap or dip stick is secured before starting the motor again to prevent spraying oil.

  • Do not dispose of used oil in a drain or trash can. Take it to an auto parts store for recycling.

How to Buy Pipes for a Harley

How to Buy Pipes for a Harley

Harleys are known for the awesome sound they make. But after riding it for awhile, the pipes that came with your bike may simply not be doing anything for you, and you may want to upgrade. Here are some tips on how to find that perfect set of pipes for your Harley-Davidson.

Difficulty:
Challenging

Instructions

    • 1

      Avoid asking others' opinions about the sound made by the pipes you may be considering, because what may sound terrific to them may sound awful to you. Since sound is such a subjective thing, you'll be satisfied only after hearing them yourself.

    • 2

      Never buy Harley pipes from a catalog. Without hearing them mounted on a Harley, you'll have no idea how they'll sound on yours. The pictures in a catalog are there to sell pipes. They might even show those pipes on a custom bike, but you have no idea how they'll look on your machine. Instead, ask the people at your local Harley-Davidson store where you can find a Harley locally with the pipes you think you want.

    • 3

      Don't skimp on buying pipes for your Harley. You may find "that perfect set of pipes” at a bargain price, but it's likely you'll soon become dissatisfied because they're probably made with inferior materials by no-name companies. Remember that your displeasure with your purchase will last far longer than the satisfaction of saving a few dollars.

    • 4

      Go online after you have decided which pipes to buy. Often, you will save up to 33 percent or more on those pipes versus buying them at the dealership. And if you intend to install them on your bike yourself, the savings really do pile up. Be aware that most dealers will build installation into the cost of the pipes they sell, and they probably will not give you a discount if you plan to install them yourself (see Resources below).

    • 5

      Have everything you need ahead of installation if you are doing the work yourself. For example, you will need a reflash or a PCM upgrade if you have a newer Harley that's fuel-injected. For older Harleys, you may need a rejet if it has a carburetor. Without them, you may damage your bike because it will run too lean. Once installed, the proper device will enable you to conform your fuel to your new pipes.

How to Make Your Own Harley Patches

How to Make Your Own Harley Patches

How to Make Your Own Harley Patchesthumbnail
Design your own Harley patches and add some style to your motorcycle jacket.

Biker patches have been most famously used by a number of motorcycle gangs to display bikers' membership in the gangs. However, they are also used by other bikers who have an interest in a particular brand of motorcycle. Harley Davidson patches are among the most common and even come attached with Harley Davidson brand jackets. If you are a Harley Davidson enthusiast and would like to make your own patch, you can do so easily at home.

Difficulty:
Moderately Easy

Instructions

Things You'll Need

  • Fabric
  • Fabric paint
  • Paintbrushes
  • Scissors
  • Interfacing
  • Ironing board
  • Iron
  • Needle
  • Thread
    • 1

      Paint the design for your biker patch onto a piece of cotton fabric using fabric paint and a paint brush. Biker patches come in many different designs and sizes. The patch can include a name or image, or the Harley Davidson logo. If you are painting on the Harley logo, carefully trace the design onto the fabric using a pencil and then paint it with the fabric paint. Let the paint dry.

    • 2

      Cut out your Harley patch and place it on top of the fabric interfacing. Cut out the fabric interfacing so that it is the same shape as the fabric patch.

    • 3

      Place the shiny side of the interfacing facing the back of your fabric patch. Place the patch onto an ironing board with the interfacing facing up. Iron the interfacing onto the patch. The heat from the iron will cause the interfacing to bond to the fabric.

    • 4

      Cut off any excess interfacing around the edge of the patch using a pair of scissors. Dab anti-fray liquid around the edges of the patch to keep them flat.

    • 5

      Sew the Harley patch onto your motorcycle jacket using a needle and thick thread.

How to Set End Play in the Front Wheel on My Harley Davidson

How to Set End Play in the Front Wheel on My Harley Davidson

How to Set End Play in the Front Wheel on My Harley Davidsonthumbnail
The wheel bearings on this bike are on the axle in the lower right of the photo.

From 1973 until 2000 all Harley-Davidson models used tapered Timkin wheel bearings on both the front and rear wheels. Since 2000 all Harleys have used sealed wheel bearings on both wheels. The current wheel bearings go on and come off as a unit with a bearing puller/installation tool. End play on the sealed bearings is pre-set. Only 1999 and earlier Harleys require that wheel bearing end play be set during installation and servicing. Sealed wheel bearing kits are available for older bikes. The sealed bearings should last 100,000 miles and the old bearings must be serviced every 10,000 miles. But it is a matter of debate as to whether the old bearings are superior to the new ones.

Difficulty:
Moderately Challenging

Instructions

Things You'll Need

  • Service manual for your make and year Harley
  • Hex sockets
  • Torque wrench
  • Magnetic dial indicator
  • 3 each .002 inch, .004 inch, .008 inch, .016 inch and .032 inch axle shims.
  • Multi-purpose lithium grease
    • 1

      Torque the axle nut to 60 pounds of torque, or to the torque specified in the service manual for your motorcycle if different, with a hex socket and a torque wrench after reinstalling the wheel bearings, axle and spacers.

    • 2

      Mount a magnetic dial indicator on the front fender, forks or brake caliper so you can measure the lateral movement of the axle in the wheel.

    • 3

      Push and pull the wheel along the lateral axis of the axle while reading the measurements on the dial indicator. If the end play is greater than 0.18 inches the wheel bearing must be shimmed.

    • 4

      Remove the axle nut, axle, spacer and wheel bearing assembly with a socket wrench and socket if necessary. Insert an axle shim of one of the five commonly available thicknesses, between .002 and .032 inches, on the axle next to the spacer if necessary and replace the wheel bearing assembly.

    • 5

      Re-tighten the axle nut to 60 pounds of torque, or to the torque specified in the service manual for your motorcycle if different, with a hex socket and a torque wrench.

    • 6

      Re-measure the axle end play with the magnetic dial indicator. Repeat as necessary. Repack the wheel bearings with lithium grease and continue wheel assembly when the end play measures between .004 and 018 inches.

How to Change Oil on a 2003 Harley FXD

How to Change Oil on a 2003 Harley FXD

How to Change Oil on a 2003 Harley FXDthumbnail
Change your Dyna's oil yourself and save money.

Regular oil and fluid changes are a part of the Harley-Davidson experience. Ensuring that your FXD Super Glide receives these oil changes will maintain its peak level of performance and extend its service life. While most FXD owners delegate this basic task to the capable hands of their local HD dealership, learning how to replace your bike's vital fluids can save you a great deal of money over the years. The process is fairly simple and can be done within an hour with the right tools.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Oil pan
  • Allen key or socket set
  • Socket wrench
  • Shop towels
  • Drain plug O-rings (3)
  • Strap or oil filter wrench
  • Oil filter
  • Engine oil (3 Quarts)
  • Primary fluid (1 Quart)
  • Transmission fluid (1 Quart)
    • 1

      Drain the fluids from the motor. The engine oil drain plug is located at the forward, left-hand side of the motor's oil pan. The primary fluid drain plug is located directly under the primary derby cover. The transmission fluid drain plug is located under the right side of the motor. Place an oil pan under the plugs as you remove them with an Allen wrench or socket.

    • 2

      Wipe the drain plugs with a shop towel to remove any debris that may have accumulated on them and replace the drain plug O-rings. Reinsert the drain plugs and lightly tighten them with an Allen wrench or socket.

    • 3

      Place an oil pan directly below the engine's oil filter. Remove the oil filter with a strap wrench or an oil filter wrench and allow any remaining oil to drain. Discard the oil filter.

    • 4

      Fill the new oil filter with up to four ounces of fresh oil, and spread a thin coating of oil around the filter's mating surface with your finger. Screw the oil filter onto the motor by hand until it is seated against the motor. Add up to 2.5 quarts of engine oil into the oil tank.

    • 5

      Remove the primary derby cover with a Torx driver or Allen key. Pour up to one quart of primary fluid into the primary case. Hold the motorcycle upright and inspect the fluid level. The fluid should be level with the bottom of the clutch assembly. Replace the primary derby cover and tighten the mounting bolts with a Torx driver or Allen key.

    • 6

      Remove the transmission filler cap and pour up to one quart of transmission fluid into the filler neck. Replace the filler cap.

    • 7

      Wipe away any spills with a shop towel.

Tips & Warnings

  • Warm up the motorcycle for a few minutes and remove the filler caps to quicken the draining process.

  • Use only Harley-Davidson specified oil and fluid to prevent component failure caused by improper lubrication.

  • Do not attempt this task if you lack the necessary tools to complete the job. Instead, have the work performed by a qualified Harley-Davidson technician.

How to Replace the Grips on a Harley Sportster

How to Replace the Grips on a Harley Sportster

Replacing the stock hand grips on your Harley-Davidson motorcycle can be intimidating at first. After all, you just paid thousands of dollars for this shiny machine and want to add value to it with a professional-looking upgrade. However, this is a fairly easy job and can be done by just about anybody who knows how to use a screwdriver. For many, this is the first in a long line of customizations that will be done on their motorcycle.

Difficulty:
Moderately Easy

Instructions

Things You'll Need

  • Screwdriver
  • Torx or Allen wrench
  • String
  • Ruler or tape measure
  • Shop towels
  • Needle nose pliers
    • 1

      Move your motorcycle to a level surface. With the motorcycle off, place the transmission in gear to prevent movement.

    • 2

      Identify the type of bolt or screw used on your switch housing. This is the knobby structure just outside of your brake or clutch handle housing. On newer models this is likely a Torx wrench (looks like a star). On older models this may be an Allen wrench (hexagonal) or an ordinary screw. There may be as few as one or as many as three.

    • 3

      Remove the bolt(s) from the left side (clutch) housing using the correct wrench. Separate the two halves of the housing and wrap them with shop towels to prevent damage to the parts and motorcycle finish.

    • 4

      Remove the bolt(s) from the right side (brake) housing again using the wrench. Separate the two halves of the housing. At this point you will notice two wires coming out of the housing that wrap around the grip. These are the throttle control wires. Take notes or digital pictures of the placement of these wires to refer to for reattachment later. Then use the needle nose pliers to unseat them from the grip. The right grip should slide off. Then wrap the housing with shop towels.

    • 5

      Remove the left grip. Depending on the handlebars, you may have to unscrew the left grip, but on stock models these usually slide off with a gentle back-and-forth motion. Once the grip is off, wrap the string around your handlebars and use a ruler to find the diameter of your handlebars. They will typically be 1 inch but may be as large as 2 inches if you have aftermarket handlebars.

    • 6

      Purchase the correct size grips to match your style. Replace the grip on the left side, replace the housing then bolt down.

    • 7

      Slide the right grip on. Reattach the throttle cables, being careful to attach the wires in the same position as they were detached then bolt down the housing.

Tips & Warnings

  • Some motorcycle handlebars taper at the ends. Because of this, measuring anywhere but the end of the handlebars may result in incorrect sizing.

  • Not correctly attaching your grips may cause them to come off during riding. Ensure they are properly installed and secure before attempting to ride your motorcycle.

Harley-Davidson Bike History

Harley-Davidson Bike History

Harley-Davidson Bike Historythumbnail
Harley-Davidson Bike History

Harley-Davidson motorcycles have been manufactured by the Milwaukee-based Harley-Davidson Company since 1903 and remain today the premier motorcycle. Its classic design and outlaw image is an American pop culture icon. Harley-Davidson builds heavyweight bikes for highway cruising and is a favorite for customization. It has met with little success in building lightweight bikes and the company has virtually ignored the off-road market.

  1. Origins

    • The 1903 Harley-Davidson

      The company was founded in 1903 by William Harley and Arthur Davidson. The first bike was Harley's 1901 project of placing a small 116cc engine on a pedal bicycle frame. The bike did well on flat land and small hills, but a bigger engine was needed to make it more versatile. The partners came up with a 405cc engine that helped define the modern motorcycle.

    Growth

    • The U.S. Army's 1917 Harley-Davidson Model J

      The years leading up to World War I were prosperous for Harley-Davidson as the company advertised in small journals offering engines for do-it-yourself bike projects. Competition grew stiff as motorcycle makers proliferated throughout the U.S. But Harley-Davidson led in technological advancements, including its 1911 810cc V-Twin model. By 1917, more than 16,000 motorcycles were manufactured by the company annually.

    World War I

    • A 1930 Harley-Davidson powered by a V-Twin Flathead engine

      Harley-Davidson had success in security military contracts with the 1916 Pancho Villa Expedition and won an important agreement when the U.S. entered World War I by providing 15,000 motorcycles. These contracts helped push Harley-Davidson to become the largest motorcycle builder in the world, producing nearly 30,000 a year.

    Between the Wars

    • The 1936 Knucklehead

      During the 1920s and 1930s, Harley-Davidson perfected the V-Twin engine, boosting engine displacement to 1200cc. Front brakes were added and the trademark "Teardrop" gas tank made its debut in 1925. Sales dropped after the Stock Market Crash of 1929, but engine sales for industrial use and the creation of the three-wheeled Servi-Car for deliveries helped save the company from extinction.

    World War II

    • The 1941 Harley-Davidson FL with the V-Twin Knucklehead engine

      The famed 1000cc "Knucklehead" engine, named for its unusually shaped rocker boxes, appeared in 1936, with displacement boosted to 1200cc in 1941 on the FL series motorcycles. Its reliability and power led to another series of military contracts for the war effort. It produced the WLA series motorcycles strictly for military purposes. More than 90,000 bikes were delivered during the war, earning Harley-Davidson Army-Navy "E" awards for production excellence in 1943 and 1945.

    Postwar Era

    • The 1955 Harley-Davidson Hummer was based on a Germany design

      The company also used the wartime DKW RT125 German motorcycle as a template for a similar bike that was produced from 1947 through 1966. One version, the Hummer, was produced from 1955 to 1959. The German bike also later served design for popular BSA Bantam motorcycles. From1966 to 1985, 1200 cc Shovelhead made its debut and had its displacement increased to 1345 cc in 1978.

    Today

    • The film "Easy Rider" eventually helped the company achieve mythical status

      The 1960s brought image problems to Harley-Davidson with negative press accounts of motorcycle gangs and the outlaw nature of customized "chopper" motorcycles depicted in such films as "Easy Rider" and other films. A disastrous sale to American Machinery and Foundry resulted in bikes built on the cheap and creating quality control problems. The company eventually overcame those issues and also responded to the influx of Japanese imports by emphasizing Harley's traditional look to distinguish itself from the street and off-road bikes.

How to Install LED Lights on a Harley Sportster 1200 Custom

How to Install LED Lights on a Harley Sportster 1200 Custom

How to Install LED Lights on a Harley Sportster 1200 Customthumbnail
The Harley-Davidson Sportster can be customized any way you like.

Adding LED lights to your Harley-Davidson Sportster 1200 is one of the easiest and most functional modifications you can make on your motorcycle. Not only do LED lights look fresh and up-to-date on your bike, but they also significantly improve your night and day visibility to other drivers. Add to that the fact that LED light bulbs last as much as 10 times longer than ordinary bulbs while using just 10 percent of an ordinary light bulb's power, and you've really got no reason not to make the switch.

Difficulty:
Easy

Instructions

Things You'll Need

  • Slotted screwdriver
  • Dielectric grease
    • 1

      Remove the turn signal lenses from the stock turn signal housings of the Harley-Davidson Sportster as well as the taillight lens by unscrewing the fittings that attach the lenses to their light housings. The lenses have a rubber O-ring that seals against the light housing, so they won't just fall away. With the screws removed from the lens, use your fingers to pull the lens away from the housing.

    • 2

      Twist the light bulb located within the Harley-Davidson light housing in a counterclockwise direction to free it from the socket, then pull it straight out. The replacement LED light bulb installs into this socket. Smear a small amount of dielectric grease onto the LED light bulb's electrical plug, then push the LED bulb into the socket and turn it in a clockwise direction to fasten it in place. Do this to all four turn signals as well as the brake light on the motorcycle.

    • 3

      Push the Sportster's turn signal lenses back into place and then run the screws into the mounting holes in the lens, tightening them down with the screwdriver until the lens is snug against the light housing. Do the same with the brake light lens to finish the installation.

Tips & Warnings

  • Change the brake light lens along with the turn signal lenses to retain a continuous theme in the Sportster's lighting.

How to Increase Horsepower for My Harley 1980 FLH

How to Increase Horsepower for My Harley 1980 FLH

How to Increase Horsepower for My Harley 1980 FLHthumbnail
The 1980 Harley-Davidson FLH was a large motorcycle for its time.

Increasing power on a 1980 Harley FLH Electra Glides is largely a matter of using available bolt-on parts commonly found in Harley performance catalogs. The traditional rules apply for building power: more air, more fuel, more exhaust. The 1980 FLH was a big motorcycle for its time, putting out 67 horsepower from 81 cubic inches of engine. Keeping up with today's motorcycles, however, presents a bit of a problem for FLH enthusiasts.

Difficulty:
Moderate

Instructions

Things You'll Need

  • High flow exhaust
  • Carburetor jetting kit
  • High-flow air filter
  • 3/8-inch socket set
    • 1

      Remove and replace the stock exhaust with a high-flowing performance exhaust. If you don't want to contend with the additional noise, there are plenty of exhaust systems on the market that produce a more mellow, relaxed exhaust note while still providing the power benefits of an open exhaust.

    • 2

      Replace the stock air filter with a high-flow air filter. Although more expensive than traditional filters, they are also cleanable, so they can last quite literally for the life of your motorcycle.

    • 3

      Re-jet the carburetors. Older carburetor jets are much smaller and more inefficient than current jets. Purchasing and installing a carburetor jet kit for your FLH will let more air and fuel into the carburetor, allowing the engine to produce more power.

Tips & Warnings

  • If you want still more power for your 1980 Electra Glide, consider replacing the engine altogether with a higher-displacement engine from a newer bike.

How to Install Harley Mirrors

How to Install Harley Mirrors

The Harley-Davidson is an iconic motorcycle that has become a standard for the industry. Customizing Harleys is as common as finding bananas in the produce aisle, and there are tons of products out there available for installation. One of the easiest modifications is to install new mirrors, and it should take about 10 minutes to do.

Difficulty:
Easy

Instructions

Things You'll Need

  • Allen key set
    • 1

      Unbolt the mirror from the handlebars by unscrewing the Allen head bolt that secures the rear-view mirror to the clamp that goes around the bars.

    • 2

      Remove the rear-view mirror from the body and place it to the side.

    • 3

      Place the new rear-view mirror onto the mount that goes around the handlebars and thread in the provided handlebar bolt using the Allen key set.

    • 4

      Sit on the bike and position the mirror where it's best for your visibility, then tighten the Allen key all the way down, securing the mirror to the bars.

    • 5

      Repeat this process with the mirror on the other side of the handlebars.

How to Install an Oil Temperature Gauge on a Harley

How to Install an Oil Temperature Gauge on a Harley

How to Install an Oil Temperature Gauge on a Harleythumbnail
Save that engine! Install an oil temperature gauge.

An oil temperature gauge is a good thing to have on your Harley-Davidson motorcycle. By monitoring the oil temperature at regular intervals you can avoid overheating and the resulting oil viscosity breakdown, which can quickly damage your engine. Harley makes it easy to install an oil temperature gauge on your bike. In fact, if you can check your oil level, you can install and use one of these gauges, as they simply replace the factory oil cap and dipstick assembly.

Difficulty:
Easy

Instructions

Things You'll Need

  • New oil tank cap and dipstick, with the built-in gauge, for your year and model bike (available at a Harley-Davidson dealer)
    • 1

      Remove the factory cap and dipstick assembly from your bike's oil tank.

    • 2

      Install the new cap/dipstick/oil temperature gauge assembly.

    • 3

      Ride the bike for a short time, then check the gauge reading to ensure it works properly.

Tips & Warnings

  • Check the gauge reading every time you stop when riding in hot weather. Stop riding your bike if the gauge temperature goes above 250 degrees. Major engine damage can occur at these temperatures. Let the bike cool off before riding it again.

  • If overheating is persistent, consider adding an oil cooler to your bike's oil system.

How to Haul a Harley in the Bed of a Truck

How to Haul a Harley in the Bed of a Truck

Harley-Davidson motorcycles are fun to drive anywhere you want to be, but there comes a time when you need to move the bike without driving it. Maybe it broke down and you need to take it to the shop, or you want to load it up for a long distance trip. Either way, if you have to load it up into the bed of a truck, there's a safe way to do it that ensures that your bike and your truck will arrive at the destination safely.

Difficulty:
Moderately Easy

Instructions

Things You'll Need

  • 8-foot ramp
  • Assistants (1-2)
  • Microfiber towels
  • Ratcheting tie-down straps with hook ends
    • 1

      Drop the tailgate on the truck and place the ramp onto the tailgate. With the help of your assistants, push the Harley up the ramp then slowly roll it forward until the front wheel is against the back wall of the bed. Have one assistant sit on the motorcycle and hold it in place for the next few steps.

    • 2

      Wrap a microfiber towel over one of the forks on the front of the bike on the fork that is closest to the driver's side. Connect one of the hooks on the ratcheting tie-down straps to a factory tie-down on the bed, then run the other hook to the fork and hook it around the microfiber towel so you don't scratch the fork. Hold the towel and hook in place with one hand and ratchet the tie-down into place. Don't tighten it all the way, just enough to have tension on the line while your assistant hold the handlebars to keep the wheel straight.

    • 3

      Repeat Step 2 on the passenger side of the truck with the right side of the motorcycle and tighten it down all the way. Once it's tight, go back to the other side and tighten down the other tie-down. The goal is to have very tight connections on the tie down and the wheel centered.

    • 4

      Wrap a microfiber towel around the rear driver's side frame of the motorcycle, right next to the axle and the wheel, and use the tie-down in the same manner as in the previous steps, ratcheting down the strap with one hook on the bed tie-down and another on the microfiber towel around the frame. Repeat this process on the other side then tighten down both straps until they're extremely tight.

    • 5

      Have your assistant get off of the motorcycle then push the bed side to side to make sure the motorcycle doesn't move. Drive around the block at a slow speed, and watch the bike to make sure it doesn't lean one way or another. Come back and tighten down the straps again if necessary.

Tips & Warnings

  • The key is to make your Harley and the bed of the truck one unit so when the bike moves, so does the truck and vice versa. Make sure those tie-downs are 100 percent secure before you go on the road; and if you have any doubt, add more straps to other stable points, using a microfiber towel to protect the paint.

How to Install Saddlebags on a Harley 883R

How to Install Saddlebags on a Harley 883R

How to Install Saddlebags on a Harley 883Rthumbnail
Saddlebags increase carrying capacity on the 883R.

Harley-Davidson built the Sportster 883R motorcycles for sport and performance riding. Harley gave little consideration for carrying capacity on this bike as is commonly found on the larger cruiser and touring models. Purchase saddlebag bracket kits from Harley-Davidson or through aftermarket retailers. Brackets and bags bolt up easily to the frame without special tools or training.

Difficulty:
Moderate

Instructions

Things You'll Need

  • Allen wrench set
  • Standard wrench set
  • Allen driver set
  • Pound-feet torque wrench
  • Saddlebag and bracket kit
  • Bike lift
  • Wood blocks
    • 1

      Remove the rear strut bolt from one side of the fender with an Allen wrench and open-end wrench. Install the 5/16 x 3-inch bolt, narrow-slot button, 3/4-inch spacer and lock nut into the rear strut mount hole and tighten securely with an Allen wrench and open-end wrench.

    • 2

      Remove the front strut bolt from one side of the fender with an Allen wrench and open-end wrench. Install the 5/16 x 3-inch bolt, wide-lot button, 3/4-inch spacer and lock nut into the front strut mount hole and tighten securely with an Allen wrench and open-end wrench.

    • 3

      Support the back of the frame on a bike lift so that the rear wheel is elevated clear of the ground. Block up the rear wheel with wood blocks. Remove the lower shock mounting bolt, nut and washer with wrenches.

    • 4

      Install the saddlebag roller bracket onto the lower shock mount bolt. Rotate the roller bracket so that the teardrop is pointed down and the rollers are pointed to the rear of the bike. Torque the lower shock bolt between 30 and 50 pound-feet with a torque wrench. Repeat Steps 1 to 4 on the other side of the bike.

    • 5

      Open the bag lid and peel up the vinyl locking lever cover. Lift up on the lever and slide the rear bag mounting bracket onto the rear strut button. Push the front of the bracket onto the front strut button. Push the lever down until it snaps into position and locks the bracket into place. Push the vinyl lever cover down and close it securely with the hook-and-loop fastener.

Tips & Warnings

  • Rear turn signals must be relocated with kit number 68471-94B before installing the bracket kit.

Types of Harley-Davidson Bikes

Types of Harley-Davidson Bikes

For more than a century, the pulse-pounding throb of Harley-Davidson's signature 45-degree V-twin motor has been the anthem of the open road. America's two-wheeled crown jewel, the Harley-Davidson Motor Co., has influenced generations of riders with a long line of motorcycles. Today, each of the motorcycles embodies its heritage while offering a distinct personality.

  1. History

    • The Harley-Davidson Motor Co. was founded in 1903 by William Harley and Arthur Davidson. Arthur's brothers, Walter and William, would later join the company. The company first produced small displacement single-cylinder motorcycles. The first glimpse of what would become Harley-Davidson's signature motor was shown at the 1907 Chicago Automobile Show. Displacing a total of 879.7cc (53.68 cubic inches), the v-twin produced about 7 horsepower, almost twice as much power as the previous motor. Since then, the revised versions of this v-twin motor have been used by almost every motorcycle Harley-Davidson has produced.

    Functions

    • In the early days, a prospective customer's attention was drawn to a race-winning motorcycle, making competitive racing important to the success of a fledgling motorcycle manufacturer. Many of Harley-Davidson's models, such as the Sportster, were designed with this intent in mind. Racing, however, was only one venue for which Harley-Davidson built motorcycles. By the 1940s, cross-country touring by motorcycle was growing in popularity and Harley-Davidson had motorcycles to fit the bill. These early touring bikes were powered by large displacement motors and featured amenities such as saddlebags and windshields.

    Types

    • Modern Harley-Davidson motorcycles fall into five categories: Sportster, Dyna, Softail, Touring and Revolution. The smaller Sportster was introduced in 1957 as a competitive race bike and became highly successful in flat-track racing. Touring bikes are designed for long-distance riding and are available in two basic designs: the Road King and the Glide series. The Road King pays homage to the 1940s' touring bikes, featuring a large headlight with a windscreen and saddlebags. Glides are distinguished by their batwing fairing, hard saddlebags and other amenities such as CD players and CB radios. Softail models mimic the appearance of early rigid tail motorcycles, offering comfort and performance through the use of a concealed rear suspension system. The Dyna series, introduced in 1971, melds a smaller, more agile frame with the power of a big v-twin. The Revolution series stands apart from the rest of the lineup, using a drastically redesigned liquid-cooled motor.

    Breaking Tradition

    • Harley-Davidson, in a joint venture with Porsche, worked to develop a ground-breaking motor. The result was a 1,250cc motor that broke away from the traditional v-twin setup used since 1907. Featuring a 60-degree cylinder angle and liquid-cooling, the Revolution motor was introduced in 2001 with the VRSCA V-Rod. Competing against the rise of muscle bikes from other manufacturers, the V-Rod was the first of the Revolution models and was intended to expand the Harley-Davidson appeal to different markets.

    Buell Motorcycle Co.

    • A division of the Harley-Davidson Motor Co., the Buell Motorcycle Co. was originally created by Erik Buell, a former Harley engineer. As opposed to the classic cruiser-style motorcycles produced by its parent company, Buell focuses on developing hard-edged sport motorcycles. Buell has proved itself a serious contender in the marketplace with innovations such as using the frame as a fuel tank and mounting the exhaust system under the motor to lower the center of gravity.