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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 coils. . . . . . . . . 1-85/87 Spark plug wires.. . . . . . . 1-114 Acorn Head, Nuts. . . . 10-34/35 Advance Unit for Ignition ................... 1-93/94 Air Deflectors for Touring Models........... 2-6 Air Filter Air cleaner screws. . . . 8-93/94 Assemblies.. . . . . . . . 8-95/102 Cover mount screws . . 8-92/94 Elements . . . . . . . . . 8-103/104 Max Flow Intake kits.. . . . 8-102 Mounts and adapters.. 8-92/94 Supports (Brackets). . . . . . 8-92 Alignment Tool Wheel...............10-54 ALL BALLS Battery Cable lug/terminals ....................... 1-9 Battery cables.. . . . . . . . . . . 1-9 Starter motors.. . . 1-123, 1-126 Allen Head Bolts & screws. . . . . . . . . 10-37 Powertrain kit. . . . . . . . . . 10-33 Alternator Charging systems.. . 1-145/147 Mounting hardware.. . . . . 1-147 Stator plug retainer.. . . . . 1-148 Stators............... 1-142 ALTO PRODUCTS Clutch plate assemblies .7-53/54 Clutch steel drive plates BigTwin...............7-54 Clutch steel drive plates Sportster.. . . . . . . . . . . 7-59/60 Clutch spring plate. . . . . . . 7-61 ANCRA Tie Down Straps.. . . . . . . 10-14 ANDREWS Cams, Big Twin Evo.. . . . . 6-72 ANDREWS (cont) Cams, Big Twin Pre-Evo. . 6-70 Cams, Milwaukee-Eight® ...................6-76,80 Cams, Sportster.. . . . . . . . 6-85 Cams, Twin Cam. . . . . 6-78/79 Engine pushrods . . . . . 6-59/64 Shifter forks, Big Twin. 7-30/31 Transmission gear sets ..................7-28,7-39 Transmission parts .............. 7-8/9,7-26/28 Transmission pulleys. . . . 7-119 Valve collars.. . . . . . . . . . . 6-32 Valve springs. . . . . . . . 6-31/32 Anti-Seize Lubricant.. . . . 10-21 Ape Hanger Bars.. . . . . 4-21/33 Assortment Kits Allen screw plugs.. . . . . . 10-38 Battery cable builders kit . . . 1-9 Electrical terminals.. . . 1-67/68 Heat shrink tubing . . . . . . . 1-69 Nuts, bolts & washers . . . 10-39 Orings...............10-39 Automatic Primary Chain Tensioners.............. 7-90 AUTOMETER Oil pressure gauge.. . . . . . 8-58 Speedometer. . . . . . . . . . 4-140 Tachometer . . . . . . . . . . . 4-139 AVON Handlebar grips . . . . . . 4-13/15 AVON, Tires............ 5-6/7 Axle Axle/Chain adjusters . . . . . 5-41 Front.................. 5-34 Nut covers . . . . . . . . . . 5-37/38 Nuts............... 5-36/38 Rear............... 5-32/33 Spacers.. . . . . . . . . . . 5-39/40 BADLANDS Turn signal load equalizer .1-28
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 Baffles, Exhaust .. . . . . 9-18/19 Ball Milled Accessories Cable clamps. . . . . . . . . . . 4-77 Saddlebag latch covers. . . 2-72 Banjo Bolt, Crush Washers ...................... 4-95 Bandannas ........... 10-101 Banners .. . . . . . . . . . . . . 10-115 Barometric Pressure Sensor EFI.............. 8-73 Base Gasket Sets .. . 6-134/135 Battery Cableboot.. . . . . . . . . . . . 1-15 Cable crimping tool . . . . . 10-42 Carrier tray kit & parts . . . . 1-10 Chargers.............. 1-4/7 Covers................ 1-10 Cushions..............1-15 Electric cables . . . . . . 1-9, 1-14 Hold down straps. . . . . . . . 1-16 Jumper cables.. . . . . . . . . . 1-8 Maintenance free type. . . 1-2/3 Tray.................. 1-10 Baseball Caps.........10-113 Bee Hive Valve Springs.6-26/31 Belt Drive Alignment tool.. . . . . . . . . 10-74 Assemblies.. . . . . . . . . 7-68/74 Covers for alternator . . . . . 7-82 Engine pulley nut lock . . . . 7-83 Lower debris guards. 7-128/130 Parts............... 7-78/85 Primary drive belts. . . . . . . 7-67 Rear belt guards.. . . 7-128/130 Rear drive belts . . . . 7-123/126 Rear pulleys.. . . . . . . . . . 7-121 Starter ring gears. . . . . . . . 7-79 Wide tire pulley kits.7-80, 7-127 BELT DRIVES LTD Belt drive assemblies.. 7-68/74 Belt drive parts.. . . . . . 7-78/85 BELT DRIVES LTD (cont) Clutch assemblies (conversion) ................... 7-42/45 Idler bearing. . . . . . . . . . . . 7-84 Primary chain kits (with clutch) ...................... 7-91 Primary drive belts (replacement) ...................... 7-67 Transmission pulley kits . . . . . . ................. 7-119/120 Belt Rear belt length chart.. . . 7-124 Replacement front belts.. . 7-67 Replacement rear belts ................. 7-123/126 Tension gauge tool.. . . . . 10-73 Bendix Air filter assemblies . . . . . . 8-95 Carburetor rebuild kit. . . . . 8-87 Carburetor accelerator pump ...................... 8-85 Choke cables. . . . . . . . 8-88/89 Throttle cable bracket.. . . . 8-87 Big Bore Pistons Panhead & Shovelhead .pistons ...................... 6-52 Sportster 883 to 1200cc pistons. ...............6-47,6-50/51 Twin Cam 95ci pistons ................... 6-42/45 Bin Boxes .. . . . . . . . . . . . . 10-33 Blue Streak Coils.................. 1-86 Spark plug wires.. . . . . . . 1-115 BLUE-JOB, Metal Polish .. 10-25 Bobber Frame............ 2-4 Bobster Eyewear.. . . . 10-87/94 Bolts 12point...............10-35 Allenhead.. . . . . . . . . . . 10-37 Button head allens. . . . . . 10-36 Flathead allens.. . . . . . . . 10-36
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 Bolts (cont) Hexhead.............10-36 Powertrain kits. . . . . . . . . 10-33 Books Mid-USA catalog . . . . . . 10-116 Repair manuals . . . . . . . . 10-41 Brake Anchor arm mount hardware. . . ...................... 5-43 Anchor/Pivot kit (Sportster rear drum)................. 5-42 Banjo bolts. . . . . . . . . 4-95/105 Bleed screw repair kit.. . . . 5-44 Bleed screws.. . . . . . . . . . 5-44 Cables (rear) .. . . . . . . . . . 4-75 Caliper anchor arm (rear) ...................... 5-43 Caliper assemblies.. . . 5-46/54 Caliper bolt/washer & bracket (for Banana brake).. . . . . . 5-43 Caliper mount eliminator cover plate (for custom front fork) ...................... 3-26 Caliper mounting bracket (for custom forks).. . . . . . . 3-26 Caliper mounting brackets ...................... 5-47 Caliper mounting hardware ................. 5-45,5-51 Caliper pistons. . . . . . . . . . 5-48 Caliper rebuild kits (OE type) ...................... 5-44 Caliper seals.. . . . . . . . . . . 5-44 Caliper screen inserts . . . . 5-55 Caliper stabilizers.. . . . . . . 5-48 Clevis & pin for brake rod ..................... 4-111 Control parts mechanical, BigTwin..............4-111 Cylinders (wheel). . . . . . . . 5-42 Disc brake parts.. . . . . 5-44/45 Disc mounting kits . . . . . . . 5-68 Brake (cont) Disc (rotor). . . . . . . . . . 5-63/67 Drum mounting bolts . . . . . 5-42 Fluid.. . . . . . . . . . . 5-44, 10-20 Foot lever mount bracket ..................... 4-112 Foot lever pad . . . . . . . . . 4-117 Hand lever . . . . . . . . . . 4-79/83 Hose clamps.. . . . . . . . . . . 4-77 Hoses, custom braided ................. 4-100/106 Hoses, custom nylon. . . . . 4-99 Hoses, OE fit braided ................. 4-106/110 Light switches.. . . . . . . . . . 1-59 Line fitting thread tape. . . 10-24 Line fittings.. . . . . . . . 4-99/105 Master cylinder covers, rear ............... 4-113/115 Master cylinder, front OE ................... 4-83/89 M aster cylinder, rear OE ................. 4-112/115 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) . . . . . . . . . . 5-62 Pads (OE style) . . . . . . 5-57/61 Pedal pads.. . . . . . . . . . . 4-117 Pedals...............4-117 Rear brake switches.. . . . . 1-59 Rotors.............. 5-63/67 Shoe springs.. . . . . . . . . . 5-42 Shoes................. 5-42 Spacer, disc to hub . . . . . . 5-55
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) Springs, brake lever return ..................... 4-112 Stainless hose heat shrink covers................. 4-76 Tee fittings.. . . . . . . . . . . . 4-98 Brass Kickpedal..............7-34 Pushrod keepers . . . . . 6-55/57 Rocker box oil lines . . . . . . 8-36 Breather Crankcase.. . . . . . . . . . . . 6-97 Pipe assembly/case bolt . . 6-97 Valve & gear, Big Twin.. . . 6-91 Builder Kits Batterycable.. . . . . . . . . . . 1-9 Charging & starter kits. . . 1-149 Charging system . . . 1-145/147 Primary bushing, seal kit . . 7-96 Bulbs Dashpanel.. . . . . . . . . . . . 1-35 Headlight . . . . . . . . . . . 1-11/13 Instrument panel.. . . . . . . . 1-35 Marker lights.. . . . . . . . . . . 1-35 Spotlights.. . . . . . . . . . . . . 1-12 Taillights.. . . . . . . . . . . 1-35/36 Turn signals.. . . . . . . . . . . 1-35 Bullet Style Tire Valve Stem Caps.............. 5-25 Bungee Nets................. 10-15 Nuts................. 10-35 Burly Slammer Suspension DropKits...............3-33 Cable Brake................. 4-75 Choke................. 8-89 Clamps.. . . . . . . . . . . . 4-77/78 Clutch.. . . . . . 4-41/64, 4-72/74 Cover (clear heat shrink). . 4-76 Lubricants.. . . . . . . . . . . . 10-20 Cable (cont) Mounting brackets, clutch .4-75 Throttle repair kit . . . . . . . . 4-72 Speedometer. . . 4-65/66, 4-152 Tachometer . . . . . . . . . . . 4-151 Throttle.. . . . . 4-41/64, 4-72/74 Ties, clamps & retainers ................... 4-77/78 CAL PRODUCTS Rocket Fuel.. . . . . . . . . . 10-17 Caliper Assemblies, brake . . . . 5-49/54 Brake mounting hardware ...................... 5-45 Sealkits............... 5-44 Parts, Big Twin.. . . . . . . . . 5-43 Parts, Sportster . . . . . . 5-46/47 Cam Big Twin Evolution. . . . 6-71/73 Big Twin Pre-Evolution.. . . 6-70 Milwaukee-Eight®. . . 6-76, 6-80 ................... 6-82/83 Sportster............... 6-85 Twin Cam.. . . . . . . . . . 6-78/84 Cap Head Nuts .. . . . . . . . . 10-35 Carburetor Assemblies.. . . . . 8-60, 8-63/64 Fuel atomizers, YOST.. . . 8-62 Parts, KEIHIN .. . . . . . . 8-84/85 Parts, MIKUNI .. . . . . . 8-65/67 Parts, S&S.......... 8-62/63 Velocity stack. . . . . . . . . . . 8-98 Cargo Nets............. 10-15 Catalog (Mid-USA) .. . . . . 10-116 Cell Phone Holder.......10-12 Chain Adjusters, rear . . . . 5-41, 7-118 Alignment tool (laser type) ..................... 10-74 Axle adjusters.. . . . . . . . . 7-118 Oil................... 10-19 Rear drive.. . . . . . . . 7-116/117
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 Chain (cont) Rear guards, Big Twin ................. 7-128/131 Tools................. 10-74 Charts Equivalent chart. . . . . . . . 6-154 Rear belt length chart.. . . 7-124 Chemicals Adhesive..............10-22 Anti-seize (brush on) . . . . 10-21 Boot polish.. . . . . . . . . . . 10-26 Brakefluid.. . . . . . . . . . . 10-20 Cleaner...............10-20 Contact cleaner . . . . . . . . 10-20 Epoxy putty.. . . . . . . . . . . 10-24 Fuel stabilizer.. . . . . . . . . 10-17 Fuel tank sealant & cleaner ..................... 10-23 Gasket sealant.. . . . . . . . 10-22 Gel-lube..............10-19 Octane booster.. . . . . . . . 10-17 Polish................ 10-25 Silicone sealant . . . . . . . . 10-21 Choke Cable Assembly/Parts ...................... 8-89 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.. . . . . . . . . . . . 1-91 Mount................. 1-90 Clamps Brake hose.. . . . . . . . . 4-76/77 Cable.............. 4-76/78 Exhaust mufflers.. . . . . . . . 9-24 Exhaust pipes.. . . . . . . . . . 9-24 Frame.................. 2-6 Clamps (cont) Oil line separator . . . . . . . . 8-31 CLEARVIEW Replacement Windshields.. . . . . . . 2-74,3-42 Clutch Adjusting screws . . . . . . . . 7-46 Assemblies, Big Twin . 7-42/45 Assemblies, Big Twin 10 spring.. . . . . . . . . . . 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 Control parts.. . . . . . . . . . . 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 5speed...............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 ................... 7-51/58 Plates, Sportster.. . . . . 7-56/60 Pushrods, Big Twin . . . . . . 7-66 Release arms.. . . . . . . . . . 4-75 Springs, Big Twin 10 spring ...................... 7-48
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 Clutch (cont) Springs, Big Twin diaphragm ...................... 7-61 Tools, Big Twin 10 spring ..................... 10-72 T ools, Big Twin diaphragm ..................... 10-72 Tools, Sportster . . . . . . . . 10-72 CLYMER Repair Manuals ..................... 10-41 Coils Ignition.. . . . . . . . . . . . 1-82/89 Mounting brackets . . . . . . . 1-83 COLONY Belt Drive Pulley Nuts ...................... 7-84 COMETIC Air Filter gaskets . . . . . . . . 8-57 Base gaskets, Big Twin Evolution .. . . . . 6-134 Cam change gasket sets ..................... 6-137 Engine gasket sets, Big Twin Evolution .. 6-144/146 Engine gasket sets, Ironhead Sportster. . 6-147/148 Engine gasket sets, Panhead..............6-144 Engine gasket sets, Shovelhead .. . . . . . . . . . 6-144 Engine gasket sets, TwinCam.............6-146 Engine gasket sets, Sportster 1200cc .. . . . . . 6-149 Engine gasket sets, Sportster 883cc . . . . . . . . 6-148 Engine top end gasket sets ................. 6-139/143 Exhaust manifold gasket ................... 9-20/21 Gaskets, transmission kits ................... 7-18/21 COMETIC (cont) Gaskets/seals sets, primary ..................... 7-107 Head gaskets.. . . . . 6-134/135 H ead/Base gasket sets . . 6-134 Intake manifold seals. . . . . 8-92 Oil Pump gaskets.. . . . . . 6-137 Primary cover gasket, Sportster. ................. 7-108-110 Rocker box gasket sets, Big Twin Evolution. . 6-130/131 Rocker box gasket sets, Sportster Evolution.. . . . . 6-131 Big Twin Evolution. . . . . . 6-141 Top end gasket sets, Evolution Sportster.. 6-142/143 Top end gasket sets, Ironhead Sportster. . 6-141/142 Top end gasket sets, Panhead..............6-139 Top end gasket sets, Shovelhead . . . . . . . . . . . 6-139 Top end gasket sets, Twin Cam ..................... 6-141 Top end gasket sets, Milwaukee-Eight® ......6-141 Top end gasket sets, Sportster 883cc . . . . . . . . 6-143 Compression Release Decorative caps for valves ...................... 6-12 Valves................. 6-12 COMPU-FIRE Charging systems.. . 1-145/146 Ignition modules.. . . . . . . 1-101 Regulator/Rectifiers. . . . . 1-138 Connecting Rod, Assemblies. . . . . . . . . . . . . 6-99 Connectors & Electrical Terminals............ 1-67/68
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 Contact Cleaner Control .. 10-20 Handlebar control assemblies ................... 4-85/91 Counter Display, Tire Valve Stem Caps.............. 5-25 Countershafts Big Twin, 4 speed.. . . . . . . 7-27 Big Twin, 5 speed.. . . . . . . . 7-9 Sportster, 4 speed. . . . . . . 7-38 Crank Pins............. 6-108 Crankcase Assemblies, Big Twin.. . . . . 6-7 Balloon diagram, Big Twin ................... 6-86/87 Balloon diagram, K Model & Sportster............... 6-89 Balloon diagram, Twin Cam ...................... 6-88 Breather...............6-97 Covers for under cylinders ...................... 6-12 Drain/Timing hole plugs.. 10-65 Main bearings, Big Twin . . 6-96 Main bearings, Sportster ..................... 6-102 Crash Bar Assemblies. 2-76/79 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 Gauge Mounts.. . . . . . . . . . 4-143 Cylinder Base & crankcase covers.. 6-12 Base nuts & studs . . . . . . . 6-43 Engine bypass pigtail kit.. . 6-12 Cylinder (cont) Stud removal tool.. . . . . . 10-56 Torque plate tool . . . . . . . 10-59 DAKOTA DIGITAL Electric calibrator. . . . . . . 4-151 Electronic antenna. . . . . . . 1-65 Mounting brackets. . 4-144/148 Oil pressure gauge.. . . . . 4-144 Oil pressure gauge sending unit .. . . . . . . . . . . . . . . . . 4-144 Speedometers . . . . . 4-144/148 Tachometers . . . . . . 4-144/148 Assemblies.. . . . . . . 4-144/148 DAYTONA TWIN TEC Coils & plug wires.. . . . . . . 1-84 EFI controller . . . . . . . . . . . 8-77 Fuel injection kits. . . 1-103/105 Ignition module.. . . . . . . . 1-100 USB interface.. . . . . . . . . 1-100 Debris Deflector .. . . . . . . . . . 2-7 Degreaser .. . . . . . . . . . . . . 10-20 Derby Covers .. . . . . . 7-102/103 DEUTSCH Electrical Wire Connectors .. . . . . . . . . . . . . 1-67 DIAMOND CHAIN Primary................ 7-86 Reardrive.. . . . . . . . . . . . 7-117 Diamond Rail Accessories Footrests..............2-57 Handlebar grips . . . . . . . . . 4-12 Shiftpeg..............4-120 Dice Style Valve Stem Caps .. . . ...................... 5-19 Directional Signal Assemblies.. . . . . . . . . 1-26/34 Flasher................ 1-59 Lightbulbs.. . . . . . . . . . . . 1-31 Load equalizer. . . . . . . 1-27/28 Mounting bracket.1-25/26, 1-32 Relocation kits . . . . . . . . . . 1-27 Disc Brake Brake rotors. . . . . . . . . 5-63/67
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 Disc Brake (cont) Pads............... 5-55/62 Displacement Chart, Engine ..................... 6-104 Distributor Assemblies.. . . . . . . . . . . . 1-91 Parts............... 1-92/94 DOC BAILEYS Leather Black.. . . . . . . . . 10-26 Leather Clear. . . . . . . . . . 10-26 Drag Bars............... 4-30 DUNLOP TIRES......... 5-4/5 Dust Boots Front Fork.. . . 3-37 DYNATEK Coils, ignition . . . . . . . . 1-82/86 Complete ignition systems ................... 1-97/99 Ignition modules.. . . . . . . . 1-99 DYNOJET Powervision. 8-68/70 Eagle Spirit Accessories Air filter cover insert.. . . . . 8-94 Clutch covers. . . . . . . . . . 7-103 Front fender ornament. . . . 2-39 Handlebar riser clamps . . . 4-38 EASY Shift Kit.......... 4-124 EASYBOY Clutch Lever Kits ...................... 7-13 Electric Battery cable boot . . . . . . . 1-15 Builders kits (charging & starter).. ..................... 1-149 Cable ties, clamps & .. retainers.. . ...................... 4-77 Cables for starter, battery & solenoid.. . . . . . . . . . 1-9, 1-14 Circuit breakers . . . . . . . . . 1-62 EFI System Relay . . . . . . . 1-60 Fuseholder.. . . . . . . . . . . 1-61 Heat shrink tubing . . . . . . . 1-69 Starter motors.. . . . . 1-122/128 Starter relays . . . . . . . . 1-59/61 Electric (cont) Starter switches (custom).. . . . . ................... 1-63/64 Switches for handlebar. 1-70/80 Switches for ignition.. . 1-56/58 Switches for rear brake . . . 1-59 Terminal box.. . . . . . . . . . . 1-62 Terminals/Connectors. 1-67/68 Turn signal flasher. . . . . . . 1-59 VOES................. 1-58 Wire.................. 1-49 Wire harness kits. . . . . 1-70/80 Wireloom..............1-69 Electronic Fuel Injection Fuel management system .1-104 Kits................ 8-68/71 Parts............... 8-73/76 Engine Cam case parts, 45ci.. . . . 6-89 Cam case parts, Big Twin ................... 6-86/88 Cam case parts, Sportster.6-89 Cam case tools . . . . . 10-65/67 Cam tools.. . . . . . . . . 10-65/67 Cams, Big Twin . . . . . . 6-70/84 Cams, Sportster.. . . . . . . . 6-85 Compression release valves ...................... 6-12 Connecting rod roller retainer set.................... 6-99 Connecting rods.. . 6-99, 6-105 Cover for cylinder/crankcase ...................... 6-12 Crank pins.. . . . . . . . . . . 6-108 Crankcase assemblies, BigTwin ............... 6-7 Crankcase bearings, Big Twin pinion.. . . . . . . . . 6-97 Crankcase drain/timing hole plugs................. 6-103 Crankcase nut, bolt & stud kits................... 6-43
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 Engine (cont) Crankcase parts, Big Twin.. . . . ................... 6-86/89 Crankcase parts, Sportster ...................... 6-90 Crankcase tools. . . . . 10-57/58 Cylinder base nuts . . . . . . 6-43 Cylinder by-pass pigtail kits ...................... 6-12 Cylinder torque plates . . . 10-59 Cylinders, Big Twin . . . . 6-8/11 Flywheel parts, Big Twin . . 6-98 Flywheel parts, K Model Sportster.. . . . . . . . . . . . . 6-104 Gasket sets, Panhead. . . 6-139 Gasket sets, Shovelhead.6-144 Gasket sets, Sportster ................. 6-141/143 Gasket sets, Twin Cam .. 6-146 Gear case drain plugs. . . 6-103 Gear case parts, 45ci.. . . . 6-90 Gear case parts, Big Twin ................... 6-86/88 Gear case parts, Sportster.6-89 Gear case tools . . . . . 10-62/67 Head bolt covers . . . . . . . . 6-46 Head bolts & washers . . . . 6-46 Head holding tool.. . . . . . . 6-42 Lifter block mounting hardware ...................... 6-69 Lower end parts, Big Twin 6-96 Lower end parts, K Model Sportster.. . . . . . . . . . . . . 6-104 Mount hardware.. . . 2-41, 2-45 Mounts.. . . . . . . . . . . . 2-41/45 Oil pump parts. . . . . 6-111/112 Oils................. 10-2/5 Pinion shaft.. . . . . . . . . . . 6-106 Piston assemblies . . . . 6-44/53 Piston pin lock rings.. . . . . 6-54 Piston rings.. . . . . . . . . 6-53/54 Piston tools.. . . . . . . . 10-58/59 Engine (cont) Pushrod assemblies.. . 6-59/64 Pushrod covers . . . . . . 6-55/58 Pushrod cover seals.. . 6-57/59 Rocker box gasket sets ................. 6-130/133 Rocker cover tool.. . . . . . 10-57 Rocker shaft seal. . . . . . . . 6-15 Sprocket shafts, Big Twin ..................... 6-107 Sprocket shafts, Sportster ..................... 6-107 Tappet assemblies.. . . 6-65/68 Tappet block alignment tool ..................... 10-64 Tappet block mounting hardware..............6-69 Tappet blocks.. . . . . . . . . . 6-68 Timer cover screws . . . . . 6-101 Timer covers.. . . . . . . . . . 6-101 Top end gasket sets, Sportster .. . . . . . . . . . . 6-141/143, 6-150 Top end gasket sets, Panhead ............... 6-139,6-150 Top end gasket sets, Shovelhead . . . . . 6-139, 6-150 Top end gasket sets, Evolution Sportster.. . . . 6-142/143, 6-150 Milwaukee-Eight®....... 6-141 Top end gasket sets, Twin Cam.. . . . . . 6-141, 6-150 Top end gaskets, Big Twin Evolution ............... 6-140,6-150 Top end, Big Twin Evolution (diagram)..............6-16 Top end, Ironhead Sportster .. . .. (diagram) .. . . . . . . . . . . . . 6-18 Top end, Knucklehead (diagram)..............6-13 Top end, Panhead (diagram).. . ...................... 6-14
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) Top end, Shovelhead (diagram)..............6-15 Top end, Sportster Evolution (diagram)..............6-19 T op end, Twin Cam 88 (diagram)..............6-17 Valve guide seals.. . . . . . . 6-41 Valve guides.. . . . . . . . 6-39/40 Valveseats.. . . . . . . . . . . . 6-33 Valve springs. . . . . . . . 6-25/32 Valvetools.. . . . . . . . . . . . 6-42 Valves.............. 6-34/38 Wrist pin bushing tools.. . 10-60 Wrist pin bushings. 6-99, 6-105 Epoxy Putty............ 10-24 Equivalent Chart........ 6-154 EVOLUTION INDUSTRIES Clutch kits.. . . . . . . . . . 7-44/45 Exhaust Anti-reversion power cones ...................... 9-22 Baffles................ 9-18 Clamps & Mounts.. . . . 9-23/25 Drag pipes.. . . . . . . . . . . 9-7/8 Dresser mufflers. 9-2/4, 9-12/16 Exhaust wrap. . . . . . . . . . . 9-31 Fishtail extensions. . . . . . . 9-17 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 Exhaust (cont) 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 ..................... 9-7/8 Systems, Shovelhead late ..................... 9-7/8 Systems, Softail. . . . . . . 9-8/10 Systems, Sportster Evolution ....................... 9-8 Systems, Softail/FX Evolution .................... 9-8/10 Tips................... 9-17 Torque cones.. . . . . . . . . . 9-22 Weld to fit pipes. . . . . . . . . 9-26 Wrap.................. 9-31 Face Masks.. . . . . . . 10-95/101 Fairing Wind deflector . . . . . . 2-6 Fender Assemblies, front. . . . . 2-31/36 Assemblies, rear.. . . . . 2-26/30 Bibs.................. 2-40 Bracket, front (custom).. . . . 3-8 Brackets................ 3-8 Ornaments. . . . . . . . . . 2-38/39 Removable mounts for springers ....................... 3-8 Saddlebag filler panels.. . . 2-28 Support hardware.. . . . . . . 2-23 Supports, rear.. . . . . . . . . . 2-22 Tips................ 2-38/40 Filters Air................ 8-95/104 Fuel............... 8-11/12 Oil................. 8-46/53 Fishtail Extensions....... 9-17 Exhaust Heat Shields. . 9-28/30 Flasher, Turn Signal...... 1-59
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 Flat Straps, Exhaust Mount ................... 9-23/24 Float Bowl Screws. . .8-67, 8-83 Floorboard Assemblies.. . . . . . . . . 2-62/67 Mounts................ 2-61 Flywheel Parts, Big Twin.. . . . . . . . . 6-98 Parts, K Model & Sportster ..................... 6-104 Foot Shift Levers................ 4-119 Pegs.. . . . . . . . . . . . 4-120/121 Footboard Assemblies.. . . . . . . . . 2-62/67 Mounts................ 2-61 Assemblies.. . . . . . . . . 2-53/59 Highway style.. . . . . . . 2-59/60 Mounting brackets . . . . 2-60/61 Footrest Spring washer . . . . . . . . . . 2-56 Forceflow Head Cooler..... 6-9 Fork Front.............. 3-21/25 Front assembly, Springers ..................... 3-3/7 Tools.............. 10-48/51 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 Front Fork (cont) Assemblies.. . . . . . . . . 3-21/22 Axlecap...............5-37 Bootcovers.. . . . . . . . . . . 3-37 Bottom cap hardware.. . . . 3-27 Brackets...............3-27 Covers.. . . . . . . . . . . . 3-37/39 Damper spring. . . . . . . 3-31/34 Damper tubes.. . . . . . . . . . 3-31 Drainscrew.. . . . . . . . . . . 3-27 Head cup bearing.. . . . 3-12/13 Head cups.. . . . . . . . . 3-14/15 Headlight housing/nacelle ................... 3-39/41 Internal parts kit. . . . . . 3-31/33 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 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.. . . . 3-3/7 Springs.. . . . . . . . . . . . 3-32/34 Stem bolt.. . . . . . . . . . 3-11/13 Stem bolt cap.. . . . . . . 3-12/13 Stem nut.. . . . . . . . . . . 3-11/13 Stem nut & lock.. . . . . . . . 3-12 Tools.............. 10-48/51 Tubes.............. 3-29/30 Tube plugs. . . . . . . . 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
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 Fuel (cont) Injection Parts.. . . . . . . 8-72/76 Line Bulk, all types.. . . 8-29/31 Line Clamp tools . . . . . . . . 8-31 Line Clamps.. . . . . . . . . . . 8-31 LineCover.. . . . . . . . . . . . 8-16 Line Crossover, Fat Bob . . 8-13 Line Fittings . . . . . . . . . 8-30/35 Line Kits (with end clamps) ...................... 8-13 Management system for EFI ................... 8-68/71 Pressure regulator, fuel injection ...................... 8-75 Tank Assemblies . . . . . 8-17/27 Tank Mounting parts . . 8-14/15 Funnel Oil Filter .. . . . 8-50, 10-5 Fuse Holder............. 1-61 GARDNER WESTCOTT Engine timing hole & drain plug ..................... 6-103 Fender support hardware (rear) ...................... 2-23 Oil pump plug kits.. . . . . . 6-118 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.. . . . . . 8-29 Line Clamp tools . . . . . . . . 8-31 Line Clamps.. . . . . . . . 8-30/31 Line Crossover, Fat Bob . . 8-13 Line Fittings (with end clamps) ...................... 8-13 LineKits............... 8-13 Tank Assemblies . . . . . 8-17/27 Tank Center Panels. . . . . 4-132 Tank Mounting parts . . 8-14/16 Gas (cont) Valve Assemblies . . . . . . . 8-6/10 GASGACINCH, Gasket Sealant ......... 10-22 Gasket Base, Big Twin Evolution ................. 6-134/135 Cam change kit, Big Twin ..................... 6-137 Cam case cover, Big Twin ..................... 6-138 Cam case cover, Sportster ...................... 6-89 Cylinder head.. . . . . . . . . 6-134 Engine sets, Big Twin Evolution ................. 6-145/146 Engine sets, Ironhead Sportster ................. 6-147/148 Engine sets, Panhead . . . 6-144 Engine sets, Shovelhead .6-144 Engine sets, Sportster 1200cc ..................... 6-149 Engine sets, Sportster 883 ................. 6-148 Engine sets, Twin Cam . . 6-146 Exhaust port.. . . . . . . . 9-20/21 Gear case cover, Big Twin ................... 6-86/87 Gear case cover, Sportster ...................... 6-89 Lifter block, Big Twin . . . . 6-138 Lifter cover, Twin Cam.. . 6-128 Master cylinder, front. . . . . 4-93 Master cylinder, rear . . . . 4-117 Oil pump, Big Twin.. . . . . 6-137 Primary covers, Big Twin ................. 7-107/108 Primary covers, Sportster ..................... 7-106 Rocker arm, Big Twin Evolution. ................. 6-130/131
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 Gasket (cont) Rocker arm, Sportster Evolution ..................... 6-131 Rocker box sets, Big Twin Evolution.. . . . . . . . . 6-130/132 Rocker box sets, Sportster Evolution.. 6-131/132 Shifter, Big Twin 4 Speed ...................... 7-31 Timer cover .. . . . . . . . . . 6-101 Top end sets, Ironhead Sportster . . . . . . . . . 6-141/142 Milwaukee-Eight®....... 6-141 Sportster.. . . . . . . . . 6-142/143 Top end sets, Panhead .. 6-139 Top end sets, Shovelhead ..................... 6-139 Top end sets, Twin Cam ..................... 6-141 Top end, Big Twin Evo.. . 6-140 Transmission kits, Big Twin 4 & 5 speed .. . . . . . . . 7-18/21 GATES, Rear Drive Belts ................. 7-123/126 Gauge Mounts (custom) ................. 4-142/143 Gauges Oil pressure, AUTOMETER ...................... 8-58 Speedo, AUTOMETER. . 4-140 Tachometer, AUTOMETER ..................... 4-139 Gear Case Balloon diagram, Big Twin 1936/1969.. . . . . . . . . . . . 6-86 Balloon diagram, Big Twin Evolution............... 6-87 Balloon diagram, K Model & Sportster..............6-89 Balloon diagram, Shovelhead 1970/1984.. . . . . . . . . . . . 6-87 Gear Case (cont) Balloon diagram, Twin Cam ...................... 6-88 Cover screw kits.. . . . . . . . 6-90 Covers, Big Twin . . . . . . . . 6-94 Tools.............. 10-62/70 Gears Breather valve, Big Twin . . 6-91 Oil pump drive, Big Twin . . 6-93 Pinion, Big Twin. . . . . . . . . 6-93 Transmission, Big Twin 4 speed ................... 7-24/28 Transmission, Big Twin 5 speed ..................... 7-8/9 Sportster 4 speed.. . . . 7-37/39 Sportster 5 speed.. . . . . . . 7-36 Generator Assemblies.. . . . . . . . . . . 1-136 Parts.. . . . . . . . . . . . 1-135/137 Gloves. . . . . . . . . . . . . . . 10-107 Goggles............ 10-87/89 GOLAN PRODUCTS INC. FuelValves..............8-8 Banjo bolts with brake switch ...................... 4-95 Brake hose (cut to length) .................. 4-99/102 Brake hose (universal length) ................. 4-103/105 GOODRIDGE Brake hose (OE fitment) ................. 4-107/110 Custom rear brake tee.. . . 4-98 EFIlines............... 8-29 Engine oil line kits . . . . 8-32/35 Hoseends.............8-31 Oil & fuel line (bulk lengths) ................... 8-34/36 Top end feed lines. . . . . . . 8-36 Grease Fittings........... 2-7 Grease................ 10-21 Hand Shift Knob........ 4-124
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 Handlebar Assemblies.. . . . . . . . . 4-21/32 Cell phone mount.. . . . . . 10-12 Clamp covers.. . . . . . . . . . 4-38 Clamp hardware.. . . . . 4-39/40 Control assemblies.. . . 4-85/91 Grips............... 4-11/17 Levers.............. 4-79/83 Riser bushings. . . . . 4-38, 4-40 Riser hardware.. . . . . . 4-39/40 Riser lower clamps.. . . 4-34/37 Riser solid mount adapters ................. 4-38,4-40 Riser upper clamps . . . . . . 4-38 Risers, custom style.. . 4-34/37 Switches.. . . . . . . . . . . 1-70/80 HARDBODY Brand Brake caliper assemblies ................... 5-46/47 Debris deflector . . . . . . . . . . 2-7 Front fork assemblies.. 3-21/22 Front fork bracket kits.. 3-17/20 Oil filter mount . . . . . . . . . . 8-55 Oil tank assemblies, Big Twin ................... 8-42/45 Oil tank filler/temp cap. . . . 8-39 Oil tank mounts . . . . . . . . . 8-41 HARDWARE Brand Brake line fittings. . 4-97, 4-104 Engine pushrods . . . . . . . . 6-59 Engine valve seats.. . . . . . 6-33 HASTINGS Piston Rings .. . . . . . ................... 6-53/54 HAYDEN Primary Chain Tensioner............... 7-90 Head Cups........... 3-13/15 Head Boltcovers.. . . . . . . . . . . . 6-46 Bolts & washers. . . . . . . . . 6-46 Gaskets . . . . . . . . . . 6-134/135 Headbands............ 10-102 Headlight Assemblies.. . 1-11/13, 1-17/20 Bulbs.............. 1-17/19 Housing...............1-13 Housing/nacelle. . . . . . 3-39/41 Lensgrills.. . . . . . . . . . . . . 1-13 Mounting brackets . . . . . . . 1-22 Sealbeams.. . . . . . . . . . . 1-19 Wire connector.. . . . . . . . . 1-13 Heat Deflectors for Touring Models.................. 2-6 Heat Shields, Exhaust (all models) .. . . . . . . . . . . . . . . . 9-28 Heat Shrink Tubing....... 1-69 Heat Wrap for Exhaust.. . . 9-31 Head Wraps........... 10-102 Heim Joints, Brake/Shift Rod End........... 4-122/123 Helmet Liner .. . . . . . . . . . . 10-97 Helmet Snap Straps.. . . . 10-16 Helmet Visors.......... 10-15 HIFLOFILTRO Oil Filters .. . 8-48 Highway Bars .. . . . . . . . 2-76/79 Horn Assemblies.. . . . . . . . . . . 1-150 Covers...............1-150 Hoses Brake, custom braided ................. 4-100/110 Brake, custom nylon.. . . . . 4-99 Brake, OE fit braided.4-106/110 Hub Assemblies.. . . . . . . . . 5-26/27 Wheel hub parts.. . . . . 5-28/29 Hydraulic Clutch Housings ................... 7-13/14 Ignition Coil Covers.. . . . . . . . . . . . 1-81/83 Ignition coils. . . . . . . . . 1-82/89 Mounting brackets . . . . . . . 1-83
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 Ignition Advance unit parts. . . . . . . 1-94 Advance units.. . . . . . . 1-93/94 Anti-drop relay . . . . . . . . . . 1-60 Circuit breaker parts.. . 1-92/94 Circuit breakers . . . . . . . . . 1-62 Coil covers. . . . . . . . . . 1-81/82 Coils............... 1-82/89 Complete systems. . . 1-97/100 Distributor parts . . . . . . 1-90/94 Distributors.. . . . . . . . . 1-90/91 Modules. . . . . . . . . . . 1-96/102 Spark plugs . . . . . . . 1-111/113 Switches.. . . . . . . . . . . 1-56/58 Timer cover screws . . . . . 1-110 Timer covers.. . . . . . 1-109/110 VOES................. 1-58 Inline Spark Tester......10-42 Inner Primary Covers.....7-98 Inspection Covers.......7-109 Instrument Panel Assemblies ..................... 4-136 Lightbulbs.. . . . . . . . . . . . 1-31 Parts.. . . . . . . . . . . . 4-132/136 Intake Air temp sensor EFI.. . . . . 8-73 Manifold adapters.. . . . . . . 8-90 Manifold engine breather kits.. . ................... 8-93/94 Manifold parts.. . . . . . . . . . 8-91 Jiffy Stand Assemblies.. . . . . . . . . 2-47/52 Parts............... 2-46/48 JIMS Balancer shaft removal tool ..................... 10-63 Bearing race tool . . . . . . . 10-62 Breather valves & gears.. . 6-91 Cam case tools . . . . . 10-66/69 Clutch tools.. . . . . . . . 10-72/73 Connecting rod races.. . . . 6-99 JIMS (cont) Crank pins, Big Twin . . . . 6-108 Crank pins, Sportster. . . . 6-108 Crankcase tools. . . . . 10-62/65 Cylinder torque plates.10-59/61 Engine piston tools.. . . . . 10-59 Engine tools. . . . . . . . 10-58/71 Exhaust tools. . . . . . . . . . 10-56 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. . . . 6-116 Oil pump gears.. . . . . . . . 6-112 Oil pump parts. . . . . 6-111/112 Oil pump tools . . . . . . 10-65/66 O2 sensor socket tool . . . 10-83 Pinion shafts, Sportster &BigTwin.. . . . . . . . . . . 6-106 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 offplate................ 7-4 Sprocket shafts, Big Twin ..................... 6-107 Tappet assemblies.. . . 6-65/67 Tappet block alignment tool ..................... 10-64 Tappet blocks.. . . . . . . . . . 6-68 Transmission pulley nuts ..................... 7-120 Transmission rebuild kits ................... 7-10/11 Transmission sprocket/pulley wrench...............10-77 Transmission tools.. . 10-75/80
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 JIMS (cont) Valve spring compressor tool.................. 10-59 Wrist pin bushings. . . . . . . 6-99 KEIHIN Carburetor Parts ................... 8-84/85 KEITH BLACK Piston pin lock rings.. . . . . 6-48 Pistons, Big Twin. . . . . 6-44/52 Pistons, Sportster.. . . . . . . 6-47 KENDA Tires............. 5-8 Key Fobs............. 10-113 KHROME WERKS Sissybars..............2-80 Kickstand Assemblies.. . . . . . . . . 2-47/52 Extensions.. . . . . . . . . . . . 2-48 Parts............... 2-46/47 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 Gas cap covers.. . . . . . . . . 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 LE PERA (cont) Seats, solo style.. . . . . 2-87/91 Seats, Sportster. . . . 2-105/106 Leather Gloves........10-107 LED Light assemblies.. . . . . 1-12/18 Mirrors................. 4-6 Taillight assemblies . . . 1-39/47 Lever Assemblies, clutch & brake ................... 4-79/83 Footshift.. . . . . . . . . . . . . 4-119 Handlebar lever parts.. . . . 4-84 Shift covers.. . . . . . . . . . . 4-118 License Backing plates . . . . . . . 1-50/53 Frames.. . . . . . . . . . . . 1-50/54 Mount hardware.. . . . . . . . 1-55 Mounting brackets . . . . 1-48/54 Taillight/License. . . . . . 1-43/54 Lifter Assemblies.. . . . . . . . . 6-65/67 Block mounting hardware.. 6-69 Blocks.............. 6-67/68 Lights Directional signal parts ................... 1-26/39 Headlight assemblies.. 1-11/20 Headlight bulbs.. . . . . . . . . 1-21 Headlight lens kits . . . . . . . 1-20 Headlight mounting brackets ...................... 1-22 Indicator bulbs . . . . . . . . . . 1-35 Marker & running assemblies ................... 1-24/32 Marker light bulbs.. . . . . . . 1-35 Marker light mount brackets.. . . ................... 1-37/38 Mounting brackets . . . . 1-22/23 Spotlight assemblies . . . . . 1-24 Spotlight bulbs. . . . . . . 1-24/25
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 Lights (cont) Taillight assemblies . . . 1-39/47 Taillight bulbs.. . . . . . . 1-35/36 Taillight parts . . . . . . . . 1-46/47 Turn signal bulbs. . . . . 1-35/36 Turn signal parts . . . . . . . 1-32, ................... 1-37/38 Turn/Directional assemblies ................... 1-26/34 Locks Front fork lock cover.. . . . . 3-16 Lower End Parts, Big Twin.. . . . . . 6-86/99 Parts, K Model & Sportster ..................... 6-102 Lowering Kits Front forks . . . . . . . . . . 3-32/34 Rear.................. 2-21 LUCAS OIL Assembly oil.. . . . . . . . . . 10-19 Chainoil..............10-19 Detailer............... 10-25 Engine oil.. . . . . . . . . . . 10-2/4 Forkoil............... 10-20 Fuel stabilizer.. . . . . . . . . 10-17 Fuel treatment . . . . . . . . . 10-17 Grease...............10-21 Octane booster.. . . . . . . . 10-17 Oil stabilizer. . . . . . . . . . . 10-18 Tireshine.. . . . . . . . . . . . 10-25 Transmission oil.. . . . . . . . 10-3 Lubricants Anti-seize. . . . . . . . . . . . . 10-21 Assembly oil.. . . . . . . . . . 10-19 Cable................ 10-20 Chainoil..............10-19 Detailer............... 10-25 Engine oil.. . . . . . . . . . . 10-2/5 Front fork oil.. . . . . . . . . . 10-20 Gel-lube..............10-19 Primary case oil. . . . . . . . 10-18 Lubricants (cont) Transmission & primary oil ...................... 10-3 Transmission oil.. . . . . . . 10-18 Luggage Racks.......... 2-69 Mainshafts Big Twin, 4 speed.. . . . . . . 7-26 Big Twin, 5 speed.. . . . . . . . 7-8 Sportster, 4 speed. . . . . . . 7-38 Sportster, 5 speed. . . . . . . 7-36 MALLORY Distributor/circuit breaker kit ...................... 1-90 Maltese Cross Ignition timer cover.. . . . . 1-109 Marker/running lights. . . . . 1-38 Mirrors................. 4-9 Taillights............... 1-43 MANLEY Bee Hive Valve Spring Set ...................... 6-31 Engine valves.. . . . . . . . . . 6-36 Valve springs. . . . . . 6-26, 6-31 Manifold Exhaust clamps . . . . . . 9-23/24 Intake adapters, Mikuni . . . 8-90 Intake adapters, spigot type ...................... 8-90 Intake engine breather kit ................... 8-94/95 Intake parts.. . . . . . . . . 8-93/94 Manuals CLYMER Repair .10-41 Marker Light Assemblies.. . . . . . . . . 1-27/34 Bulbs................. 1-35 Mounting brackets . . . . . . . 1-32 MARSHALL Oil pressure gauges.. . . . . 8-59 Master Cylinder Assemblies, front OE style ................... 4-85/87
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 Master Cylinder (cont) Assemblies, front custom ...................... 4-94 Assemblies, rear . . . 4-112/115 Body covers, rear.. . . . . . 4-116 Clutch hydraulic. . . . . . . . . 4-87 Clutch, rebuild kits. . . . . . . 4-92 Rebuild kits, front. . . . . . . . 4-92 Rebuild kits, rear . . . . . . . 4-116 Reservoir, rear. . . . . . . . . 4-116 Reservoir covers, front.. . . 4-93 Reservoir covers, rear. . . 4-115 Mechanical Advance Unit for Ignition.............. 1-92/93 Mid Frame Type Heat Deflectors.. ....................... 2-6 MIKUNI Air filter parts.. . . . . . . . . . 8-65 Carburetor assemblies & kit ................... 8-63/66 Carburetor parts.. . . . . 8-65/67 Mini Floorboards.. . . . . 2-64,67 Mirror Assemblies.. . . . . . . . . . 4-2/10 Mount.................. 4-9 Momentary Push Button Switches (custom) .. . . . . . . 1-63 Modules Ignition assemblies.. 1-96/1-101 Ignition covers . . . . 1-109/1-110 MOROSO Spark plug wires.. . . . . . . 1-121 MOTION PRO Airchuck.. . . . . . . . . . . . 10-52 Alignment tool.. . . . . . . . . 10-54 Belt tension gauge. . . . . . 10-73 Brake Bleeder tool. . . . . . 10-56 Brake cables.. . . . . . . . . . . 4-75 Cable clamps. . . . . . . . 4-76/78 Cableluber.. . . . . . . . . . . . 4-72 Cable lubricant.. . . . . . . . 10-20 Choke/enricher cables. . . . 8-91 MOTION PRO (cont) Clutch cables. . . . . . . . 4-41/74 Drive chain tools.. . . . 10-73/74 Fuel line (clear) . . . . . . . . . 8-30 Speedometer cables . . 4-65/66 T-handle rack.. . . . . . . . . 10-40 T-handle socket driver. . . 10-40 Throttle cables. . . . . . . 4-41/65 Valve core remover . . . . . 10-56 Wheel bearing remover. . 10-54 Motor Mount assemblies . . . . 2-41/45 Mount hardware.. . . . . . . . 2-41 Motorcycle Tie Down Straps .................. 10-11/13 Mounting Brackets Ignition switch.. . . . . . . . . . 1-65 Oil tank.. . . . . . . . . . 8-41, 8-45 Rear brake lever.. . . . . . . 4-112 Shift foot lever . . . . . . . . . 4-117 Mounts for Transmission. . 7-22 Mufflers Bracket Cover.. . . . . . . . . . 9-13 Dresser models. 9-3/4, 9-15/17 Trike Models.. . . . . . . . . . . 9-14 MUSTANG Fenderbibs.. . . . . . . . . . . 2-40 Saddlebag lid covers. . . . . 2-72 Seat back pads . . . . . . . . 2-102 Seats, Big Twin 4 speed . . 2-97 Seats, Dresser or Bagger models. ...................... 2-98 Seats, Dyna models.. . . . . 2-94 Seats, FLT models.. . 2-98/102 Seats, Road King models ..................... 2-100 Seats, Softail models. . . . . . . . . ............... 2-100,2-103 Seats, Sportster models.. 2-106 Sissy bar pads. . . . . . . . . 2-102 NAMZ Extension Harness.. . . . . . 1-77
1 2 3 4 5 6 7 8 9 10 11 Table Of Contents TABLE OF CONTENTS i-20 CONTENTS REFERENCE GENERAL EXHAUST FUEL DRIVE TRAIN ENGINE WHEEL CONTROL FRONT END FRAME ELECTRICAL NAMZ (cont) Deutsch connectors. . . . . . 1-65 Molex connectors.. . . . . . . 1-65 Throttle-By-Wire sensors. . 4-18 NOVISTRETCH Fairing and saddlebag mask ...................... 2-74 Nets, Cargo............ 10-15 Nose Cone, Gear/Cam Case Covers................. 6-88 Nuts Acorn head.. . . . . . . . 10-34/35 Caphead.............10-35 Hexhead.............10-36 Hex nylon insert. . . . . . . . 10-34 Pikehead ............10-34 O Ring Matching Accessories Footrests..............2-55 Highway footrests.. . . . . . . 2-56 Shiftpegs.. . . . . . . . . . . . 4-120 O Ring Assortment......10-39 Octane Booster......... 10-16 Oil Filter Assemblies.. . . . . . . . . 8-46/50 Cup wrench tools. . . . . . . . 8-50 Elements . . . . . . . . . . . 8-48/52 Funnel................ 10-5 Mounts.. . . . . . . . . . . . 8-54/55 Oil Line Assemblies & kits.. . . . 8-32/35 Bulk............... 8-29/30 Clamptools.. . . . . . . . . . . 8-31 Clamps................8-31 Fittings.. . . . . . . . . . . . 8-32/35 Rocker boxes.. . . . . . . . . . 8-36 Separator clamp.. . . . . . . . 8-31 Oil Pressure Gauge assemblies. . . . 8-58/59 Gauge fittings.. . . . . . . . . . 8-57 Oil Pump Assemblies.. . . . . . . . . . . 6-113/118 Chrome covers.. . . . . . . . . . . 6-118 Oil Pump (cont) Gaskets, Big Twin. . . . . . . . . 6-123 Gears, Big Twin.. . . . . . . . . . . 6-87 Mounting hardware . . . . . . . . 6-118 Oil stabilizer. . . . . . . . . . . . . . 10-17 Parts, Big Twin.. . . . . . . . . . . 6-112 Parts, Sportster . . . . . . . . . . . 6-117 Pressure switch. . . . . . . . . . . 6-111 Tools.................10-65/66 Oil Tank Assemblies.. . . . . . . . . . . . . 8-42/46 Drainplugs................ 8-38 Filler plugs & caps. . . . . . . . . . 8-69 Fittings................... 8-33 FLT filler spout.. . . . . . . . . . . . 8-37 Mounting bracket.. . . . . . . . . . 8-41 Mounting parts.. . . . . . . . . . . . 8-41 Oil spout spacer kit . . . . . . . . . 8-37 Temperature gauges. . . . . . . . 8-39 Oils Assembly................ 10-19 Chain................... 10-20 Engine..................10-2/4 Frontfork................ 10-20 Motor...................10-2/4 Primary case . . . . . . . . . 10-3, 10-17 Transmission. . . . . . . . . . . . . 10-18 Transmission & primary case .. . . . . . . . . . . . . . . . . . . . . 10-17/18 OLD STF CYCLE Aircleaner.. . . . . . . . . . . . . . 8-100 BeeBlocker............... 8-59 Brass kick pedal.. . . . . . . . . . . 7-34 Brass pushrod keepers. . . . . . 6-57 Neck Cup Conversion Kit.. . . . . 3-8 Rocker box lines.. . . . . . . . . . 8-36 Outer Primary Covers (Big Twin) .. . . . . . . . . . . . . . . . . . . . . . . . 7-97 Oxygen Sensors........ 1-108 Oxygen Sensor Plug...... 9-22 Oxygen Sensor Socket Tool ..................... 10-83
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