INDEX 1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-1 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE REFERENCE SECTION Cross reference charts including a chart with our catalog part number, catalog section and page number, as well as a conversion chart for Harley-Davidson® part number to MID-USA part number with catalog section and page number and helpful reference charts. GENERAL MERCHANDISE SECTION General merchandise such as leathers, t-shirts, cold weather gear, goggles, tie downs, service/performance manuals, chemicals, oil & lubricants, battery chargers, shop equipment, tools, security and shop items, nuts, bolts, washers, spacers and decorative fasteners. EXHAUST SECTION Exhaust systems, exhaust builders kit, drag pipes, baffles, mufflers, heat shields, exhaust gaskets, exhaust studs and hardware, brackets and clamps. FUEL SECTION (GAS, OIL, AIR) Carburetors, carburetor rebuild kits, EFI parts, manifolds, replacement air filters, gas tanks & hardware, gas lines, oil filters, oil line kits, oil tanks & hardware and oil pressure gauges. DRIVE TRAIN SECTION Everything for Standard and Wide Tire primary drive train and final drive train, transmissions, shifters, kick starters, clutches, drive chains, chain adjusters, sprockets, belt drives, chain covers, chain guards and all related parts. ENGINE SECTION Complete engines, parts on and in the engine and starter drive parts (excluding electrical, ignition and carburetor). WHEEL SECTION Wheel assemblies, axles & related parts, brake discs, brake pads, brake calipers & related, brake disc hardware, drum brakes, wheel hubs & related, rims, spokes, tires and inner tubes. CONTROL SECTION Brake lines & fittings, cables, forward controls, handlebar controls, handlebars & related, speedometers, tachometers, dashes & related, mirrors, rear brake control & related, shift controls and jockey control parts. FRONT END SECTION Fork brackets, headlight housings & covers, fork tubes & internals, fork sliders, fork seals, stem bearings & hardware, springer front ends and springer related parts. FRAME / BODY SECTION Frames, rear forks, footrests, fenders, shocks, engine mounts, jiffy stands, footboards, seats, highway bars, luggage racks, windshields, sissy bars, saddlebag supports and related items. ELECTRICAL SECTION Electronic and points type ignition parts and accessories, headlights, taillights, turn signals, license plate mounts, horns, batteries & related, wiring and wiring harnesses. CONTENTS SECTION Alphabetical listing of parts and corresponding page numbers.
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-2 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL ACCEL Ignition module .. . . . . . . . . . . . 1-97 Ignition coils.. . . . . . . . . . . . . 1-84/85 Ignition, points & plugs . . . . . . . 1-90 Spark plug wires . . . . . . . . 1-114/115 Tuneupkits................ 1-90 Acorn Head, Nuts.. . . . . . . .10-34/35 Advance Unit for Ignition. . . . 1-92/94 Air Deflectors for Touring Models............... 2-6 Air Filter Air cleaner screws.. . . . . . . . 8-94/96 Assemblies. . . . . . . . . . . . . 8-97/105 Cover mount screws . . . . . . . 8-94/96 Elements.. . . . . . . . . . . . . 8-106/108 Max Flow Intake kits . . . . . . . . 8-105 Mounts and adapters.. . . . . . 8-94/96 Supports (Brackets).. . . . . . . . . 8-94 Alignment Tool Wheel................... 10-54 ALL BALLS Battery Cable lug/terminals. . . . . 1-8 Battery cables.. . . . . . . . . . . . . 1-7/9 Starter motors . . . . . . . . . . 1-124/127 Allen Head Bolts & screws.. . . . . . . . . . . . 10-37 Powertrain kit.. . . . . . . . . . . . . 10-33 Alternator Charging systems . . . . . . . 1-144/148 Mounting hardware . . . . . . . . . 1-148 Stator plug retainer . . . . . . . . . 1-148 Stators................... 1-141 ALTO PRODUCTS Clutch plate assemblies . . . . 7-53/54 Clutch steel drive plates (each) BigTwin................... 7-54 ALTO PRODUCTS (cont) Clutch steel drive plates (each) Sportster.. . . . . . . . . . . . . . . 7-62/64 Clutch spring plate.. . . . . . . . . . 7-64 ANCRA Tie Down Straps . . . . . . . . . 10-11/13 ANDREWS Cams, Big Twin Evo . . . . . . . . . 6-67 Cams, Big Twin Pre-Evo.. . . . . 6-65 Cams, Milwaukee-Eight®...... 6-71 Cams, Sportster.. . . . . . . . . . . . 6-79 Cams, Twin Cam.. . . . . . . . . 6-69/74 Engine pushrods. . . . . . . . . . 6-54/59 Shifter forks, Big Twin. . . . . . 7-30/32 Transmission gear sets. . . 7-28,7-39 Transmission parts . . . . 7-8, 7-25/27 . Transmission pulleys.. . . . . . . 7-119 Valvecollars.. . . . . . . . . . . . . . 6-29 Valvesprings.. . . . . . . . . . . . . . 6-28 Anti-Seize Lubricant......... 10-21 Ape Hanger Bars...........4-21/32 Assortment Kits Allen screw plugs.. . . . . . . . . . 10-38 Battery cable builders kit. . . . . . . 1-8 Electrical terminals.. . . . . . . . . . 1-66 Heat shrink tubing. . . . . . . . . . . 1-66 Nuts, bolts & washers. . . . . . . 10-39 Orings................... 10-39 Automatic Primary Chain Tensioners................7-90/91 AUTOMETER Oil pressure gauge . . . . . . . . 8-60/61 Speedometer.. . . . . . . . . . . . . 4-140 Tachometer.. . . . . . . . . . . . . . 4-139 AVON Handlebar grips. . . . . . . . 4-13, 4-15`
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-3 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE AVON, Tires.................5-6/7 Axle Axle/Chain adjusters. . . . . . . . . 5-35 Front. . . . . . . . . . . . . . . . . . . . . .5-28 Nutcovers................. 5-31 Nuts....................5-30/32 Rear....................5-26/27 Spacers.................5-33/34 BADLANDS Turn signal load equalizer.. . 1-25/26 Baffles, Exhaust ............. 9-18 Ball Milled Accessories Cableclamps.. . . . . . . . . . . . . . 4-77 Fork tube sliders . . . . . . . . . . 3-29/30 Saddlebag latch covers.. . . . . . 2-73 Taillight/License mounts . . . . 1-48/50 Banjo Bolt, Crush Washers.. . . 4-95 Bandannas ............... 10-101 Banners .. . . . . . . . . . . . . . . . . 10-115 Barometric Pressure Sensor EFI.................. 8-75 Base Gasket Sets .. . . . . . . 6-128/130 Battery Cableboot.................. 1-9 Cable crimping tool . . . . . . . . . 10-42 Carrier tray kit & parts. . . . . . . 1-9/11 Chargers................... 1-2 Covers..................1-10/11 Cushions................... 1-9 Electric cables. . . . . . . . . . . . . . 1-7/8 Hold down straps.. . . . . . . . . . . 1-11 Jumpercables.. . . . . . . . . . . . . . 1-6 Maintenance free type.. . . . . . . 1-4/5 Terminal hardware.. . . . . . . . . . . 1-6 Tray...................... 1-10 Baseball Cap.............. 10-113 Bee Hive Valve Springs. . . . . 6-26/28 Belt Drive Alignment tool.. . . . . . . . . . . . 10-77 Assemblies. . . . . . . . . . . . . . 7-68/74 Covers for alternator . . . . . . . . . 7-83 Engine pulley nut lock. . . . . . . . 7-85 Lower debris guards . . . . . 7-128/129 Parts. . . . . . . . . . . . . . . . . . . 7-78/92 Primary drive belts.. . . . . . . . . . 7-67 Rear belt guards . . . . . . . . 7-128/129 Rear drive belts. . . . . . . . . 7-123/126 Rearpulleys.. . . . . . . . . . . . . . 7-121 Starter ring gears.. . . . . . . . . . . 7-43 Wide tire pulley kits. . . . 7-80, 7-127 BELT DRIVES LTD Belt drive assemblies.. . . . . . 7-68/77 Belt drive parts.. . . . . . . . . . . 7-78/85 Clutch assemblies (conversion).. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 7-81 Idlerbearing.. . . . . . . . . . . . . . . 7-84 Primary chain kits (with clutch). 7-91 Primary drive belts (replacement) .. . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Transmission pulley kits .7-119, 7-127 Belt Rear belt length chart . . . . . . . 7-124 Replacement front belts.. . . . . . 7-67 Replacement rear belt.. . . 7-123/125 Tension gauge tool . . . . . . . . . 10-73 Bendix Air filter assemblies. . . . . . . . . . 8-97 Carburetor rebuild kit.. . . . . . . . 8-89 Carburetor accelerator pump.. . 8-89 Chokecables.. . . . . . . . . . . . . . 8-91
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-4 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL Bendix (cont) Throttle cable bracket. . . . . . . . . . 8-89 Big Bore Pistons Panhead & Shovelhead pistons..................6-42/43 Sportster 883 to 1200cc pistons. . . . . .. . . . . . . . . . . . . . . . . . 6-42, 6-45/46 Twin Cam 95ci pistons . . . . . 6-42/45 Bin Boxes .. . . . . . . . . . . . . . . . . 10-33 Blue Streak Coils...................... 1-83 Spark plug wires . . . . . . . . . . . 1-116 BLUE-JOB, Metal Polish .. . . . . 10-25 Bobber Frame................ 2-4 Bobster Eyewear.. . . . . . . . .10-86/93 Bolts 12point.................. 10-35 Allenhead................ 10-37 Button head allens.. . . . . . . . . 10-36 Flathead allens . . . . . . . . . . . . 10-36 Hexhead................. 10-36 Powertrain kits.. . . . . . . . . . . . 10-33 Books Mid-USA catalog. . . . . . . . . . 10-116 Repair manuals. . . . . . . . . . . . 10-41 Bracket Kits for Portable Electronic Devices (handlebar mount) .. . . . . . . . . . . . . . . . Cellphone................. 10-10 Brake Anchor arm mount hardware.. . 5-37 Anchor/Pivot kit (Sportster rear drum). .. . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Banjo bolts.. . . . . . . . . . . . . 4-95/105 Bleed screw repair kit . . . . . . . . 5-38 Bleedscrews.. . . . . . . . . . . . . . 5-38 Brake (cont) Cables(rear).. . . . . . . . . . . . . . 4-75 Caliper anchor arm (rear) . . . . . 5-37 Caliper assemblies . . . . . . . . 5-40/48 Caliper bolt/washer & bracket (for Banana brake).. . . . . . . . . . 5-37 Caliper mount eliminator cover plate (for custom front fork).. . . . 3-26 Caliper mounting bracket (for custom forks).. . . . . . . . . . . 3-26 Caliper mounting brackets.. . . . 5-41 Caliper mounting hardware. . . . . . . . .. . . . . . . . . . . . . . . . . . . 5-5-39, 5-45 Caliper pistons.. . . . . . . . . . . . . 5-42 Caliper rebuild kits (OE type). . .5-38 Caliperseals.. . . . . . . . . . . . . . 5-38 Caliper screen inserts . . . . . . . . 5-49 Caliper stabilizers . . . . . . . . . . . 5-42 Clevis & pin for brake rod .. . . 4-111 Control parts mechanical, Big Twin.. . .. . . . . . . . . . . . . . . . . . . . . . . . 4-111 Cylinders (wheel).. . . . . . . . . . . 5-36 Disc brake parts.. . . . . . . . . . 5-38/39 Disc mounting kits. . . . . . . . . . . 5-62 Disc (rotor).. . . . . . . . . . . . . . 5-57/61 Drum mounting bolts. . . . . . . . . 5-36 Fluid................ 5-38,10-20 Foot lever mount bracket.. . . . 4-112 Foot lever pad.. . . . . . . . . . . . 4-117 Handlever.. . . . . . . . . . . . . .4-79/83 Hoseclamps............... 4-77 Hoses, custom braided. . . 4-100/106 Hoses, custom nylon.. . . . . . . . 4-99 Hoses, OE fit braided . . . . 4-107/110 Light switches.. . . . . . . . . . . . . 1-57 Line fitting thread tape.. . . . . . 10-24
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-5 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Brake (cont) Line fittings.. . . . . . . . . . . . . 4-99/105 Master cylinder covers, rear . . 4-115 Master cylinder, front OE.. . . 4-83/89 Master cylinder, rear OE . 4-113/115 Master cylinder rebuild kits, front . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Master cylinder rebuild kits, rear . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 4-116 Master cylinder reservoir covers, front...................... 4-93 Master cylinder reservoir covers, rear. . . . . . . . . . . . . . . . . . . . . .4-115 Master cylinder reservoirs. . . . 4-116 Pads (custom).. . . . . . . . . . . . . 5-56 Pads (OE style). . . . . . . . . . . 5-51/55 Pedalpads................ 4-117 Pedals................... 4-117 Rear brake switches . . . . . . . . . 1-57 Rotors..................5-57/61 Shoesprings.. . . . . . . . . . . . . . 5-36 Shoes..................... 5-36 Spacer, disc to hub. . . . . . . . . . 5-49 Springs, brake lever return . . . 4-112 Stainless hose heat shrink covers.. . .. . . . . . . . . . . . . . . . . . . . . . . . . 4-76 Teefittings................. 4-98 Brass Kickpedal................. 7-34 Pushrod keepers. . . . . . . . . . . . 6-52 Rocker box oil lines. . . . . . . . . . 8-38 Breather Crankcase................. 6-91 Pipe assembly/case bolt . . . . . . 6-91 Valve & gear, Big Twin . . . . . . . 6-85 Builder Kits Batterycable................ 1-8 Charging & starter kits.. . . 1-147/151 Charging system. . . . . . . . 1-147/149 Primary bushing, seal kit. . . . . . 7-95 Bulbs Dashpanel................. 1-33 Headlight.. . . . . . . . . . . . . . . 1-14/17 Instrument panel . . . . . . . . . . . . 1-33 Bulbs .. . . . . . . . . . . . . . . . . . . . . . . . . . Markerlights.. . . . . . . . . . . . . . 1-33 Spotlights.. . . . . . . . . . . . . . . 1-22/23 Taillights................... 1-34 Turnsignals................ 1-34 Bullet Style Tire Valve Stem Caps .. . .. . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Bungee Nets..................... 10-14 Nuts..................... 10-35 Burly Slammer Suspension DropKits.................. 3-33 Cable Brake..................... 4-75 Choke. . . . . . . . . . . . . . . . . . . . .8-91 Clamps.................... 4-77 Clutch.. . . . . . . . . . 4-41/65, 4-72/74 Cover (clear heat shrink).. . . . . 4-76 Lubricants................ 10-20 Mounting brackets, clutch . . . . . 4-75 Throttle repair kit. . . . . . . . . . . . 4-72 Speedometer.. . . . . . . . . . . . 4-65/66 Tachometer.. . . . . . . . . . . . . . 4-152 Throttle.. . . . . . . . . 4-41/64, 4-67/71 Ties, clamps & retainers . . . . 4-77/78 CAL PRODUCTS RocketFuel.. . . . . . . . . . . . . . 10-17
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-6 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL Caliper Assemblies, brake. . . . . . . . . 5-40/48 Brake mounting hardware. . . . . 5-39 Sealkits................... 5-38 Parts, Big Twin. . . . . . . . . . . . . .5-42 Parts, Sportster. . . . . . . . . . . 5-45/48 Cam Big Twin Evolution.. . . . . . . . 6-66/68 Big Twin Pre-Evolution . . . . . . . 6-65 Milwaukee-Eight® .. . . . . . . . .6-75/78 Sportster.................. 6-79 TwinCam.. . . . . . . . . . . . . . .6-69/74 Cap Head Nuts .. . . . . . . . . . . . . 10-35 Carburetor Assemblies. . . . .8-62, 8-66/66, 8-88 Fuel atomizers, YOST........ 8-87 Parts, KEIHIN............8-86/87 Parts, MIKUNI............8-67/68 Parts, S&S...............8-63/64 Velocity stack.. . . . . . . . . . . . . 8-100 Cargo Nets................. 10-14 Catalog (Mid-USA) .. . . . . . . . . 10-116 Cell Phone Holder........... 10-10 Chain Adjusters, rear. . . . . . . . 5-35, 7-118 Alignment tool (laser type).. . . 10-74 Axle adjusters.. . . . . . . . . . . . 7-118 Oil....................... 10-19 Rear drive.. . . . . . . . . . . . 7-116/117 Rear guards, Big Twin.. . . 7-128/131 Tools.................... 10-74 Charts Engine specifications.. . . . 6-103/104 Equivalent chart.. . . . . . . . . . . 6-150 Rear belt length chart . . . . . . . 7-110 Chassis Stabilizer Link ....... 7-14 Chemicals Adhesive................. 10-22 Anti-seize (brush on). . . . . . . . 10-21 Bootpolish................ 10-26 Brakefluid................ 10-20 Cleaner.................. 10-20 Contact cleaner. . . . . . . . . . . . 10-20 Epoxyputty.. . . . . . . . . . . . . . 10-24 Fuel stabilizer.. . . . . . . . . . . . . 10-16 Fuel tank sealant & cleaner.. . 10-23 Gasket sealant.. . . . . . . . . . . . 10-22 Gel-lube.................. 10-19 Octane booster . . . . . . . . . . 10-16/17 Polish.................... 10-25 Silicone sealant. . . . . . . . . . . . 10-21 Choke Cable Assembly/Parts. . .8-91 Chrome Rail Matching Accessories Brake pedal pad. . . . . . . . . . . .4-117 Footrests.................. 2-58 Handlebar grips. . . . . . . . . . . . . 4-12 Shiftpeg.................. 4-120 Circuit Breaker Electronic Fuses .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . 1-60 Circuit Breaker Ignition Distributors................. 1-89 Mount..................... 1-89 Parts...................... 1-89 Clamps Brakehose.. . . . . . . . . . . . . .4-76/77 Cable...................4-76/78 Exhaust mufflers . . . . . . . . . . . . 9-24 Exhaust pipes.. . . . . . . . . . . . . 9-24 Frame...................... 2-6 Oil line separator. . . . . . . . . . . . 8-32
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-7 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE CLEARVIEW Replacement Windshields............ 2-75,3-42 Clutch Adjusting screws. . . . . . . . . . . . 7-46 Assemblies, Big Twin . . . . . . 7-42/45 Assemblies, Big Twin 10spring.. . . . . . . . . . . . . . .7-47/49 Assemblies, Big Twin diaphragm.. . . . . . . 7-42/57 Assemblies, Buell Blast.. . . . . . 7-59 Assemblies, Sportster. . . . . . 7-59/61 Assemblies, V-Rod . . . . . . . . . . 7-59 Cable mounting brackets.. . . . . 4-75 Cables..................4-41/74 Controlparts.. . . . . . . . . . . . . . 4-78 Hand lever assemblies . . . . . 4-79/91 Handlebar master cylinders.. 4-82/90 Hubs, Big Twin 10 spring. . . . . .7-47 Hubs, Big Twin diaphragm . . . . 7-50 Hydraulic housings Big Twin 5 speed .. . . . . . . . . . . . . . . . . . 7-14 Master Cylinder rebuild kits . . . . . . . .. . . . . . . . . . . . . . . . . . . 4-92, 4-115 Parts,45ci................. 7-65 Parts, Big Twin 10 spring. . . 7-47/49 Parts, Big Twin diaphragm . . 7-51/52 Parts, Sportster diaphragm. . 7-63/64 Plates, Big Twin 10 spring.. . 7-53/58 Plates, Big Twin diaphragm.. 7-50/58 Plates, Sportster . . . . . . . . . . 7-54/59 Pushrods, Big Twin. . . . . . . . . . 7-66 Releasearms.. . . . . . . . . . . . . . 4-75 Springs, Big Twin 10 spring.. . . 7-48 Springs, Big Twin diaphragm.. . 7-61 Tools, Big Twin 10 spring . . . . 10-72 Tools, Big Twin diaphragm . . . 10-72 Clutch (cont) Tools, Sportster. . . . . . . . . . . . 10-72 CLYMER Repair Manuals.. . . . 10-41 Coils Ignition..................1-82/87 Mounting brackets. . . . . . . . . . . 1-81 COLONY Belt Drive Pulley Nuts.7-85 COMETIC Air Filter gaskets . . . . . . . . . . . . 8-59 Base gaskets, Big Twin Evolution . . . . . . 6-128/129 Cam change gasket sets.. 6-131/132 Engine gasket sets, Big Twin Evolution . . . . . . 6-141/142 Engine gasket sets, Ironhead Sportster.. . . . . . 6-142/144 Engine gasket sets, Panhead. . . . . . . . . . . . . . . . . .6-140 Engine gasket sets, Shovelhead.. . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-140 Engine gasket sets, Twin Cam.6-142 Engine gasket sets, Sportster 1200cc . . . . . . . . . . .6-145. Engine gasket sets, Sportster 883cc .. . . . . . . . . . . . . . . . . . . . . . . . 6-144 Engine top end gasket sets.. . . . . . . .. . . . . . . . . . . . . . . . . . . . .6-133/139 Exhaust manifold gasket .. . 9-20/21 . Gaskets, transmission kits . . . . 7-18 Gaskets/seals sets, primary. . .7-107 Head gaskets.. . . . . . . . . . 6-128/130 Head/Base gasket sets. . . 6-128/130 Intake manifold seals.. . . . . . . . 8-92 Oil Pump gaskets. . . . . . . . . . .6-132 Primary cover gasket, Sportster . . . . . .. . . . . . . . . . . . . . . . . . . . .7-108-110
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-8 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL COMETIC (cont) Rocker box gasket sets, Big Twin Evolution.. . . . . . 6-124/126 Rocker box gasket sets, Sportster Evolution . . . . . . . . . 6-125 Big Twin Evolution.. . . . . . . . . 6-135 Top end gasket sets, Evolution Sportster . . . . . . 6-136/139 Top end gasket sets, Ironhead .. . . . . Sportster . . . . . . . . . . . . . . 6-136/137 Top end gasket sets, Panhead.6-132 Top end gasket sets, Shovelhead.. . .. . . . . . . . . . . . . . . . . . . . . . . . 6-140 Top end gasket sets, Twin Cam. . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-136 Topendgasketsets, .. . . . . . . . . . . . Milwaukee-Eight® .......... 6-136 Top end gasket sets,Sportster 883cc. .. . . . . . . . . . . . . . . . . . . . . . . . 6-139 Compression Release Decorative caps for valves . . . . 6-12 Valves.................... 6-12 COMPU-FIRE Charging systems . . . . . . . . . . 1-147 Ignition modules.. . . . . . . . . . . 1-101 Regulator/Rectifiers.. . . . . . . . 1-140 Connecting Rod, Assemblies .. . 6-99 Connectors & Electrical Terminals. . . .. . . . . . . . . . . . . . . . . . . . . .1-65/664 Contact Cleaner .. . . . . . . . . . . . 10-54 Control Handlebar control assemblies.. . . . . .. . . . . . . . . . . . . . . . . . . . . . .4-85/91 Counter Display, Tire Valve Stem Caps....................... 5-19 Countershafts Big Twin, 4 speed.. . . . . . . . . . 7-27 BigTwin,5speed.. . . . . . . . . . . 7-8 Sportster, 4 speed.. . . . . . . . . . 7-38 Crank Pins................. 6-102 Crankcase Assemblies, Big Twin. . . . . . . . . .6-7 Balloon diagram, Big Twin.. . 6-80/82 Balloon diagram, K Model & Sportster.................. 6-83 Balloon diagram, Twin Cam . . . 6-82 Breather................... 6-91 Covers for under cylinders.. . . . 6-12 Drain/Timing hole plugs.. . . . . 10-65 Main bearings, Big Twin . . . . . . 6-90 Main bearings, Sportster. . . . . . 6-96 Crash Bar Assemblies.. . . . . 2-77/80 CRUZTOOLS Multi-purpose.. . . . . . . . . . . . . 10-43 Roadside tool kits (roll up type).. . . . . .. . . . . . . . . . . . . . . . . . . . . .10-45/46 Spring puller hook tool.. . . . . . 10-40 Tire pressure gauges.. . . . . . . 10-52 Tirelever................. 10-55 Cup...................... 10-110 Cup Holder................ 10-110 CYCLE PERFORMANCE PRODUCTS GaugeMounts.. . . . . . . . . . . . . . 4-143 Cylinder Base & crankcase covers . . . . . 6-12 Base nuts & studs.. . . . . . . . . . 6-39 Engine by-pass pigtail kit.. . . . . 6-12 Stud removal tool.. . . . . . . . . . 10-56 Torque plate tool. . . . . . . . . . . 10-59
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-9 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE DAKOTA DIGITAL Electric calibrator.. . . . . . . . . . 4-151 Electronic antenna.. . . . . . . . . . 1-63 Mounting brackets. . . . . . . 4-144/148 Oil pressure gauge . . . . . . . . . 4-144 Oil pressure gauge sending unit. . . . .. . . . . . . . . . . . . . . . . . . . . . . . 4-144 Speedometers. . . . . . . . . . 4-144/148 Tachometer. . . . . . . . . . . . 4-144/148 Assemblies. . . . . . . . . . . . 4-144/148 DAYTONA TWIN TEC Coils & plug wires.. . . . . . . . . . 1-82 EFI controller.. . . . . . . . . . . . . . 8-79 Fuel injection kits.. . . . . . . . . . 1-104 Ignition module . . . . . . . . . . . . 1-100 USB interface.. . . . . . . . . . . . . 1-100 Debris Deflector .. . . . . . . . . . . . . . 2-7 Degreaser .. . . . . . . . . . . . . . . . . 10-20 Derby Covers .. . . . . . . . . . .7-102/103 DEUTSCH Electrical Wire Connectors .. . . . . . . . . . . . . . . . . 1-65 DIAMOND CHAIN Primary.................... 7-86 Reardrive................ 7-117 Diamond Rail Accessories Footrests.................. 2-58 Handlebar grips. . . . . . . . . . . . . 4-12 Shiftpeg.................. 4-120 Dice Style Valve Stem Caps .. . . 5-19 Directional Signal Assemblies. . . . . . . . . . . . . . 1-25/32 Flasher.................... 1-57 Lightbulbs................. 1-34 Load equalizer.. . . . . . . . . . . 1-25/26 Mounting bracket.. . . . . . 1-23, 1-30 Relocation kits. . . . . . . . . . . . . . 1-30 Disc Brake Brake rotors.. . . . . . . . . . . . . 5-57/61 Pads....................5-51/56 Displacement Chart, Engine. . .6-104 Distributor Assemblies. . . . . . . . . . . . . . 1-88/89 Parts. . . . . . . . . . . . . . . . . . . 1-90/91 DOC BAILEYS Leather Black.. . . . . . . . . . . . . 10-26 Leather Clear.. . . . . . . . . . . . . 10-26 Drag Bars................... 4-29 DUNLOP TIRES..............5-4/5 Dust Boots Front Fork........ 3-37 DYNATEK Coils, ignition. . . . . . . . . . . . . 1-82/83 Complete ignition systems.. . . . 1-99 Ignition modules.. . . . . . . . . . . . 1-99 DYNOJET Powervision........ 8-72 Eagle Spirit Accessories Air filter cover insert.. . . . . . . . . 8-97 Clutch covers.. . . . . . . . . . . . . 7-103 Front fender ornament.. . . . . . . 2-39 Handlebar riser clamps. . . . . . . 4-37 EASY Shift Kit.............. 4-124 EASYBOY Clutch Lever Kits.. . 7-12 Electric Battery cable boot. . . . . . . . . . . . 1-9 Builders kits (charging & starter).. . . . .. . . . . . . . . . . . . . . . . . . . . . . . 1-151 Cable ties, clamps & retainers.. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Cables for starter, battery & solenoid. .. . . . . . . . . . . . . . . . . . . . . . . . .1-7/8 Circuit breakers. . . . . . . . . . . . . 1-60 EFI System Relay.. . . . . . . . . . 1-58 Fuseholder................ 1-59
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-10 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL Electric (cont) Heat shrink tubing. . . . . . . . . . . 1-67 Starter motors . . . . . . . . . . 1-123/129 Starter relays. . . . . . . . . . . . . 1-58/59 Starter switches (custom) . . . 1-61/62 Switches for handlebar . . . . . 1-68/78 Switches for ignition.. . . . . . . 1-54/56 Switches for rear brake. . . . . . . 1-57 Terminalbox.. . . . . . . . . . . . . . 1-60 Terminals/Connectors. . . . . . . . 1-66 Turn signal flasher.. . . . . . . . . . 1-57 VOES..................... 1-56 Wire...................... 1-47 Wire harness kits.. . . . . . . . . 1-68/78 Wireloom.................. 1-67 Electronic Fuel Injection Fuel management system . . . 1-104 . Kits..................... 870/73 Parts. . . . . . . . . . . . . . . . . . . 8-74/78 Engine Cam case parts, 45ci.. . . . . . . . 6-84 Cam case parts, Big Twin. . . 6-65/78 Cam case parts, Sportster.. . . . 6-83 Cam case tools . . . . . . . . . . 10-66/67 Cam change gasket sets, BigTwin.................. 6-132 Milwaukee-Eight® Twin Cam.. 6-132 Camtools.. . . . . . . . . . . . . .10-66/71 Cams, Big Twin. . . . . . . . . . . 6-65/78 Cams, Sportster.. . . . . . . . . . . . 6-79 Compression release valves. . . 6-12 Connecting rod roller retainer set . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6-93 Connecting rods.. . . . . . . . . . . . 6-99 Cover for cylinder/crankcase.. . 6-12 Crankpins................ 6-102 Engine (cont) Crankcase assemblies, Big Twin.6-7 Crankcase bearings, Big Twin pinion.. . . . . . . . . . . . 6-91 Crankcase drain/timing hole plugs . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Crankcase nut, bolt & stud kits. 6-39 Crankcase parts, Big Twin.. . . . 6-90 Crankcase parts, Sportster. . . . 6-96 Crankcase tools.. . . . . . . . . 10-57/58 Cylinder base nuts . . . . . . . . . . 6-39 Cylinder by-pass pigtail kits.. . . 6-12 Cylinder torque plates. . . . . . . 10-59 Cylinders, Big Twin . . . . . . . . . 6-8/11 Flywheel parts, Big Twin. . . . . . 6-92 Flywheel parts, K Model Sportster.................. 6-95 Gasket Sets, Big Twin Evolution . . . . . . . . . 6-141 Gasket sets, Panhead.. . . . . . 6-140 Gasket sets, Shovelhead.. . . . 6-140 Gasket sets, Sportster . . . 6-142/144 . Gasket sets, Twin Cam . . . . . 6-142 Gear case drain plugs. . . . . . . . 6-97 Gear case parts, 45ci . . . . . . . . 6-84 Gear case parts, Big Twin.. . 6-80/82 Gear case parts, Sportster . . . . 6-83 Gear case tools. . . . . . . . . . 10-62/70 Head bolt covers.. . . . . . . . . . . 6-38 Head bolts & washers. . . . . . . . 6-38 Head holding tool.. . . . . . . . . . . 6-37 Lifter block mounting hardware. 6-64 Lower end parts, Big Twin.. . . . 6-90 Lower end parts, K Model/Sportster. . .. . . . . . . . . . . . . . . . . . . . . . . . . 6-96
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-11 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Engine (cont) Mount hardware.. . . . . . . 2-42, 2-44 Mounts..................2-42/46 Oil pump parts.. . . . . . . . . 6-105/106 Oils......................10-2/5 Pinionshaft.. . . . . . . . . . . . . . 6-100 Piston assemblies. . . . . . . . . 6-40/47 Piston pin lock rings.. . . . . . . . . 6-49 Piston rings.. . . . . . . . . . . . . 6-48/49 Piston tools . . . . . . . . . . . . . 10-58/59 Pushrod assemblies . . . . . . . 6-54/59 Pushrod covers. . . . . . . . . . . 6-50/53 Pushrod cover seals . . . . . . . 6-52/53 Rocker box gasket sets.. . 6-124/127 Rocker cover tool.. . . . . . . . . . 10-57 Rocker shaft seal.. . . . . . . . . . . 6-18 Sprocket shafts, Big Twin . . . . 6-101 Sprocket shafts, Sportster.. . . 6-101 Tappet assemblies.. . . . . . . . 6-61/62 Tappet block alignment tool.. . 10-64 Tappet block mounting hardware .. . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Tappetblocks.. . . . . . . . . . . . . 6-63 Timer cover screws. . . . . . . . . . 6-95 Timercovers.. . . . . . . . . . . . . . 6-95 Top end gasket sets, Sportster. . . . . . .. . . . . . . . . . . . . . . 6-137/139, 6-146 Top end gasket sets, Panhead .. . . . . . . . . . . . . . . . . . 6-140, 6-146 Top end gasket sets, Shovelhead . . . . . . . . . 6-140, 6-146 Top end gasket sets, Evolution Sportster.6-138/139, 6-146 Milwaukee-Eight® .. . . . . . . . . . 6-136 Top end gasket sets, Twin Cam.. . . . . . . . . . 6-136, 6-146 Engine (cont) Top end gaskets, Big Twin Evolution.. . . 6-135, 6-146 Top end, Big Twin Evolution .. . . . . . . .. . . . . . . . . . . . . . . . . (diagram) 6-16 Top end, Ironhead Sportster . . . . . . .. .. . . . . . . . . . . . . . . . . (diagram) 6-18 Top end, Knucklehead (balloon . . . . . diagram)................... 6-13 Top end, Panhead (diagram).. . 6-14 Top end, Shovelhead (diagram).6-15 Top end, Sportster Evolution . . . . . . . (diagram).................. 6-19 Top end, Twin Cam 88 (diagram). . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Valve guide seals. . . . . . . . . . . .6-36 Valve guides.. . . . . . . . . . . . 6-34/36 Valveseats................ 6-30 Valve springs.. . . . . . . . . . . . 6-26/29 Valvetools................. 6-37 Valves..................6-31/37 Wrist pin bushing tools . . . . . . 10-60 Wrist pin bushings.. . . . . 6-93, 6-99 Epoxy Putty................ 10-24 Equivalent Chart............ 6-150 EVOLUTION INDUSTRIES Clutch kits.. . . . . . . . . . . . . . 7-44/45 Clutchshell................ 7-51 Exhaust Anti-reversion power cones.. . . 9-22 Baffles.................... 9-18 Clamps & Mounts . . . . . . . . . 9-23/25 Dragpipes.................9-7/8 Dresser mufflers . . . . 9-2/4, 9-12/16 Exhaustwrap.. . . . . . . . . . . . . . 9-31 Fishtail extensions.. . . . . . . . . . 9-17
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-12 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL Exhaust (cont) Flat straps.. . . . . . . . . . . . . . 9-23/24 Footboard mounting bracket. . . 9-25 Heat shield (louver). . . . . . . . 9-28/30 Heat shields.. . . . . . . . . . . . . 9-28/30 Heatwrap................. 9-31 Make your own (exhaust pipes).9-26 Manifold clamps.. . . . 9-20, 9-23/24 Mounting parts, all models.. . 9-23/25 Mufflers . . . . . . . . . . . 9-2/4, 9-12/19 O2 sensor eliminator. . . . . . . . . 9-22 O2 sensor socket tool. . . . . . . 10-83 PipePolish.................. 9-7 Systems, FLT Evo.. . . . . . . . 9-10/11 Systems, Ironhead Sportster.. . . 9-8 Systems, Panhead.. . . . . . . . . . . 9-7 Systems, Shovelhead early.. . . 9-8/9 Systems, Shovelhead late.. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .9-8/9 Systems, Softail.. . . . . . . . . . . . 9-8/9 Systems, Sportster Evolution. . . .9-8 . Systems, Softail/FX Evolution. . 9-8/9 . Tips...................... 9-12 Torquecones.. . . . . . . . . . . . . . 9-22 Weldtofitpipes.. . . . . . . . . . . . 9-26 Wrap..................... 9-31 Face Masks.............10-95/100 Fairing Wind deflector.. . . . . . . . . . . . . 2-15 Fender Assemblies, front.. . . . . . . . . 2-32/37 Assemblies, rear . . . . . . . . . . 2-25/31 Bibs...................... 2-41 Bracket, front (custom) . . . . . . . . 3-8 Brackets.................... 3-8 Ornaments................. 2-39 Fender (cont) Removable mounts for springers.3-8 . Saddlebag filler panels . . . . . . . 2-28 Support hardware . . . . . . . . . . . 2-23 Supports, rear.. . . . . . . . . . . . . 2-22 Tips....................2-40/41 Filters Air....................8-101/108 Fuel....................8-11/12 Oil......................8-48/52 Fishtail Extensions........... 9-17 Exhaust heat shields. . . . . . . . . 9-28 Flasher, Turn Signal.......... 1-57 Flat Straps, Exhaust Mount.. . . 9-23 Float Bowl Screws. . . . . . .8-64, 8-69 Floorboard Assemblies. . . . . . . . . . . . . . 2-63/68 Mounts.................... 2-64 Flywheel Parts, Big Twin. . . . . . . . . . . . . .6-92 Parts, K Model & Sportster. . . . 6-98 Foot Shift Levers................... 4-119 Pegs..................4-120/121 Footboard Assemblies. . . . . . . . . . . . . . 2-63/68 Mounts.................... 2-64 Footrest Assemblies. . . . . . . . . . . . . . 2-54/60 Highway style.. . . . . . . . . . . . 2-59/60 Mounting brackets. . . . . . . . . 2-61/62 Spring washer.. . . . . . . . . . . . . 2-57 Forceflow Head Cooler......... 6-9 Fork Front...................3-21/22 Front assembly, Springers.. . . . 3-2/7
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-13 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Fork (cont) Tools..................10-47/50 Tubes...................3-29/30 Forward Control Assemblies (custom).. . . . 4-125/131 OE style brake parts . . . . . 4-111/115 OE style shift parts . . . . . . 4-117/120 Frame Assemblies, Rigid style. . . . . . . . 2-4 Assemblies, Softail style . . . . . . . 2-2 Assemblies, Swingarm style. . . . 2-3 Clamps..................... 2-6 Covers..................... 2-6 Parts. . . . . . . . . . . . . . . . . . . . . . .2-5 Seat post/coil mount . . . . . . . . . . 2-5 Front Fork Acorn stem nut. . . . . . . . . . . 3-11/12 Assemblies. . . . . . . . . . . . . . 3-21/25 Axlecap................... 5-31 Bootcovers................ 3-37 Bottom cap hardware. . . . . . . . .3-28 Brackets................... 3-26 Covers..................3-37/39 Damper spring.. . . . . . . . . . . 3-31/34 Dampertubes.. . . . . . . . . . . . . 3-31 Drainscrew................ 3-27 Head cup bearing . . . . . . . . . 3-12/13 Headcups.. . . . . . . . . . . . . .3-14/15 Headlight housing/nacelle. . . 3-40/41 Internal parts kit.. . . . . . . . . . . . 3-31 Lock cover (for Road King). . . . 3-16 Lower dust shield.. . . . . . . . . . . 3-12 Lowering kits. . . . . . . . . . . . . 3-32/34 Oil........................ 3-31 Pinch bolts.. . . . . . . . . . . . . . 3-11/12 Seal & bushing kit. . . . . . . . . 3-35/36 Front Fork (cont) Seal retaining ring.. . . . . . . . . . 3-28 Seals..................... 3-35 Slider seal washer.. . . . . . . . . . 3-28 Slider tube assemblies. . . . . . . .3-30 Slider tubes.. . . . . . . . . . . . . 3-29/30 Spacers for fender mount . . . . . 3-27 Springer assemblies . . . . . . . . . 3-2/7 Springs..................3-32/34 Stembolt.. . . . . . . . . . . . . . .3-11/13 Stem bolt cap.. . . . . . . . . . . . 3-12/13 Stemnut.. . . . . . . . . . . . . . .3-12/13 Stemnut&lock.. . . . . . . . . . . . 3-12 Tools..................10-47/50 Tubes...................3-29/30 Tube plug.. . . . . . . . . . . . 3-12, 3-16 Upper bracket bolt.. . . . . . . . . . 3-12 Upper dust shield.. . . . . . . . . . . 3-12 Fuel Cap Assemblies.. . . . . . . . . . . . 8-2/5 Catalyst, FITCH............. 8-10 Filter Assemblies. . . . . . . . . . 8-11/12 Injection Parts . . . . . . . . . . . . 8-74/78 Line Bulk, all types.. . . . . . . . 8-30/37 Line Clamp tools.. . . . . . . . . . . 8-32 Line Clamps.. . . . . . . . . . . . . 8-31/37 LineCover................. 8-16 Line Crossover, Fat Bob. . . . . . 8-13 Line Fittings. . . . . . . . . . . . . . 8-31/37 Line Kits (with end clamps). . . . 8-13 Management system for EFI.. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .8-71/84 Pressure regulator, fuel injection.. . . . .. . . . . . . . . . . . . . . . . . . . . . .8-76/77 Tank Assemblies. . . . . . . . . . 8-17/28 Tank Mounting parts . . . . . . . 8-14/15
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-14 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL Funnel Oil Filter .. . . . . . . . 8-52, 10-5 Fuse Holder................. 1-59 GARDNER WESTCOTT Engine timing hole & drain plug.. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Fender support hardware (rear) . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Oil pump plug kits . . . . . . . . . . 6-112 Rocker arm cover screws (Evolution). .. . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Sprocket/pulley hardware . . . . 7-122 Gas Cap Assemblies.. . . . . . . . . . . . 8-2/5 CapCovers................. 8-2 Catalyst, FITCH............. 8-10 Line Bulk, all types.. . . . . . . . . . 8-30 Line Clamp tools.. . . . . . . . . . . 8-32 Line Clamps.. . . . . . . . . . . . . 8-31/32 Line Crossover, Fat Bob. . . . . . 8-13 Line Fittings (with end clamps). 8-13 LineKits................... 8-13 Tank Assemblies. . . . . . . . . . 8-17/28 Tank Center Panels.. . . . . . . . 4-132 Tank Mounting parts . . . . . . . 8-14/16 Valve Assemblies . . . . . . . . . . 8-6/10 GASGACINCH, Gasket Sealant.10-22 Gasket Base, Big Twin Evolution.. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .6-128/129. Cam change kit, Big Twin. . . . 6-132 Cam case cover, Big Twin.. . . 6-133 Cam case cover, Sportster . . . . 6-83 Cylinder head.. . . . . . . . . . . . . 6-129 Engine sets, Big Twin Evolution . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-141 Gasket (cont) Engine sets, Ironhead Sportster .. . . . .. . . . . . . . . . . . . . . . . . . . .6-143/144 Engine sets, Panhead. . . . . . . 6-140 Engine sets, Shovelhead .. . . 6-140. Engine sets, Sportster 1200cc.6-145 Engine sets, Sportster 883 .. . 6-144 . Engine sets, Twin Cam. . . . . . 6-142 Exhaust port.. . . . . . . . . . . . . 9-20/21 Gear case cover, Big Twin . . 6-81/82 Gear case cover, Sportster. . . . 6-83 Lifter block, Big Twin. . . . . . . . 6-133 Lifter cover, Twin Cam.. . . . . . 6-122 Master cylinder, front.. . . . . . . . 4-93 Master cylinder, rear . . . . . . . . 4-117 Oil pump, Big Twin . . . . . . . . . 6-132 Primary covers, Big Twin.. 7-107/108 Primary covers, Sportster . . . . 7-106 Rocker arm, Big Twin Evolution . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-126 Rocker arm, Sportster Evolution. . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-125 Rocker box sets, Big Twin Evolution.. .. . . . . . . . . . . . . . . . . . . . .6-124/126 Rocker box sets, Sportster Evolution.. .. . . . . . . . . . . . . . . . . . . . .6-125/126 Shifter, Big Twin 4 Speed. . . . . 7-31 Timercover................ 6-95 Top end sets, Ironhead Sportster. . . .. . . . . . . . . . . . . . . . . . . . .6-136/138 Milwaukee-Eight® .. . . . . . . . . . 6-136 Sportster . . . . . . . . . . . . . . 6-136/138 Top end sets, Panhead . . . . . 6-134 Top end sets, Shovelhead.. . . 6-134 Top end sets, Twin Cam . . . . 6-136 Top end, Big Twin Evo . . . . . . 6-135
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-15 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Gasket (cont).................... Transmission kits, Big Twin 4&5speed .. . . . . . . . . . . .7-18/21 GATES, Rear Drive Belts. . 7-123/126 Gauge Mounts (custom).. . 4-142/143 Gauges Oil pressure, AUTOMETER .. . . 8-60 Speedo, AUTOMETER...... 4-140 Tachometer, AUTOMETER .. . 4-139 Gear Case Balloon diagram, Big Twin 1936/1969. .. . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Balloon diagram, Big Twin Evolution.. .. . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Balloon diagram, K Model & Sportster. .. . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Balloon diagram, Shovelhead .. . . . . . 1970/1984................. 6-81 Balloon diagram, Twin Cam . . . 6-82 Cover screw kits.. . . . . . . . . . . 6-84 Covers, Big Twin. . . . . . . . . . . . 6-88 Tools..................10-62/70 Gears Breather valve, Big Twin. . . . . . 6-85 Oil pump drive, Big Twin. . . . . . 6-87 Pinion, Big Twin.. . . . . . . . . . . . 6-87 Transmission, Big Twin 4 speed. . . . . .. . . . . . . . . . . . . . . . . . . . . . .7-24/28 Transmission, Big Twin 5 speed. . . . . .. . . . . . . . . . . . . . . . . . . . . . . .7-7/10 Sportster 4 speed . . . . . . . . . 7-37/39 Sportster 5 speed . . . . . . . . . . . 7-36 Generator Assemblies. . . . . . . . . . . . . . . .1-137 Parts. . . . . . . . . . . . . . . . . 1-136/138 Gloves. . . . . . . . . . . . . . . . . . . .10-107 Goggles.................10-87/89 GOLAN PRODUCTS INC. FuelValves................. 8-8 GOODRIDGE Banjo bolts with brake switch. 4-105 Brake hose (cut to length).. 4-99/102 Brake hose (universal length). . . . . . .. . . . . . . . . . . . . . . . . . . . .4-103/105 Brake hose (OE fitment) . . 4-107/110 Custom rear brake tee.. . . . . . . 4-98 EFIlines................... 8-30 Engine oil line kits. . . . . . . . . 8-35/37 Hoseends................. 8-36 Oil & fuel line (bulk lengths).. 8-34/36 Top end feed lines.. . . . . . . . . . 8-38 Grease Fittings.............. 2-17 Grease.................... 10-21 Hand Shift Knob............ 4-124 Handlebar Assemblies. . . . . . . . . . . . . . 4-21/32 Cell phone mount. . . . . . . . . . .10-10 Clampcovers.. . . . . . . . . . . . . . 4-37 Clamp hardware . . . . . . . . . . 4-38/39 Control assemblies . . . . . . . . 4-85/91 Grips...................4-11/17 Lever...................4-79/83 Riser bushings.. . . . . . . . 4-37, 4-39 Riser hardware . . . . . . . . . . . 4-38/39 Riser lower clamps . . . . . . . . 4-33/36 Riser solid mount adapters. . . . 4-39 Riser upper clamps. . . . . . . . . . 4-37 Risers, custom style.. . . . . . . 4-33/38 Switches. . . . . . . . . . . . . . . . 1-68/78 HARDBODY Brand Brake caliper assemblies.. . . 5-40/41
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-16 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL HARDBODY Brand (cont) Debris deflector. . . . . . . . . . . . . . 2-7 Front fork assemblies . . . . . . 3-21/25 Front fork bracket kits . . . . . . 3-17/20 Oil filter mount.. . . . . . . . . . . . . 8-53 Oil tank assemblies, Big Twin .. . . . . . . . . . . . . . . . . . . . . . . 8-44/47 Oil tank filler/temp cap.. . . . . . . 8-41 Oil tank mounts.. . . . . . . . . . . . 8-43 Pulley/sprocket spacers.. . . . . 7-126 HARDWARE Brand Brake line fittings.. . . . . 4-97, 4-104 Engine pushrods. . . . . . . . . . 6-54/59 Engine valve seats. . . . . . . . . . .6-30 HASTINGS Piston Rings .. . . .6-48/49 HAYDEN Primary Chain Tensioner................... 7-90 Head Cups................3-12/15 Head Boltcovers................. 6-38 Bolts & washers.. . . . . . . . . . . . 6-38 Gaskets.. . . . . . . . . . . . . . 6-128/130 Headbands................ 10-102 Headlight Assemblies. . . . . . . . . . . . . . 1-12/18 Bulbs...................1-17/19 Housing................... 1-17 Housing/nacelle.. . . . . . . . . . 3-40/41 Lensgrills.................. 1-16 Mounting brackets. . . . . . . . . . . 1-20 Sealbeams................ 1-17 Wire connector.. . . . . . . . . . . . . 1-20 Heat Deflectors for Touring Models. . .. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Heat Shields, Exhaust (all models). . . .. . . . . . . . . . . . . . . . . . . . . . . . . 9-28 Heat Shrink Tubing........... 1-67 Heat Wrap for Exhaust........ 9-31 Head Wraps............... 10-101 Heim Joints, Brake/Shift Rod End .. . . .. . . . . . . . . . . . . . . . . . . . .4-122/123 Helmet Liner .. . . . . . . . . . . . . . . 10-96 Helmet, Snap Straps......... 10-15 Helmet Visors.............. 10-14 HIFLOFILTRO Oil Filters .. . . . . . 8-50 Highway Bars .. . . . . . . . . . . . .2-77/80 Horn Assemblies. . . . . . . . . . . . . . . .1-152 Covers................... 1-152 Hoses Brake, custom braided.. . . . 4-99/106 Brake, custom nylon . . . . . . . . . 4-99 Brake, OE fit braided.. . . . 4-106/110 Hub Assemblies. . . . . . . . . . . . . . 5-20/21 Wheel hub parts. . . . . . . . . . 5-20/21 Hydraulic Clutch Housings. . 7-13/14 Ignition Coil Covers..................1-79/81 Ignition coils.. . . . . . . . . . . . . 1-80/87 Mounting brackets. . . . . . . . . . . 1-81 Ignition Advance unit parts.. . . . . . . . . . 1-93 Advance units . . . . . . . . . . . . 1-92/93 Anti-drop relay. . . . . . . . . . . . . . 1-59 Circuit breaker parts . . . . . . . 1-89/93 Circuit breakers. . . . . . . . . . . . . 1-60 Coilcovers................. 1-79 Coils....................1-80/87 Complete systems.. . . . . . . 1-96/100 Distributor parts. . . . . . . . . . . 1-89/93 . Distributors.. . . . . . . . . . . . . . 1-88/89
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-17 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Ignition (cont) Magneto parts.. . . . . . . . . . . . . 1-89 Modules.. . . . . . . . . . . . . . .1-94/101 Spark plugs. . . . . . . . . . . . 1-111/113 Switches. . . . . . . . . . . . . . . . 1-54/56 Timer cover screws. . . . . . . . . 1-110 Timer covers . . . . . . . . . . . 1-109/110 Tuneupkits................ 1-90 VOES..................... 1-56 Inline Spark Tester.......... 10-42 Inner Primary Covers......... 7-98 Inspection Covers........... 7-102 Instrument Panel Assemblies. . 4-136 Lightbulbs................. 1-33 Parts. . . . . . . . . . . . . . . . . 4-132/135 Intake Air temp sensor EFI.. . . . . . . . . 8-75 Manifold adapters . . . . . . . . . . . 8-92 Manifold engine breather kits . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .8-94/96 Manifold parts.. . . . . . . . . . . . . 8-92 Jiffy Stand Assemblies. . . . . . . . . . . . . . 2-50/53 Parts. . . . . . . . . . . . . . . . . . . 2-47/50 JIMS Balancer shaft removal tool.. . 10-63 Bearing race tool. . . . . . . . . . . 10-62 Breather valves & gears . . . . . . 6-85 Cam case tools . . . . . . . . . 10-66/67 . Clutch tools . . . . . . . . . . . . . 10-72/73 Connecting rod races. . . . . . . . .6-93 Crank pins, Big Twin. . . . . . . . 6-102 Crank pins, Sportster.. . . . . . . 6-102 Crankcase tools.. . . . . . . . . 10-62/65 Cylinder torque plates. . . . . 10-59/61 Engine piston tools . . . . . . . . . 10-59 JIMS (cont) Engine tools.. . . . . . . . . . . . 10-58/71 Exhaust tools.. . . . . . . . . . . . . 10-58 Force flow head cooler . . . . . . . . 6-9 Front fork tools.. . . . . . . . . . 10-48/51 Gear case tools. . . . . . . . . . 10-62/64 Head cup & race installer tool. 10-50 Kickstart parts.. . . . . . . . . . . . . 7-35 Oil pump assemblies.. . . . . . . 6-110 Oilpumpgears.. . . . . . . . . . . . 6-87 Oil pump parts.. . . . . . . . . 6-105/106 Oil pump tools. . . . . . . . . . . 10-65/66 O2 sensor socket tool. . . . . . . 10-83 Pinion shafts, Sportster &BigTwin................ 6-100 Primary drive tools.. . . . . . . 10-77/78 Rear fork bushing tools. . . . . . 10-47 Roller tip rocker arm . . . . . . . . . 6-24 Shifter shaft bushing, Sportster. 7-40 Speedometer sensor block off plate. . .. . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Sprocket shafts, Big Twin . . . . 6-101 Tappet assemblies.. . . . . . . . . . 6-60 Tappet block alignment tool.. . 10-64 Tappetblocks.. . . . . . . . . . . . . 6-62 Transmission pulley nuts.. . . . 7-120 Transmission rebuild kits.. . . . 7-9/10 Transmission sprocket/pulley wrench. .. . . . . . . . . . . . . . . . . . . . . . . . 10-78 Transmission tools.. . . . . . . 10-75/80 Valve spring compressor tool. 10-59 Wrist pin bushings.. . . . . . . . . . 6-93 KEIHIN Carburetor Parts. . . . . . .8-86 KEITH BLACK Piston pin lock rings.. . . . . . . . . 6-43 Pistons, Big Twin.. . . . . . . . . 6-42/43
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-18 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL KEITH BLACK (cont) Pistons, Sportster . . . . . . . . . . . 6-47 KENDA Tires................. 5-8 Key Fobs................. 10-113 KHROME WERKS Sissybars................. 2-80 Kickstand Assemblies. . . . . . . . . . . . . . 2-50/53 Extensions................. 2-49 Parts. . . . . . . . . . . . . . . . . . . 2-47/49 Kickstart Conversion kits.. . . . . . . . . . . . 7-32 Endcovers................. 7-33 Gaskets, Big Twin. . . . . . . . . . . 7-35 Parts, Big Twin. . . . . . . . . . . 7-34/35 Parts, Sportster. . . . . . . . . . . . . 7-41 Pedals.................... 7-34 KREEM PRODUCTS Fuel tank sealant/cleaner. . . . .10-23 Krommets Gascapcovers.. . . . . . . . . . . . . 8-2 LE PERA Pillion pads . . . . . . . . . 2-85, 2-95/96 Seats, Big Twin 4 speed. . . . 2-96/97 Seats, Dresser or Bagger.2-105/110 Seats, FXR models. . . . . . . . . . 2-94 Seats, Rigid frame.. . . . . . . . . . 2-96 Seats, Softail models.. . . . . . . . . . . . .. . . . . . . . . . 2-95, 2-101, 2-104/106 Seats, solo style. . . . . . . . . . 2-87/91 Seats, Sportster.. . . . . . . . 2-107/108 Leather Chaps............. 10-106 Leather Gloves............ 10-107 LED Light assemblies . . . . . . . . . . 1-13/16 LED (cont) Mirrors...................4-2/10 Taillight assemblies. . . . . . . 1-337/46 Lever Assemblies, clutch & brake.. 4-79/83 Footshift................. 4-119 Handlebar lever parts . . . . . . . . 4-84 Shiftcovers.. . . . . . . . . . . . . . 4-118 License Backing plates. . . . . . . . . . . . 1-49/51 Frames..................1-48/52 Mount hardware.. . . . . . . . . . . . 1-53 Mounting brackets. . . . . . . . . 1-45/52 Taillight/License.. . . . . . . . . . 1-45/55 Lifter Assemblies. . . . . . . . . . . . . . 6-61/62 Block mounting hardware . . . . . 6-64 Blocks.................... 6-63 Lights Directional signal parts . . . . . 1-23/36 Headlight assemblies.. . . . . . 1-12/18 Headlight bulbs . . . . . . . . . . . 1-18/19 Headlight lens kits. . . . . . . . . . . 1-18 Headlight mounting brackets.1-20/21 Indicator bulbs. . . . . . . . . . . . . . 1-33 Marker & running assemblies.1-24/32 Marker light bulbs . . . . . . . . . . . 1-33 Marker light mount brackets . . . 1-35 Mounting brackets. . . . . . . . . 120/21 Spotlight assemblies. . . . . . . . . 1-22 Spotlight bulbs.. . . . . . . . . . . 1-22/23 Taillight assemblies. . . . . . . . 1-37/46 Taillight bulbs.. . . . . . . . . . . . 1-33/34 Taillight parts.. . . . . . . . . . . . . . 1-45 Turn signal bulbs.. . . . . . . . . . . 1-33 Turn signal parts . . . . . 1-30, 1-35/36
1 2 3 4 5 6 7 8 9 10 11 TABLE OF CONTENTS Table Of Contents i-19 CONTENTS ELECTRICAL FRAME FRONT END CONTROL WHEEL ENGINE DRIVE TRAIN FUEL EXHAUST GENERAL REFERENCE Lights (cont) .. . . . . . . . . . . . . . . . . . . . Turn/Directional assemblies. 1-24/32. Locks Front fork lock cover . . . . . . . . . 3-16 Lower End Parts, Big Twin. . . . . . . . . . . 6-86/99 Parts, K Model & Sportster. . . . 6-96 Lowering Kits Front forks.. . . . . . . . . . . . . . 3-32/34 Rear...................... 2-21 LUCAS OIL Assemblyoil.. . . . . . . . . . . . . . 10-19 Chainoil.................. 10-19 Detailer. . . . . . . . . . . . . . . . . . .10-25 Engine oil.. . . . . . . . . . . 10-2/3, 10-5 Forkoil................... 10-20 Fuel stabilizer.. . . . . . . . . . . . . 10-16 Fuel treatment. . . . . . . . . . . . . 10-16 Grease................... 10-21 Octane booster . . . . . . . . . . . . 10-16 Oil stabilizer.. . . . . . . . . . . . . . 10-18 Tireshine................. 10-25 Transmission oil.. . . . . . . . . . . . 10-3 Lubricants Anti-seize................. 10-21 Assemblyoil.. . . . . . . . . . . . . . 10-19 Cable.................... 10-20 Chainoil.................. 10-19 Detailer. . . . . . . . . . . . . . . . . . .10-25 Engineoil.. . . . . . . . . . . . . . . .10-2/5 Frontforkoil.. . . . . . . . . . . . . . 10-20 Gel-lube.................. 10-19 Primary case oil.. . . . . . . . . . . 10-18 Lubricants (cont) Transmission & primary oil . . . . . . . . .. . . . . . . . . . . . . . . . . . . 10-2/3, 10-7 Transmission oil.. . . . . . . . . . . 10-18 Luggage Racks.............. 2-70 Mainshafts Big Twin, 4 speed.. . . . . . . . . . 7-26 BigTwin,5speed.. . . . . . . . . . . 7-7 Sportster, 4 speed.. . . . . . . . . . 7-38 Sportster, 5 speed.. . . . . . . . . . 7-36 MALLORY Distributor/circuit breaker kit . . . 1-87 Electronic advanced ignition. . . 1-87 E-Spark ignition. . . . . . . . . . . . . 1-87 Maltese Cross Ignition timer cover . . . . . . . . . 1-109 Marker/running lights.. . . . . . . . 1-37 Mirrors..................... 4-9 Taillights................... 1-41 MANLEY Bee Hive Valve Spring Set . . . . 6-28 Enginevalves.. . . . . . . . . . . . . 6-33 Valve spring collars. . . . . . . . . . 6-30 Valve springs.. . . . . . . . . . . . 6-26/28 Manifold Exhaust clamps. . . . . . . . . . . 9-23/24 Intake adapters, Mikuni. . . . . . . 8-69 Intake adapters, spigot type . . . 8-92 Intake engine breather kit .. . 8-94/95 Intake parts.. . . . . . . . . . . . . 8-92/94 Manuals CLYMER Repair .. . . 10-41 Marker Light Assemblies. . . . . . . . . 1-33, 1-36/37 Bulbs..................... 1-34 Mounting brackets. . . . . . . . . 1-31/32
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