1 | Rear crossover pipe heat shield clamp |
2 | Rear crossover pipe heat shield |
3 | Muffler support bolt (4) |
4 | Muffler, right |
5 | Muffler, left |
6 | Muffler support bracket |
7 | Keps nut |
8 | Exhaust support bracket bolt (2) |
9 | Exhaust support bracket |
10 | Transmission clamp |
11 | Front header pipe heat shield |
12 | Rear header pipe heat shield |
13 | Exhaust flange nut (4) |
1. | Support engine. | |||||||
2. | See Figure 2. Remove the lower 7/16-14 x 1-1/4 inch swingarm bolts (1) from left and right swingarm bracket (2) and discard bolts. NOTE In the following step, it may be necessary to spread the vertical arms apart in order to position them in line with the lower left and right rear swingarm bracket holes. |
Figure 2. Swingarm Bolt Location | ||||||
3. | See Figure 7. Position the display stand (1) around the bottom of motorcycle frame (B) with the vertical arms (H) in line with the lower swingarm bolt holes. From the kit, install the 7/16-14 x 1-1/4 inch swingarm bolts (2) into the lower left (D) and right (E) swingarm bracket locations but do not tighten completely. | |||||||
4. | Swing front of display stand up to the frame support bracket (C). | |||||||
5. | Place plate (3) on top of frame support bracket (C) directly in line with the display stand mounting holes. | |||||||
6. | Insert two 1/4-20 x 7/8 inch long hex head bolts with washers (4) through display stand mounting hole, frame support bracket (C) and into plate (3). Tighten one side until bolt head and washer starts to compress plate. Move to the other side and tighten until bolt head and washer starts to compress plate. Repeat this process with both bolts to bring the display stand mounting hole areas up against the bottom of the frame support bracket (C). At this time, display stand ends (L) will be up against the bottom of the frame (B). NOTE In the following step, it may be necessary to place a spacer (1/4 inch thick) between the top of the plate (3) and oil pan fins in order to hold the plate (3) in position. If required, insert spacer next to one of the 1/4-20 x 7/8 inch long hex head bolts before removing bolt. After removing one 1/4-20 x 7/8 inch long hex head bolt and replacing it with a 1/4-20 x 1/2 inch bolt from kit, repeat process for other bolt. Remove spacer after tightening kit bolts. | |||||||
7. | Apply LOCTITE® 271 (Red) to the two 1/4-20 x 1/2 inch bolt from kit. Remove one 1/4-20 x 7/8 inch long hex head bolt and replace with washer (4) and 1/4-20 x 1/2 inch bolt (5). Do not tighten at this time. Repeat for second 1/4-20 x 1/2 inch bolt. | |||||||
8. | Tighten the 1/4-20 x 1/2 inch bolts (5) to 12.2 N·m (9 ft-lbs). | |||||||
9. | Tighten the left and right 7/16-14 x 1-1/4 inch rear swingarm bolts (2) to 41–54 N·m (30–40 ft-lbs). | |||||||
10. | After the two 1/4-20 x 1/2 inch bolts from kit have been tightened, inspect the area between the display stand tube (top center), the plate (3) and bottom of the oil pan fins. There must be 1/4 to 5/16 inch of clearance between these components. NOTE Inspect the brake line and brake harness wires (right side of frame) to verify that they are not pinched between the frame and display stand. |
1. | See Figure 1. Remove rolled up rag from between the rear exhaust pipe and transmission side cover. NOTE Verify that the exhaust pipes do not contact the motorcycle frame or any mounted components. Contact will cancel the effect of the rubber isolation mounts and transmit vibration to the rider. | |
2. | Using a long 1/2 inch swivel socket, tighten the top nut of the front cylinder head exhaust flange to 1–2 N·m (9–18 in-lbs). | |
3. | Tighten the bottom nut to 11.3–13.6 N·m (100–120 in-lbs). | |
4. | Final tighten the top nut to 11.3–13.6 N·m (100–120 in-lbs). | |
5. | Tighten the bottom nut of the rear cylinder head exhaust flange to 1–2 N·m (9–18 in-lbs). | |
6. | Tighten the top nut to 11.3–13.6 N·m (100–120 in-lbs). | |
7. | Final tighten the bottom nut to 11.3–13.6 N·m (100–120 in-lbs). | |
8. | Tighten the front header pipe heat shield (11) clamp and tighten to 2.3–4.5 N·m (20–40 in-lbs). | |
9. | Tighten the rear header pipe heat shield (12) clamp and tighten to 2.3–4.5 N·m (20–40 in-lbs). | |
10. | Tighten the rider right hand footboard support bracket cap head screws (not shown) to 41–48 N·m (30–35 ft-lbs). | |
11. | On the right hand side of vehicle, install the transmission clamp (10) and tighten to 27–34 N·m (20–25 ft-lbs). | |
12. | Install the exhaust support bracket (9) using two screws (8) and washers. For 2006 and earlier models: Apply LOCTITE 243 (blue) to threads and tighten to 18–27 N·m (13–20 ft-lbs). For 2007 and later models: Apply LOCTITE 243 (blue) to threads and tighten to 34–37 N·m (25–27 ft-lbs). | |
13. | Install Keps nut (7) and tighten to 16.3–20.3 N·m (12–15 ft-lbs). | |
14. | Snug two screws (3) (with lockwashers) holding the right side muffler (4) to the lower saddlebag support rail. Alternately tighten screws to 10.8–16.3 N·m (96–144 in-lbs). | |
15. | Snug two screws (3) (with lockwashers) holding the left side muffler (5) to the lower saddlebag support rail. Alternately tighten screws to 10.8–16.3 N·m (96–144 in-lbs). | |
16. | Rotate the clamp drive screw (1) on the rear crossover pipe heat shield (2) so that screw is on the outboard side in the most accessible position and then tighten to 2.3–4.5 N·m (20–40 in-lbs). | |
17. | Install left side cover. | |
18. | Install saddlebags. Refer to the applicable Service Manual for Saddlebag Installation procedures. | |
WARNING Connect positive (+) 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. (00068a) | ||
19. | Install battery cables, positive (+) cable first. |
1. | See Figure 5. Position the jiffy stand (3) to support the vehicle. |
Figure 3. Display Stand Leg Adjustment Procedure
Figure 4. Display Stand Adjustments | ||||||||||||||||||||||||||||||
2. | See Figure 4. For initial adjustment, loosen both jam nuts (1) and turn jam nuts up against foot pad (2). | |||||||||||||||||||||||||||||||
3. | Spin both foot pads with jam nuts all the way into legs (3). See Figure 7. Spin both feet with jam nuts back out until flat (K) faces down. Do not tighten jam nut at this time. See Figure 4. This is the starting point position (6) for all models. |
1 | Passenger footboard |
2 | Display stand foot lever |
3 | Jiffy stand |
1 | Jiffy stand |
2 | Handbar, left side |
3 | Saddlebag guard, left side |
4 | Display stand, engaged |
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
---|---|---|---|---|---|---|
1 | Display stand | Not Sold Separately | A | Front of vehicle | Reference only | |
2 | Bolt, hex head, 7/16-14 x 1-1/4 inch (2) | 3057 | B | Frame | Reference only | |
3 | Plate | Not Sold Separately | C | Frame support bracket | Reference only | |
4 | Washer (2) | 6703 | D | Left hand rear swingarm bracket | Reference only | |
5 | Bolt, 1/4-20 x 1/2 inch (2) | 3728 | E | Right hand rear swingarm bracket | Reference only | |
6 | Bolt, 1/4-20 x 7/8 inch (2) (not shown) | 3802W | F | Left hand foot | Reference only | |
G | Right hand foot | Reference only | ||||
H | Vertical arm | Reference only | ||||
I | Factory installed bolts, DO NOT LOOSEN, TIGHTEN or REMOVE | Reference only | ||||
J | Factory installed set screw, DO NOT LOOSEN, TIGHTEN or REMOVE | Reference only | ||||
K | Foot flat down | Reference only | ||||
L | Display stand ends | Reference only |