How to Install Harley Grips

Put grips on your Harley motorcycle.

Keeping that firm grip on the handles of your Harley is a crucial part of maintaining control over it. Handle grips pass the vibrations of the motor onto the rider’s hands. Therefore it is important to keep them in shape in order to provide that much-needed buffer for the hands and wrists--during those long rides, every little helps to add to the rider's comfort. Friction caused by rubbing the grips will cause the grips to wear and become thinner and loose, necessitating their replacement.

Difficulty:

Moderate

Instructions

Things You'll Need

• Screwdriver
• Torx wrench
• Bolts
• Utility knife
• Flat-head screwdriver
• Sandpaper
• Cloth
• Adhesive
• Needle-nose pliers

1. • 1

     Position your motorcycle on a flat surface. Turn off the motor and put it in gear.

   • 2

     Observe the bolts and the screws of the clutch or brake assembly. Use a screwdriver or a Torx wrench to remove the bolts of the clutch assembly, which is wrapped around the left handle. Separate the upper and the lower switch housing and place it away from the handle. The switch housing holds the the switches used to control the motorcycle.

   • 3

     Place a towel on a counter. Put all the detached parts on the towel so they won’t get lost or roll off.

   • 4

     Cut the left grip carefully lengthwise, using a utility knife. Take a flat-head screwdriver and insert it between the handle and the grip to help get the grip off. Take sandpaper and a cloth and wipe away any residue on the handle. By doing so, the new adhesive layer will get a better hold.

   • 5

     Slide on the new grip to test if its edges are aligned with the channel of the clutch housing. Slide it off and spread adhesive inside the grips. Use your fingers to spread the glue. Pay attention to not put too much glue on the grips, otherwise excess glue could get on the clutch housing.

   • 6

     Slide the grip onto the handle by rotating it back and forth. Level it with the channels of the housing. Grip the handle and squeeze it firmly. Hold the grip for a few moments for the glue to bond.

   • 7

     Reassemble the clutch assembly. Position the channel of the switch housing around the grip’s edge. Adjust the position of the clutch lever. Fasten it with the bolts, using a Torx wrench.

   • 8

     Insert the grip on the right handle. Take the Torx wrench and remove the bolts holding the switch housing. Separate the upper part from the bottom one. Observe the position of the throttle cables that are now visible and remember their exact position.

   • 9

     Move the throttle cables away from the throttle sleeve using needle-nose pliers. Push and slide off both the throttle sleeve and the switch housing.

   • 10

     Cut off the grip using the utility knife, in the same way that you did in Step 4. Clean the area with sandpaper and cloth, then apply adhesive into the right hand grip. Slide the grip while rotating it onto the handle. Align and squeeze the grip and wait a moment for the glue to bond.

   • 11

     Slide the new throttle sleeve onto the handle and reattach the throttle cables in their position. Put back the switch housing and fasten it in place using bolts.

Tips & Warnings

• Use a spray carb cleaner to dissolve the glue if you do not want to cut the grip off.

• Do not lubricate the grips prior to their installation. This may cause them to slide off when riding.

• Not installing the handlebar grips the proper way may result in injuries and even death.

• Use only compatible parts for your Harley, to avoid malfunction of the motorcycle.

How to Time a Harley-Davidson Motorcycle

Learn how to set the timing on a Harley-Davidson motorcycle.

Checking the timing on your Harley-Davidson motorcycle every 5,000 miles plays an important role in a comprehensive maintenance routine. As a Harley-Davidson engine ages, you must adjust the ignition timing to compensate for the wear of internal engine parts. Setting the timing correctly keeps your motorcycle running smoothly and efficiently. Maladjusted timing may result in sluggish performance, poor fuel economy and possible damage to internal engine components. Setting the timing is relatively easy and ensures the maximum life from the engine.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Allen wrench
• Clear plastic timing hole plug
• Inductive timing light
• Phillips screwdriver
• Slotted screwdriver

1. • 1

     Remove the crankcase timing plug using an Allen wrench, and expose the timing hole. The timing hole is located on the primary chain case side of the motor on the engine block and capped with a solid hex-head plug. Install a clear plastic timing hole plug to prevent oil splash.

   • 2

     Connect the positive terminal of an inductive timing light to the positive battery terminal of the motorcycle. Connect the negative terminal of the timing light to the negative terminal of the battery. Connect the inductive pickup probe of the timing light to the front cylinder spark plug wire.

   • 3

     Start the engine, and run it at idle. Point the timing light into the timing inspection hole. If the ignition is properly timed, the timing bar will align with the circular timing reference mark. The reference marks on a correctly timed engine will appear as a vertical bar through the center of the circle. Some models only have a timing reference mark on the flywheel of the motor; on these models, the engine is correctly timed when the reference mark is visible in the timing inspection hole.

   • 4

     Remove the timing cover from the right side of the motor with a Phillips screwdriver or Allen wrench, depending on your specific model. Loosen the the timing plate screws with a slotted screwdriver, and turn the timing plate to adjust the timing. Recheck the timing marks with the timing light. Tighten the timing plate screws, and install the cover.

   • 5

     Shut off the engine, and remove the timing light. Remove the clear plastic timing hole plug, and install the solid plug in the hole.

Tips & Warnings

• The reusable clear plastic timing hole plug is available from your local Harley-Davidson dealership. The plugs are not interchangeable between production models; purchase the one made specifically for your bike.

• Exhaust fumes are toxic; work only in a well-ventilated area.

• Exhaust pipes become extremely hot during, and for some time after, engine operation. Severe burns may result from contacting the pipes with exposed skin. Avoid contacting the pipes with test equipment wires or other tools.

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 Adjust a Harley Drive Belt

Harley Davidson belt drives are highly engineered and effective drive systems. They are extremely quiet and immune to the corrosion due to their fiber/polymer materials. They require no lubrication and resist stretching and wear from the enormous loads placed upon them by the engine. Belt tension and rear axle alignment are the main concerns when adjusting the belt, and these conditions are easily checked with a few inexpensive specialty tools.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• 1/2-inch torque wrench
• Belt deflection tool
• Standard 1/2-inch socket set
• Rear axle alignment tool
• Machinist's rule (optional)
• Crescent wrench

1. • 1

     Break the torque on the rear axle, but only loosen enough to relieve the clamp pressure at the swingarm and allow the axle adjusters to move the axle. Place the transmission in high gear.

   • 2

     Check axle alignment with the alignment tool. Locate the factory-drilled hole in the swingarm. It will be about eight inches forward of the axle and on the outer face of the swingarm tubing. Insert the short end of the alignment tool into the hole and orient the tool so that it points to the rear of the bike along the swingarm until it intersects the axle. Slide the rubber O-ring on the tool down to exactly where it intersects the precise center of the axle. This is very important to the accuracy of the procedure.

   • 3

     Carefully remove the tool from the hole and transfer it to the other side of the swingarm, being sure to not disturb the O-ring and lose your measurement. Insert the tool into the new side and check the position of the center of the axle against the rubber O-ring indicator. The O-ring should fall out exactly as it did on the first side. If there is any difference, then tighten or loosen the axle adjuster on the second side until it matches the position of the first side. The axle is now aligned and an accurate belt tension test may now be made.

   • 4

     Locate the graduated sight window on the belt guard. If the model does not have a sight window, brace a machinist's rule against the swingarm and use the index slider to indicate the current position of the belt where it intersects the rule. Place the belt tension tool onto the bottom of the belt, close to the sight window. Push up on the tool until it indicates exactly 15 pounds of pressure on the belt. Observe the sight window or the machinist's rule and note the amount of deflection, in fractions of an inch (not thousandths). Refer to the factory specification for your year and model of bike to determine if the belt tension is correct, tight or loose.

   • 5

     Adjust belt tension at the axle adjusters. Tighten the adjusters on a loose belt and loosen them on a tight belt. Turn the adjuster nuts exactly the same amount, and adjust both sides before attempting to test the belt deflection. Check the axle alignment after each adjustment or you may get a false tension reading or worse, introduce a bad rear axle alignment issue into the equation.

   • 6

     Torque the rear axle to factory specification for your model of Harley and check the axle alignment one last time before attempting to test-ride the vehicle.

Tips & Warnings

• You can produce a homemade version of the axle alignment tool. Take a stiff section of wire 12 inches long (welding rod, coat hanger) and of slightly smaller diameter than the alignment hole, and bend the last inch of it 90 degrees. Ensure that a tight, abrupt bend is achieved. Slide an O-ring onto the long end of the wire. The O-ring should fit tightly and resist sliding around easily on the wire to prevent losing the reference as you move from one side of the bike to the other. To maximize the accuracy of the reference, sight along one edge of the O-ring to the center of the axle, rather than the middle of the O-ring. This is true no matter if you are using the factory alignment tool or a homemade one.

How to Check the Oil on a Harley Road Glide

The Harley Road Glide is a full-size touring-style motorcycle and comes with a few different engine sizes. The Road Glide uses 3 qt Harley motorcycle oil which is housed inside the crankcase. On the side of the crankcase, there is a metal cap with a thick raised edge. This cap is the dipstick that you will use to check the amount of oil inside the crankcase.

Difficulty:

Easy

Instructions

Things You'll Need

• Paper towel

1. • 1

     Park the Harley Road Glide on flat, level ground. Allow the engine to run so that the oil inside the crankcase warms up. The engine should run for about 10 minutes.

   • 2

     Twist the oil cap counterclockwise and pull it off the engine. Wipe the oil off the dipstick connected to the inside of the cap using the paper towel.

   • 3

     Insert the dipstick into the engine and pull it back out. Look at the dipstick: If the oil level is below the hole at the top of the dipstick, add oil until the oil level is at that hole. If the oil level is at the top hole, no oil is needed.

Tips & Warnings

• Adding to much oil will flood the crankcase and cause serious damage to the engine.

How to Install a Harley Davidson Motorcycle Seat

Most Harley-Davidson seats are mounted using a tab and slot arrangement.

Whether your are replacing your Haley-Davidson's stock seat with an aftermarket seat or simply removing the seat for maintenance, installing the seat onto the motorcycle can be tricky. The seat on most Harley-Davidson models is secured to the frame using a set of catch tabs on the front of the seat. Likewise, the rear of the seat is bolted onto the rear fender with a thumb screw. This arrangement results in a tool-free and nearly effortless removal and installation of the seat.

Difficulty:

Moderately Easy

Instructions

1. • 1

     Slip the catch tabs on the front of the seat into the slots on the frame, just below the base of the gas tank. Once inserted, the front of the seat should not be able to move from side to side.

   • 2

     Lower the rear of the seat onto the motorcycle's frame and gently push the entire seat forward. Press downward on the rear of the seat to bring the seat's mounting tab closer to the rear fender.

   • 3

     Insert the thumb screw into the seat's mounting bracket and the hole on the rear fender. Tighten the thumb screw, using a flat screwdriver if necessary, to secure the seat to the motorcycle.

   • 4

     Shake the seat from side to side ensure that it is secured. If the seat is loose, check that the catch tabs are completely inserted into the frame's slots and that the thumb screw is completely tightened.

Tips & Warnings

• Be sure that the seat is properly fastened and secured before riding the motorcycle. A loose seat may create a loss of control that could injure yourself or others.

How to Change a Harley Road King

It's easy to design your own unique Harley-Davidson Road King with the Customizer tool at the Harley-Davidson website.

While many people love the stock Harley-Davidson Road King, others find it a perfect canvas for their artistic vision. Before setting off to spend your money on parts and accessories, do your design homework in front of the computer. Harley-Davidson's Customizer tool is not only fun, it gives you the opportunity to explore all the options available to modify your existing Road King, or build a brand new one.

Difficulty:

Easy

Instructions

1. Genuine Motor Accessories Customizer for New or Used

   • 1

     Visit the Customizer tool at the Harley-Davidson website. Open an account or continue without opening an account (see Step Two). Click on the "Login to My Garage" link three-quarters of the way down the page on the left-hand side. Click the "Create Profile" link halfway down the page on the right-hand side. Fill in your e-mail address, password, name and birth date. Scroll down to read the whole form. Click the "Save" button on the bottom left-hand side of the page. Click the "Back to Login" button at the top of the page on the right-hand side. Enter your e-mail address and password in the space provided in the top left corner. Click the "Login" button.

   • 2

     Click the "Touring" button on the top navigation menu. Click the motorcycle model icon entitled "FLHRC." Click "Stock" from the drop-down menu. Click on the color of your choice from the color boxes under the Road King photo on the right-hand side. Click the small box under the Road King photo on the left-hand side when you wish to view the reverse side of the motorcycle photo.

   • 3

     Review the "Categories" section at the bottom of the page. Determine which changes you would like to make to the Road King model, keeping in mind your budget and taste preferences. Choose from the following categories to modify your stock Road King model: Bags and Luggage; Decorative Collections; Electronics, Gauges, Consoles; Engine Components; Exhaust; Foot Controls; Front End Components; Hand Controls; Racks and Backrests; Screamin' Eagle; Seats; Wheels & Sprockets; Windshields. Decide which category to view first and click on it to reveal either one or several photo options. Click on the photo option you are interested in viewing. Read the description of the option on the right-hand side of the page. Review accompanying notes such as "Important Information" and "Other Parts in Collection." Click on the "Install on Bike" button if you choose to add the option to your Road King model. Your change is immediately reflected in the photo. Continue choosing options, or move on to the next category to repeat these steps to build your own unique Road King.

   • 4

     Click the "Add to Workbook" button if you have created a profile. Click the "Save" button. Click on "My Garage" in the top navigation and click the Road King link in the body of the page. Review your completed Road King accessorized with your choices. Scroll through the list of accessories you have added, which are listed on the right-hand side of the page along with the prices of each accessory, or click on "List View" from the top navigation. Check the prices to determine if the accessories you have chosen are in your budget. Remove options or click on "Browse Online Catalog" to add even more options. If you are buying a new Road King, click "Estimate a Payment" and review the total price with a monthly payment pre-calculated for you. Change any of the fields to reflect different interest rates or monthly payment options. Click on the icons at the top right-hand side of the page to save the bike you created, print a list of the accessories you have chosen, share by e-mail, locate a dealer in your area or shop the Genuine Motor Accessories online catalog for more accessories.

   • 5

     Download a credit application by clicking on the "Download Credit Application" PDF link if you are buying a new Road King. Click the "Find a Dealer" link to find a Harley-Davidson dealership in your area. Purchase the Road King you have designed. Alternatively, if you already own a Road King, purchase the parts you have selected and install as per the instructions provided with the hardware, or hire a Harley-Davidson dealership or other Harley mechanic to install them for you.

   Shop for After-Market Parts and Acessories

   • 1

     Shop online for after-market parts. Several after-market parts suppliers for Harley-Davidson motorcycles are available.

   • 2

     Order catalogs from after-market parts and accessories distributors. Review catalogs, making notes about the accessories that interest you. Talk to others who may have experience with these products to get their feedback.

   • 3

     Visit after-market parts and accessories websites featuring products for Harley-Davidson. Search for keywords such as "Harley-Davidson exhaust systems," "custom motorcycle seats," "motorcycle saddlebags," "tires for Harley-Davidson," "luggage for Road King," "fairings for Road King," "wheels for Harley-Davidson" and "electronic components for Road Kings."

Tips & Warnings

• Jot down notes as you review the options for designing your Road King.

• Invite your spouse to view your Road King and ask for his opinion about the changes you are making to the stock model.

• Share your vision with friends and family by clicking on the "Email a Friend" link.

• If you are on a budget, purchase only what you can afford now -- you can always make more modifications next season.

How to Care for Harley Boots

Authentic Harley boots have a waterproofing shield and are made from genuine leather. Some Harley boots lace up, some have buckles and some have zippers. Choices of styles include the Faded Glory, Hustin and Dipstick. A well-fitting pair of boots is essential for maintaining proper motorcycle riding safety; after all, they are not just a fashion statement.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Black creme polish
• Water repellent
• Wax

Suggest Edits

1. • 1

     Polish your leather boots. Harley-Davidson.com not only has boots for sale, but cleaning accessories such as polish as well (see Resources). Use black creme polish for best results in maintaining the original color.

   • 2

     Shelter your boots from weather such as snow and rain when not out in the elements. Dry them up in natural outdoor air after they've gotten wet. Don't use too much heat, such as a dryer, as this is can dry out the leather. Make sure it's not going to rain if you put them outside.

   • 3

     Waterproof your boots with a mild detergent and let them stand dry. Once you remove the factory waterproofing, the new weatherproofing repellent will stick to your boots effectively. Use beeswax or lanolin to fill up the porous leather. This will prevent water from harming the integrity of the leather fiber. Reapply water repellent or wax weekly if you're using your boots consistently.

Tips & Warnings

• The "Faded Glory" version have a relatively large buckle and medallion. Use jewelry-cleaning liquid on the metal to maintain the shine.

How to Interpret a Harley VIN Number

If it looks like a Harley, checking the VIN is a way to make sure..

Since its founding in 1903 Harley-Davidson motorcycles have established an image of mystique and lore; bold revving engines, leather-clad bikers in sunglasses and chrome engines glistening in the sun. Beyond the surface however, Harley-Davidson is known for maintaining a high standard of quality for all its products. The vehicle identification number (VIN) on a Harley-Davidson motorcycle is not only an important part of registering legal ownership but also a way of verifying that the engine and frame are genuine Harley-Davidson items.

Difficulty:

Easy

Instructions

Before 1970

• 1

  Locate the VIN. For bikes manufactured up to 1969, the identification is found on the left side of the engine case. There is no number on the frame.

• 2

  Read the first two digits. This is the model year.

  For example: 59FLH1234, is the year 1959.

• 3

  Read the letters. The VIN on a Harley will have up to four of them. The letters represent the model.

• 4

  Read the last four numbers. This number is the production number of the bike.

1970 - 1980

• 1

  Locate the VIN. Beginning in 1970 Harley-Davidson began stamping the number on both the engine and the frame, with the exception of those bikes dating 1979. The number for legal registration is on the frame.

• 2

  Read the first two digits. This is the model code.

  For example: 2C12345H5, the model code would be 2C.

• 3

  Read the next five numbers. This group of five numbers is the production number.

• 4

  Read the last two digits. These two digits stand for the last two digits of the model year with "H" meaning "7" and the last digit matching that of the year.

1981 - present

• 1

  Locate the VIN. The number on the frame is 17 digits long, while that on the engine is abbreviated. The number necessary for legal registration is on the frame.

• 2

  Read the first number of the VIN on the frame. This indicates the country of origin code. A "1" means the bike was made in the United States.

  For example: 1HD4BFH1XNY123456

• 3

  Read the following two letters. "HD" means the bike is a genuine Harley-Davidson.

• 4

  Read the next number. This is the weight class for the bike.

• 5

  Read the two letters. These designate the model code.

• 6

  Read the next single letter. This is the engine model code.

• 7

  Read the following number. This is the introduction date.

• 8

  Read the next letter. This is the check digit.

• 9

  Read the next letter. This is the model year code.

• 10

  Read the next letter (the last letter of the sequence). This is the location of manufacture code.

• 11

  Read the last six numbers. This is the bike's serial number

How to Replace the Headlights on a Harley Road Glide

A couple of dressed classics front this line of Harley-Davidson motorcycles.

The Road Glide was intended by the manufacturer to be a flagship model for the fleet of Harley-Davidson motorcycles. With its impressive fairing and dual headlights, it certainly looks the part. Changing the headlights when they burn out, however, can be a daunting task. It is necessary to remove the outer fairing and work on the inside of it in order to change the bulbs. This task is best accomplished in a garage with a clean work bench. The length of time it takes to complete this task is between 30 and 60 minutes.

Difficulty:

Moderate

Instructions

Things You'll Need

• Cross-tip screwdriver
• 10mm wrench
• Torx wrench set
• New headlight bulbs

1. Remove the Seat

   • 1

     Unscrew the back fastener on the rear of the seat with a cross-tip screwdriver to free the seat.

   • 2

     Move the seat toward the rear of the bike and lift it free of the chassis. Set the seat aside.

   • 3

     Disconnect the negative terminal of the battery using a 10mm open-ended wrench. The battery is under the seat.

   Remove the Outer Fairing

   • 1

     Loosen and remove the seven screws that secure the outer fairing, using a Torx-head driver. These screws are located around the inner fairing at the windshield, the radio speakers, and the handlebar triple-trees.

   • 2

     Lean the outer fairing forward while carefully holding it. Reach inside the fairing and disconnect the wire connectors that attach this outer fairing to the rest of the bike.

   • 3

     Move the fairing to a clean workbench.

   Change the Headlights

   • 1

     Pull the wire harness located at the back of each headlight. Pull the harness gently by hand.

   • 2

     Loosen and remove the plastic retaining rings on each headlight by turning them counterclockwise by hand. Pull out the old bulbs and discard them.

   • 3

     Insert new bulbs into their position with the larger tab on their back plates pointing toward the top of the fairing. Screw the plastic retaining rings back onto the bulbs and reconnect the bulb wiring harnesses.

   • 4

     Take the outer fairing back to the motorcycle for reinstallation. Close the job out in reverse order, installing the fairing, then the battery terminal, then the seat.

Tips & Warnings

• Keep interruptions to a minimum when performing this task and keep a close eye on the outer fairing when you are working on it to avoid scratches and dings.

• Remove all watches and rings when working around motorcycle batteries.

How to Troubleshoot an Alternator on a Harley

That little black box in front of your engine can cause you some big problems.

A Harley-Davidson motorcycle will give you hours of riding pleasure for years on end. But when the battery goes dead and it won't start, it can have you cursing very quickly. Replacing the battery won't help at all if you have problems with your charging system, so a few tests are needed in order to determine what is causing the problem. Although these tests may be beyond the ability of some do-it-yourself mechanics, if you have moderate skills and own or can borrow the proper tools, you can save yourself some money and may even be able to fix the problem on your own.

Difficulty:

Moderately Challenging

Instructions

Things You'll Need

• Digital multimeter
• Alligator clip test leads

1. • 1

     Remove the motorcycle seat from the bike's frame. Open the battery compartment or remove the outer enclosure.

   • 2

     Set your multimeter's function to DC volts in the 25-volt range if it is not an auto-ranging meter. Connect the red test lead to the positive (red) terminal of the battery. Connect the black test lead to the ground (black) battery terminal. Observe the reading. A fully charged battery should read between 12.5 and 13.2 volts. Charge the battery, if necessary, to bring the reading up to specifications.

   • 3

     Start the bike and smoothly rev the engine up to around 2,500 RPM. If your Harley doesn't have a tachometer, you'll have to approximate this, being careful not to over-rev the engine. With the engine at steady RPM, observe the multimeter reading. It should be between 13.5 and 14.5 volts if the charging system is okay. If it still shows only resting battery voltage or less, you will need to test the alternator output.

   • 4

     Locate the alternator output wires on your Harley's engine. These wires generally extend out of the front of the engine case on the left side, behind the frame tubes. Trace the wires until you locate the connector that links them to the voltage regulator, which is bolted to the frame tubes behind the front wheel. Unplug the connector.

   • 5

     Set your multimeter on the "Resistance" or "Ohms" function. Probe each of the pins in the alternator side of the connector separately. You should again see a very low (less than 1 ohm) resistance reading. If you get a higher resistance on any pin (several ohms), you may have a bad winding. If the reading is extremely high or shows an open circuit (infinity) reading, that winding is definitely bad. If you get good readings on the stator windings, proceed to the next step.

   • 6

     Connect the probes across the pins and change the meter's function to AC Volts. Start the engine and note the reading. You should see between 15 to 25 volts at idle speed. Open the throttle a little to increase the RPM. The readings should rise steadily as the RPM increases. If it doesn't, then you likely have a short in the stator windings. If the alternator passes all the tests, the problem is most likely in the voltage regulator.

Tips & Warnings

• A digital multimeter is required because of its ease of use, and the readings are much easier for the average person to interpret. An analog multimeter can be used if you are well-versed in its operation.

• A small pocket screwdriver can be helpful in separating some types of electrical connectors. Use caution to avoid breaking off the latches that hold them snugly together.

• Modern voltage regulators are solid-state designs, with no serviceable components inside. If your tests indicate a bad regulator, then the entire unit must be replaced. This is a simple bolt-on installation and is well within the abilities of the average home mechanic.

• The battery must be fully charged before any testing is performed. Be sure to charge any battery showing between 11.5 and 12 resting volts or less before proceeding with the tests. Use only a charger designed specifically for motorcycle battery use. Using a high-amperage charger can destroy your battery.

• Unlike the voltage regulator, the alternator on your Harley requires the use of specialty tools in order to service it. It is therefore highly recommended that you let an authorized Harley-Davidson dealer or a well-equipped independent motorcycle repair shop perform any alternator work that may be indicated by the tests.

How to Oil a Harley-Davidson

Change your Harley's oil frequently to ensure the bike is always ready to ride.

A Harley-Davidson motorcycle can be ridden almost indefinitely when cared for properly. Although completely maintaining your Harley will involve a broad spectrum of procedures, periodically changing the oil is one of the most vital tasks that contribute to your motorcycle's overall health. Under normal circumstances, the oil within your Harley's motor, transmission and primary chaincase assembly should be changed in 2,500-mile increments. However, extended riding sessions may degrade the oil supply much sooner. The entire process is fairly straightforward and shouldn't take longer than one and a half hours to complete.

Difficulty:

Moderate

Instructions

Things You'll Need

• 5/8-inch socket
• Socket wrench
• Oil pan
• Torque wrench
• Strap wrench
• Oil filter
• 20W50 motor oil, 3 qts.
• 85w140 gear oil or Harley-Davidson transmission oil, 1 qt.
• Torx T-27 screwdriver
• 5W30 motor oil or Harley-Davidson primary oil, 1 qt.

1. Motor Oil

   • 1

     Locate your Harley-Davidson's motor oil drain plug. Softail models place their drain plugs along the cross-member on the bottom of their frames, while Touring models place their drain plugs beneath the transmission, behind the motor. Alternatively, Sportster models use a drain hose that is plugged into the bottom of the left frame rail.

   • 2

     Remove the drain plug from your Harley-Davidson, using a 5/8-inch socket and a socket wrench. Allow the motor's oil supply to drain into an oil pan until the flow is reduced to a slight trickle.

   • 3

     Clean the drain plug with a shop towel, then screw it into place with your 5/8-inch socket. Tighten the drain plug to 20 foot-pounds with a torque wrench.

   • 4

     Unscrew the oil filter from the front of the motor with a strap wrench, then discard it. Remove the packaging from your new oil filter, then fill it with fresh 20W50 motor oil. Rub a small amount of oil along the filter's sealing O-ring with your finger.

   • 5

     Screw the new oil filter into place by hand until it is seated gently against the motor. Tighten the oil filter an extra quarter-turn by hand.

   • 6

     Fill your Harley-Davidson's oil tank with 3 qts. of 20W50 motor oil, using a funnel.

   Transmission Oil

   • 1

     Locate the transmission's drain plug along the bottom of the transmission housing. Unscrew the drain plug with a 5/8-inch socket and a socket wrench. Allow the transmission oil to drain into an oil pan until it reduces to a trickle.

   • 2

     Clean the transmission drain plug with a shop towel, then screw it into place with your 5/8-inch socket. Tighten the drain plug to 20 foot-pounds with a torque wrench.

   • 3

     Fill the transmission with 1 qt. of 85w140 gear oil or Harley-Davidson transmission oil, using a funnel.

   Primary Fluid

   • 1

     Unscrew the bolts from the round clutch inspection cover on the primary chaincase on the left side of the motor, using a Torx T-27 screwdriver. Pull the cover and its gasket away from the primary chaincase.

   • 2

     Unscrew the small drain bolt directly below the clutch inspection cover's port with a Torx T-27 screwdriver to drain the fluid from the primary chaincase into an oil pan.

   • 3

     Clean the the drain bolt with a shop rag, then screw it into place with your Torx T-27 screwdriver once the flow of the primary fluid has reduced to a trickle. Tighten the drain bolt to 16 foot-pounds with a torque wrench.

   • 4

     Pour 1 qt. of 5W30 motor oil or Harley-Davidson primary oil directly into the primary chaincase through the clutch inspection port.

   • 5

     Reinstall the clutch inspection cover and its gasket onto the primary chaincase. Screw the cover's bolts into place with your Torx T-27 screwdriver. Tighten the bolts to 10 foot-pounds with a torque wrench, alternating between bolts in a criss-cross pattern.

Tips & Warnings

• Warm your Harley-Davidson up to its normal operating temperature before beginning to ensure a quick and complete drain of the motorcycle's fluids. Once warm, allow the motorcycle to cool for another 10 minutes to avoid burning yourself with the heated oils.

How to Remove Stock Harley Baffles

When most people think of Harley-Davidson motorcycles, the first thing they recall is the deep, often loud exhaust note of a big cruising bike. The loud exhaust has become a staple of motorcycle culture because it acts as a safety buffer. A loud bike ensures that drivers and other riders know you are around, preventing accidents that even the stock horn on most motorcycles would not help. Make your bike louder and safer by removing the stock baffles at home.

Difficulty:

Moderately Challenging

Instructions

Things You'll Need

• Bike lift (optional)
• Basic tool set
• Hand-held drill
• Drill extension
• 3/8-inch metal cutting drill bit
• Vise
• Rubber mallet

1. • 1

     Set your motorcycle on its kickstand or center stand so that it will not fall over or tip while you are working. If you have a motorcycle lift, put your Harley on the lift to access the necessary bolts more easily.

   • 2

     Examine how the exhaust pipes are attached to your motorcycle by consulting the owner's manual. Most bikes will have two nuts holding each pipe at the cylinder and mounts that hold the exhaust onto the frame.

   • 3

     Remove the bolts that hold the exhaust to the motorcycle using a socket or combination wrench. Separate the entire exhaust from the bike to avoid drilling near important running parts.

   • 4

     Clamp the exhaust in a vise. Cover the vise in rags or towels to protect the chrome finish of the pipes. Attach a 3/4-inch metal cutting drill bit to your hand-held drill and drill through the first two baffles inside the tip of the exhaust.

   • 5

     Take the exhaust pipes out of the vise. Tap the end of the mufflers with a rubber mallet to knock out any remaining pieces of baffle.

   • 6

     Reinstall the exhaust on the bike using the mounts removed earlier. Refer to your owner's manual for torque specifications. Be careful not to over-tighten the crankcase exhaust mounting bolts as they are expensive and difficult to replace.

   • 7

     Start the bike and listen for a difference in tone. If all goes well, the motorcycle should sound louder and fuller, especially when revved.

How to Make Harley Baffles Louder

Most riders call it "that Harley sound": the loud, rumbling exhaust that lets you know there is a Harley-Davidson motorcycle around. The stock pipes that come on a Harley are designed to meet federal EPA standards and don't deliver the sound most riders want. Replacing the stock exhaust can be expensive. You can create the sound if you make the Harley baffles louder. Baffles are the packing inside the rear of a motorcycle exhaust pipe that filters and dampens the noise.

Difficulty:

Moderate

Instructions

Things You'll Need

• Flat-head screwdriver
• Drill
• 1-inch metal drill bit

1. • 1

     Park your Harley on a level surface. If you have ridden it recently, let it sit until the exhaust pipes are cool to the touch.

   • 2

     Use a flat-head screwdriver to pry the end caps out of the exhaust pipes. The end caps are metal caps with a hole in the center that have been machine-pressed in to the ends. Insert your screwdriver into the center hole, and pry against the edge of the pipe until it pops free. You will then see the metal screed that covers the baffle.

   • 3

     Drill a hole through the center of the baffle. Use a drill with a metal bit that is 1 inch in diameter. Press the tip against the screen of the baffle, and press the drill into it while running it at a slow and steady speed. Push the drill into the baffle the entire length of the bit. This will place a direct hole through the screens and packing of the baffle and open it.

Tips & Warnings

• To prevent scratching the finish on the pipes when removing the end caps, drape a hand towel over the end of the pipe so that it is between the chrome of the pipe and the metal of your screwdriver when you pry the end cap out.

• Experts estimate that loud pipes, or pipes that have had the baffles modified, decrease the power of the engine 5 to 10 percent. Adjusting the carburetor to compensate for an open baffle will increase your horsepower, which will not return the actual lost performance power of the engine. The Harley sound you love is actually an indication of an engine that cannot operate at peak performance and will eventually sustain internal damage from the strain.

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.

How to Remove a Harley Brake Pedal Cover

The brake pedal cover on a Harley-Davidson motorcycle is made of thick rubber and is connected to the pedal in different ways. The cover protects the pedal and gives it a good look. Changing the cover will help you give your Harley a customized look that will fit your personality. You will need little in terms of tools, and you can remove the brake pedal cover just about anywhere.

Difficulty:

Easy

Instructions

Things You'll Need

• Flat-head screwdriver

1. • 1

     Park the Harley on level ground in an area with plenty of light. Allow the engine to completely cool before proceeding to avoid burns.

   • 2

     Look on the rear of the pedal and place the blade of the screwdriver under the edge of the cover. You may need to lie on your back or get on your knee to see behind the pedal.

   • 3

     Pry the edge of the pedal cover slowly over the edge of the brake pedal using the screwdriver. Once one side of the cover is off the brake pedal, pull the cover off.

Tips & Warnings

• On some Harley models like the Nighttrain, the Road Glide and the Sportster, you will need to cut the rubber cover off using a razor.

How to Adjust the Clutch on My Harley Heritage

Unlike automobiles with a manual transmission, you must manually adjust the clutch on motorcycles like the Harley Davidson Heritage. Adjusting the clutch ensures soft clutch lever pulls and accurate shifting. As the clutch plates wear down, you must adjust the clutch inward to compensate. Clutch adjustment is accomplished in two places: the clutch lever and the clutch itself.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Wrench set
• Allen wrench set

1. • 1

     Locate the clutch lever adjuster on the clutch cable. The adjuster is secures to the frame's front down tubes behind the front forks. A ribbed rubber cover covers the adjuster. Slide the cover upward to expose the adjuster. The adjuster consists of a threaded with a jam nut on the top end. Loosen the jam nut using a wrench and thread the adjuster downward to create "free play" in the clutch lever. The clutch lever should push into the handlebar grip without any resistance.

   • 2

     Remove the screws that secure the clutch cover plate onto the clutch housing. On the Heritage, the cover is round and the screws require Allen wrenches for removal. The cover plate is on the left side of the motorcycle.

   • 3

     Place an Allen wrench into the setscrew located in the center of the clutch and hold it steady while you loosen the jam nut that threads onto the setscrew using a wrench.

   • 4

     Back the jam nut off the setscrew several turns using your fingers. Turn the setscrew inward using the Allen wrench until it securely bottoms out inside the clutch.

   • 5

     Turn the setscrew a quarter turn counterclockwise and secure it by tightening the jam nut with a wrench. Do not allow the setscrew to move while you tighten the jam nut.

   • 6

     Place the clutch cover plate back onto the motorcycle using the screws and Allen wrench.

   • 7

     Turn lever adjuster counterclockwise until you have between ¼ inch and 3/8 inch free play in the clutch lever. Tighten the jam nut and slide the rubber cover back over the adjuster.

How to Kickstart a Panhead Harley

A Pan Head Harley is a classic motorcycle revered by many as the original and best of the Harley Davidson line. No matter what your view on that subject is, there is one way to kick start the Pan Head. It's the classic way to get your bike running.

Difficulty:

Moderate

Instructions

Things You'll Need

• Boots
• Pan head

1. • 1

     Make sure you are wearing high quality leather boots with good stiff soles, to start your Pan Head.

   • 2

     Turn the ignition key to on.

   • 3

     Open the fuel lever or petcock valve (if your bike uses one).

   • 4

     Set the bike into neutral by pressing the gear shift lever down several times until it stops, then lifting it up once until you feel the bike go out of gear. Roll the bike back softly to make sure it really is out of gear. Neutral on a motorcycle is between first and second gears.

   • 5

     Raise the kick starter to the start position, which is cocked up at nearly a 90 degree angle from the ground.

   • 6

     Grasp the throttle handle (on the right).

   • 7

     Place your foot on the kick start lever, and thrust it down in a counterclockwise arc. The lever kicks down and away from the front of the bike.

   • 8

     Adjust the Pan Head carburetor lever as needed, and repeat until the bike starts.

Tips & Warnings

• Roll the throttle only slightly to start a pan head. Older models are not fuel injected and you will flood the carburetor.