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Installation This kit fits all models equipped with Harley-Davidson 1-1/4 in. (32 mm) diameter front engine guards, except models equipped with fairing lowers or splash shields. 1. VRSC models: Refer to the Service Manual and remove the right side cover and Maxi-Fuse. All models except VRSC: This kit is not compatible with Handlebar Reservoir Cover Sets 46098-98 or 56099-98, due to the location of the switch. See the Service Parts illustration on the last page of these instructions for kit contents. CAUTION It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson Dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b) 1WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) 1WARNING Disconnect negative (-) battery cable first. If positive (+) battery cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. NOTE These lamps require 9 amps of available current from the motorcycle’s electrical system. ...
Installation This auxiliary lamp kit fits: • All 1988 and later XL and Dyna Glide model motorcycles (except FXDWG, XDS-CONV or FXDXT). • 1988 through 1994 FXR, FXRS and FXLR models. 1WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) This kit DOES NOT fit: • FXR models equipped with engine guards. • FXR models equipped with Turn Signal Relocation Kit 68517-94A. NOTE Auxiliary / fog lamps are not included in this kit. The desired style of lamp must be purchased separately. HDI (International) motorcycles should only use approved fog lamps. 1WARNING Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. See the Service Parts illustration on the last page of these instructions for kit contents. Models with turn signals mounted on the upper or lower triple clamp will also require Front Directional Relocation Kit (Part No. 68603-01), available separately at your HarleyDavidson Dealer. CAUTION It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a HarleyDavidson Dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b) 1WARNING Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. Remove the fuel tank. See FUEL TANK – REMOVAL in the applicable service manual. 3. See Figure 1. The mounting brackets (1) and clamps (2) are side-specific. Select the right-hand or left-hand bracket and clamp, and install on the fork tube using two button-head screws (3) from the kit. NOTE Tighten the outer screw first. i02292
Kit Number 76000070, 76000074 Models For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only). Additional Parts Required When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a) This amplifier requires up to 11 amps additional current from the electrical system. Models not equipped with a Non-Ultra Overlay Harness (Part No. 70169-06) will require the separate purchase of a Radio Wire Harness (Part No. 69200106). Kit Contents Tools and Supplies Required INSTALLATION Loctite® 243 Threadlocker and Sealant - Blue (Part No. 9964297) is required for the proper installation of this kit. Preparation See Figure 5 and Table 1. NOTE For vehicles equipped with security siren: • The rider's safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) Verify that the Hands-Free Fob is present. • Turn the ignition key switch to IGNITION. 1. Refer to the service manual and follow the instructions to remove the main fuse. 2. Follow the service manual instructions to remove the seat. NOTE This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Electrical Overload Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 3. It is possible to overload your vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. See an authorized Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes. (00211c) For 2008 and later models: Refer to the service manual and follow the instructions to remove the ECM caddy from the top of the battery. Disconnect the battery cables, negative (-) cable first. 4. For ALL models: Refer to the service manual, and follow the instructions to remove the fuel tank console and fuel tank.
The adapter wiring harness in this kit is designed for installation on 1984 - 1990 model year motorcycles, and is to be used in conjunction with any of the following ignition modules: 32405-91, 32410-91, 32419-91, 32432-91, 3242087A, 32421-85A. Specific vehicle applications are listed in the Instruction Sheet included with the ignition module. This Ignition Module Adapter Wiring Harness Kit consists of the following components:... DESCRIPTION Conduit, 10-inch long vinyl Conduit, 33-inch long high-temp vinyl Conduit, 34-inch long vinyl Conduit, 48-inch long high-temp vinyl Connector, 3-pin/socket Harness, ignition module adapter wiring Strap, cable Terminal, pin type Terminal, ring type (for #10 stud size) Terminal, ring type (for 1/4-inch stud size) Terminal, ring type (for 3/8-inch stud size) Terminal, socket type Terminal, spade type - female (small) Terminal, spade type - female (large) NOTE All seven wire leads of this adapter wiring harness must be terminated in the manner specified in this Instruction Sheet. Do not splice the wires of the adapter wiring harness to the wires of the original module’s wiring harness. Installation 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect battery cables from battery (negative cable first) before performing any of the following procedures. 1. Using the table on Page 2, compare wire color codes of adapter harness from kit (and new module pigtail) with those of original module on motorcycle. NOTE On 1984 - 1990 original modules, color code for both the ground wire and one of the ignition sensor wires is black. To distinguish between the two, note that the black ground wire is not grouped with any other wire lead, and that the black ignition sensor plate wire is grouped (encased by conduit) with the two other sensor plate wires (green and red). 2. Take note of the routing of original ignition module wire leads. Disconnect these module wire leads at the terminals and remove module according to Instruction Sheet included with module. 3. Position seven-pin connector of adapter harness over location on motorcycle in which original ignition module was mounted. You may wish to tape the connector in place so that it does not shift position during the wire routing procedures which follow.
1. Make sure the vehicle is on level ground. 6. Using oil resistant gloves, detach the oil filter and O-ring from the re-usable cap and dispose of properly. 2. Turn the engine off and wait a few minutes for the oil to drain into the oil pan. 3. Set the parking brake and ensure the gearshift is securely latched in P (Park) (automatic transmission) or 1st (First gear) (manual transmission). Important: To avoid engine damage, change the oil filter before draining the oil pan. This allows dirty oil in the filter housing to drain back into the oil pan. 4. Loosen the oil filter cap by using a 36mm socket and a ratchet (location #1) NOTE: Unscrewing the cap opens the oil filter drain and drains the oil from the oil filter housing into the crankcase. NOTE: Do not handle a hot oil filter with bare hands. Continuous contact with USED motor oil has caused cancer in laboratory mice. Protect you skin by washing with soap and water.
Engine Oil Level This single cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below: 8. Unscrew and remove dipstick and check to see that the oil level is in the SAFE ( XX) range. Add oil as indicated by the level on the dipstick. Do not overfill (see NOTE below!). 1. Position vehicle on a level surface. 2. Place the transmission in Park (P). 3. Be sure engine OFF has not been run for at lease 3 minutes. IMPORTANT: Do not run the machine and then immediately check the dipstick. 4. Locate the engine oil dipstick: • RZR 570 - Located on the RH side of the engine case; accessible through the RH rear wheel well area. Maintain Oil Level In SAFE Range DO NOT Overfill the Engine NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately. 9. Reinstall the dipstick and hand tighten. Engine Oil and Filter Service Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. IMPORTANT: Thoroughly clean engine around the oil drain plug, oil filter and oil dipstick to prevent contamination from entering the engine. WARNING 5. Be sure to clean area around dipstick to ensure no dirt / debris falls into the dip stick hole. 6. Unscrew and remove dipstick and wipe dry with a clean cloth. 7. Reinstall the dipstick completely. NOTE: Make certain the dipstick is threaded all the way into the engine case. Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage. Recommended Engine Oil: PS-4 Plus Synthetic 4-Cycle Engine Oil (PN 2876244) (Quart) 1. Position vehicle on a level surface. 2. Place the transmission in PARK (P). 3. Start the engine. Allow it to idle for two to three minutes until warm. Stop the engine. NOTE: Drain plug is accessed through...
Draining Oil S Start engine and run until warm. Stop engine. Disconnect spark plug wires to prevent accidental starting. S Remove oil drainplug and capture waste oil in an approved container. Dispose of waste oil properly, see Fig. 1, when completed, tighten plug. S Replace oil filter every 100 hours of operation. Before installing new oil filter, lightly oil filter gasket with fresh, clean engine oil. Screw filter on by hand until gasket contacts filter adapter. Tighten 1/2 to 3/4 turn, see, Fig. 2. Replace and Install Foam Pre-Cleaner if equipped and Paper Cartridge Air Filter S Clean air filter assembly parts. If your kit contains Briggs & Stratton paper cartridge part #693141. You can extend the replacement of the air cleaner cartridge to 100 hours of operation, unless operating under dusty conditions. A precleaner is not required for use with this paper cartridge. S Make sure cover is properly installed before starting engine. S Use Briggs & Stratton certified SAE 30 oil, part number 100028, 48 oz. (1.418 liters) or 100005, 20 oz. (.6 liters). A S Start engine and run for five minutes. Shut down engine and recheck oil level on dipstick after engine cools for five minutes. (Wipe dipstick before checking oil.)
BAKER™ transmission assemblies, transmission kits, primaries, and oil pans are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 5 years from the date of purchase or up to 50,000 miles. BAKER™ clutches, kicker cover kits, belt drives, F6F kit, reverse systems, covers and accessories are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 2 years from the date of purchase or up to 24,000 miles - whichever occurs first. If the product is found by BAKER™ to be defective, such products will, at the option of BAKER™, be replaced or repaired at cost to BAKER™. In the event warranty service is required, the original purchaser must call or write BAKER™ immediately with a description of the problem. If it is deemed necessary for BAKER™ to make an evaluation to determine whether the transmission assembly or transmission kit or accessory is defective, the entire transmission assembly, whether originally purchased as an assembly or kit, must be properly packaged and returned prepaid to BAKER™ with a copy of the original invoice of purchase. If after an evaluation has been made by BAKER™ and a defect in will, at materials and/or workmanship is found, BAKER™ BAKER™ option, repair or replace the defective part of the assembly. RETURNS AND EXCHANGES Any merchandise returned for any reason (exchange, credit or modification) must be accompanied by a Return Goods Authorization (RGA) number or it will be refused. Call BAKER™ to obtain this number prior to returning goods for any reason. There is a 15% re-stocking fee for all returned items. BAKER™ is not liable for any shipping charges.
The life span of electronics can be affected by damage caused by electrostatic discharge. This can happen if a charged tool or person touches a component. Therefore, it is very important that all tools and personnel are discharged by touching an earthed point before the printed circuit board or any of the components are touched. It is equally important to discharge the package with the new component before opening it. A person walking on carpet can be charged with up to fifteen thousand volts (15,000V). Compare this with the fact that some sensitive components can be destroyed when discharged on a much lower level (about 100V). We kindly ask you to pay close attention to this, as this is a vital point in order to ensure the life span of the product. Torx T6 for removing the Display Torx T15 for removing the Cover Torx T20 for removing the Printed Circuit Board. Step by step 1. Before disconnecting the cables mark them. 2. Disconnect the cables from terminals 1L1, 3L2, and 5L3 (main voltage). 3. Disconnect all cables from the terminals 1 to 20, external keypad, PTC sensor and the Fieldbus plug. 4. Remove the front cover (four screws). 5. Discharge the tools and yourself by touching earth (if you are not earthed). 6. Disconnect the cables on the HV-Board from the SCRs and fans. Mark the cables from the SCRs with L1, L2 and L3. 7. Remove the five screws. 8. Remove the old HV-Board. Don’t lose the connector between HV-Board and LVBoard. If only the HV-Board will be changed go to step 21. 9. Disconnect the cables on the LV-Board from the thermal switch and current transformers. Mark the cables from the current transformers with CT1, CT2 and CT3. 10. Remove the six screws...