How to Change a Harley Exhaust

Harley Davidson exhaust systems dampen engine exhaust noise and provide a precisely metered amount of back-pressure to the system. The back-pressure created at the muffler is an important part of the air/fuel circuit and has a strong impact on maintaining the air/fuel charges entering the cylinders. Harley motorcycles employ a two-part exhaust system consisting of an exhaust pipe leading from each cylinder head and terminating close to the rear of the vehicle. Slip-on mufflers are clamped onto each pipe and then mounted to a bracket at the rear of the bike. The pipes also incorporate a crossover tube to assist the backpressure and aid in exhaust gas scavenging in the heads.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Standard socket set
• 3/8-inch drive ratchet
• 3/8-inch torque wrench
• New slip-on mufflers
• Brake cleaner
• Shop rags

1. • 1

     Loosen the clamp where the exhaust pipe enters the muffler, with a socket. Slide the clamp forward and allow it to rest on the exhaust pipes.

   • 2

     Loosen with a socket and remove nuts on the muffler T-bolts where they enter the rubber mounted exhaust bracket. Lower the muffler away from the frame and wiggle it gently to loosen the slotted muffler sleeve at the pipe. Support the exhaust pipe with one hand and pull the muffler off the pipe with the other to avoid stressing the exhaust pipe gasket. Remove the T-bolts from the muffler and insert them in the muffler mount slot.

   • 3

     Push the new muffler onto the exhaust pipe. Support the pipe with one hand and the muffler with the other. The muffler may have to be wiggled on in order to spread the slotted clamp sleeve enough to fit onto the pipe. Slip the pipe in about two inches.

   • 4

     Rotate the muffler until the T-bolts are lined up with the exhaust support bracket. Insert the T-bolts in the bracket and tighten the nuts hand-tight.

   • 5

     Slide the exhaust clamps back onto the slotted clamp sleeve and torque them to factory specifications with a torque wrench and socket. Torque the T-bolt nuts to factory specifications with a torque wrench and socket.

   • 6

     Use brake cleaner and a clean shop rag to remove all fingerprints and oils from the muffler and the exhaust pipes. Any oily spots will permanently discolor the chrome components once the pipes heat up to operating temperature.

Tips & Warnings

• This procedure describes how you change from one factory style, full restriction muffler to another. This is not the same as changing to a low restriction, high performance exhaust. Adding low-restriction mufflers, such as Screaming Eagle slip-ons, without adjusting the air cleaner and carburetor will de-tune the engine and degrade performance. This three-part process is commonly called a Stage-1 upgrade and is better left to a certified technician at a factory authorized dealer/service department.

How to Build a Harley-Davidson Bear

Harley-Davidson is a motorcycle manufacturer located in the United States. Harley-Davidson riders often wear t-shirts and hats adorned with Harley-Davidson's logo. Customizing teddy bears with clothing has become popular, so it is not a surprise that teddy bears can be built with Harley-Davidson gear that you can find in all sorts of places.

Difficulty:

Easy

Instructions

1. • 1

     Determine what size you want your Harley-Davidson bear to be.

   • 2

     Buy a plush bear. A few sites to check out are Huggable Teddy Bears, Build-A-Bear Workshop and Free Bears.

   • 3

     Buy a teddy bear-sized Harley-Davidson shirt. Baby clothes will work. You can buy Harley-Davidson baby clothes at Crab Apple Kids, Adventure Harley-Davidson and Real Biker Shirts. Once you buy the clothes, place them on your bear.

   • 4

     Put a bandanna or hat on your bear. Many Harley-Davidson fanatics wear hats or bandannas adorned with the logo. To find bear-sized hats and bandannas, try Hot Leathers, JC Whitney and Biker Headwear.

How to Replace Brake Pads on a Harley

Disc brakes today on a Harley Davidson motorcycle require very little maintenance except for periodic fluid bleeding and replacement of the brake pads. Manufacturers have been producing many kinds of replacement brake pads and making various claims about their products. However, the manufacturer of your motorcycle may require that you purchase and use genuine factory parts. It's very important to replace parts according to the manufacturer, especially if your bike is still under warranty.

Difficulty:

Moderate

Instructions

Things You'll Need

• Rags
• Allen wrench
• New brake pads
• Large screwdriver
• Needle-nose pliers
• Silicone brake grease
• Aerosol brake cleaner
• Torque wrench

1. • 1

     Park your motorcycle on a flat surface and put down the center stand, leaving the fork legs (connects axle and front wheel to the frame) free to turn or rotate for better access to the retaining pins.

   • 2

     Remove the bolts from the calipers and set them aside. On a motorcycle with fixed calipers, rotate the retaining pins until the loop ends of the retaining clips are exposed, and then remove the clips with needle-nose pliers. You may also have to remove the dust shield if it does not come free upon removal of the pins from the caliper.

   • 3

     Shake the caliper until the old brake pads fall out, and then inspect the pads for cracks, general wear, and missing material. Clean the caliper pistons to remove road grime and pad residue. Reinsert the old pads in the caliper and then wedge the screwdriver in between the two pads so that the caliper pistons go back into the bores. Check for leaking fluid from the master cylinder reservoir as you are pushing the pistons back into place.

   • 4

     Prepare the new brake pads according to the directions on the package. Remove the old pads and then insert the new pads, being careful not to touch the face of the pads with your hands or to touch any other parts that will keep the face of the pads from being clean.

   • 5

     Reinstall all parts removed in the beginning such as the retaining pins and clips, if applicable to your motorcycle. Clean and lubricate any slides or pivot points with the brake grease. Perform final cleanup and bolt the calipers back to the fork leg using a torque wrench. Pump the brakes until they feel firm underneath your feet. Check the fluid level on the master cylinder.

Tips & Warnings

• The repair procedure is the same for both front and rear brakes.

How to Change the Oil in a Harley Heritage

A Heritage Harley-Davidson is a heavyweight, twin cam motorcycle with three oil compartments. To prolong your Harley's engine life, you need to change the oil routinely. Oil changes should be done while the motorcycle is in an upright position, leaning on its side stand.

Difficulty:

Moderate

Instructions

Things You'll Need

• Flat, strap or ratchet wrench Two drip pans Socket wrench Harley oil filter New oil

1. • 1

     Start the motorcycle and let it run for several minutes and then shut it off (this will allow the oil to flow faster). Use a flat wrench, simple trap wrench or ratchet wrench to remove the oil filter.

   • 2

     Put a larger drip pan under the Harley's oil filter hole to catch all the oil that flows out of the oil tank filter hole.

   • 3

     Locate your motorcycle's oil tank at the bottom near the transmission.

   • 4

     Remove the drain plug from the front of the oil tank using a socket wrench, preferably while the engine is warm. Be careful that you don't get burned by hot oil.

   • 5

     Allow the used oil to run freely and pour squarely into the drip pans. Remove the filter sticks to improve the flow. Let the used oil drain out completely.

   • 6

     Install a new ten-micron filter by hand, screwing it on tightly into the filter hole.

   • 7

     Refill your Harley's oil tank with new oil according to the amount and level stated in your owner's manual (around one quart).

   • 8

     Test-drive your Heritage Harley-Davidson to check the performance of its engine upon oil replacement. Check your oil level and add more lubricant oil as needed.

Tips & Warnings

• Allowing your Harley to run for a bit before draining the oil will allow all the old oil to drain out, but remember the oil will be slightly warm, so avoid touching it while it is draining out.

How to Clean Harley-Davidson Mag Wheels

As you ride on your Harley Davidson motorcycle, the mag wheels encounter dirt, puddles and road tar, which can make them extremely dirty. After spending the money on aftermarket upgraded mag wheels, you will want to properly maintain and care for the wheels to protect your investment. Properly cleaning and caring for alloy wheels help them look shiny and new.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Mag wheel cleaner
• Liquid dish soap and a spray bottle
• Soft cloth
• Sponge
• Soft-bristled cleaning brush
• Hose
• Towel
• Alloy or mag wheel polish

1. • 1

     Spray the wheel in a generous layer of your preferred mag wheel cleaning spray. Mag wheels sprays are specially formulated to clean the alloy metal without damaging it. If the wheels need to be cleaned and you don't have a mag wheel cleaning spray, combine a squirt of liquid dish soap with warm water in a spray bottle. Though not as effective as mag wheel cleaner, the mixture is safe to use.

   • 2

     Allow the cleaner to work into the wheel for approximately 15 minutes. If you have hard-to-remove substances, such as tar or sap on the wheels, allow the mixture to sit longer.

   • 3

     Spray the wheels with a thin layer of mag wheel cleaner. Use a soft cloth or sponge to scrub the soap into the wheel. For residue not removed with a cloth, a soft-bristled cleaning brush can be gently used.

   • 4

     Spray the mag wheels with a hose to remove soap residue.

   • 5

     Dry the mag wheels with a towel to prevent water spotting.

   • 6

     Apply a half-dollar-sized drop of alloy or mag wheel polish to a soft cloth.

   • 7

     Rub the polish into the wheel until the entire surface is coated in a thin, even layer. Allow the polish to dry on the wheels.

   • 8

     Polish the wheel by rubbing a soft cloth against the wheel in a circular motion. This will remove the polish residue. Dampen the corner of a soft cloth. Squeeze to remove extra moisture. Rub the cloth into any remaining or stubborn polish.

How to Replace Harley Rocker Boxes

Harley Davidson rocker boxes are a three-part aluminum assembly with rubber quad seal gaskets to retain top-end engine oil lubrication. The rocker boxes house the top end of the pushrods, the valve rockers, valve stems and stem seals. They incorporate sound-damping technology to reduce valve-train noise, and can be fitted with chrome or custom boxes adding "curb appeal" to the bike. These boxes can be replaced with basic mechanic's tools.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Standard wrench and socket set
• 3/8-inch ratchet
• Allen (hex) driver set
• Rocker box gasket and seal kit
• Small wooden block
• Torque wrench
• Center-stand or bike lift

Suggest Edits

1. Replacing the Rocker Boxes

   • 1

     Drain the fuel tank. Remove the fuel tank mounting bolts. Turn the fuel petcock to the "Off" position and remove the fuel line and vaccuum line from the petcock spigot. Elevate the fuel tank (for a one-tank design) and block it up with a wood block. Split-tank designs must have the fuel crossover tube removed and each side of the tank removed completely from the chassis to gain access to the top of the rocker boxes.

   • 2

     Remove the rocker box top cover bolts. Lift off the top cover, middle spacer and associated rubber seals. Place the transmission in first gear and elevate the rear of the bike with a center-stand or bike lift. Rotate the rear tire and observe the valve rocker's movement in the box. Roll the tire until the front cylinder valves are in valve overlap (both valves are depressed at once). The rear-cylinder rocker box is now de-stressed as much as possible and may safely be removed.

   • 3

     Break the torque on the two bottom rocker-box bolts closest to the pushrods, but do not loosen more than a half-turn. Break the torque on the two bottom rocker-box bolts opposite the pushrods and remove them completely. Finish backing off and removing the pushrod side bolts. Back them off, one turn at a time, until the pushrod load is released from the rockers, then back them off fully. Lift the bottom rocker box assembly from the engine.

   • 4

     Scrape any remaining gasket material from the mating surface on the top of the cylinder head. Clean and dry the mating surface, and then install the new gaskets. Tighten the bottom rocker-box mounting bolts opposite the pushrods finger-tight. Insure that the pushrod ends are properly nested into the rocker-arm cups. Install and torque the pushrod side bolts to factory spec, then torque the opposite side bolts to factory spec.

   • 5

     Install the new rubber seal into its groove and ensure that it lays flat and is not rolled at any point. Lay the spacer into position and install the top rubber seal. Rotate the rear tire until the rear cylinder valves are on overlap. The front cylinder will now be in position for removal. Position the top rocker-box cover and reinstall the mounting bolts. Torque to factory specification for your model of Harley. Repeat the process on the front cylinder.

   • 6

     Reinstall the gas tank(s), petcock fuel line, vaccuum line and fuel crossover tube.

Tips & Warnings

• Test-run the engine without driving it. If there is a leak in the new rocker boxes, the top-end oil will drain down onto the engine and can smoke or vaporize, possibly leading to a fire hazard.

• Use caution when scraping the old gasket material. The components are cast aluminum and are easily gouged, leading to a chronic leaking condition.

• Do not remove the pushrod side bolts fully until the opposite side is removed. There will still be some pre-load from the valve springs and the pushrods that will stress and crack the bottom of the rocker box if improperly removed.

How to Do an Oil Change on a Harley Davidson Road King

A motorcycle is a pretty practical idea during this time of high gas prices. Harley Davidson motorcycles typically get 50 miles to the gallon. If you want to combine practicality with horsepower, the Harley Davidson Road King is the motorcycle for you. Of course, saving money on gas doesn't help much if you spend it all on maintenance, so doing some things on your own is a good idea. An easy task to start with is to change your oil.

Difficulty:

Moderate

Instructions

Things You'll Need

• A Harley Davidson Road King A Harley Davidson Owner's Manual Four quarts of quality motor oil A bucket or pan to drain the oil into A new oil filter (Be sure it is the right size for your motorcycle.) A new crush washer (Once again, be sure it's the right size.) A funnel A screwdriver or Allen wrench Clean rags Adjustable socket wrench Oil filter wrench

1. How to Do an Oil Change on A Harley Davidson Road King

   • 1

     Locate the oil plug. It should be on the underside of the oil pan. Place your bucket or pan underneath it.

   • 2

     Remove the oil plug. Be careful when doing this, as the oil might be hot. Allow the oil to drain into the pan.

   • 3

     Remove your used crush washer, which is on the plug, and replace it with the new washer. The crush washer must be replaced during every oil change.

   • 4

     Wipe off the end of the oil plug. If this is not a brand new engine, be slightly wary of large slivers of metal.

   • 5

     While the oil is draining, remove the oil filter. Do this with an oil filter wrench. It should unscrew. When you get the oil filter off make sure that the o-ring (a rubber ring around the oil filter that ensures a proper seal) came off with the oil filter. If it did not come out, be sure to remove it.

   • 6

     Remove and wipe down the plastic mesh filter on the side of the engine case. Put this back in when it is clean. Wipe any sludge off the drain plug as well.

   • 7

     Take a bit of new motor oil and rub it on the o-ring of the new oil filter, to ensure a snug seal. Then, using your hand instead of a tool, screw the new oil filter into place. Using a tool for this can overtighten the oil filter and damage the o-ring.

   • 8

     Take a funnel and holding it at an upright angle, pour two quarts of the fresh oil in. Then let it work through the engine a bit. Screw the plug back in, turn your engine on and let it idle for a couple minutes. Finally, turn off the engine and unscrew the plug again, and using the funnel, pour the rest of the oil in, but don't overfill the oil pan.

   • 9

     Screw the plug back in and clean up any overflow.

Tips & Warnings

• Check your manual or engine to be sure of oil capacity, and do not go over the fill capacity.