Question about Harley Davidson FLHR-FLHRI Road king Motorcycles

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Lders91@yahoo.comremoving headlight assembly to replace handlebar bushings how too remove lock assembly etc.

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Do not remove the lock assembly. It requires a special tool to realign the layers of the switch.

Good Luck

Posted on May 25, 2011

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Why won't my headlight work on dim?

What did you do with the handlebars and wiring etc. and did you have the clutch perch and switch assembly open or off. Likely you have a pinched wire.

May 11, 2014 | Harley Davidson FXD Dyna Super Glide...


How to replace a chain with master link on a Schwinn Airdyne

Airdyne Chain Replacement with Master link

This video will demonstrate how to replace the chain with master link on a Schwinn Airdyne.
  • First remove the cotter pin and clevis pin from the user's right handlebar. Then lower the connecting arm and handlebar.
Caution: be sure to hold the handlebar as it will come loose after removal of the above parts.
  • Remove the connecting arm and pedal and crank arm by removing the wedge pin. To simplify this process loosen the nut and tap on it with a small hammer until the pin is loosened.
  • Remove the nut, wedge pin, crank arm and connecting arm.
  • Next remove the chain guard; there are three screws attaching it as shown in the video.
  • Remove the chain by locating the master link. Remove the lock pin and the cover, and then disconnect the chain.
  • Place the new chain on the sprockets as shown in the video.
  • Install the master link, cover and lock.
  • Re-install the chain guard and attaching screws.
  • Re-assemble the connecting arm to the handlebar and eccentric.
  • Be sure the brass bushing is installed in the front inner side of the connecting arm before installing the clevis pin and cotter pin.
  • Install the crank arm with pedal.
Be sure when completing this step that the crank arm is installed in the opposite position as the users left side crank arm.
  • Install the nut onto the wedge pin and tighten.
  • This completes the procedure.
Replacing Schwinn Airdyne Chain with Master Link

on May 23, 2016 | Schwinn Airdyne Exercise Bike

1 Answer

Handlebar risers bushing replacement

It's not too hard. Take out the old ones, put new ones in, I suggest some plastic tie wraps to hold the bars near the approximate spot while you're fiddling. You don't need to remove cables or anything, if that's what you're thinking.

May 06, 2014 | Harley Davidson FLSTC - FLSTCI Heritage...

1 Answer

Headlight handlebar

Remove headlight trim, remove ten screws holding haedlight assembly, remove nut under nacelle, pop the ignition decal up and remove the screws holding cover, remove the side bolts from windsheild bracket

Oct 21, 2013 | 2000 Harley Davidson FLHR-FLHRI Road king

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How to install a headlight

Locate the headlight bulb in the engine compartment, in the rear of the headlight assembly. It has a wiring harness connector attached to it.

Remove the wiring harness connector from the bulb. Release the locking tab on the connector and pull it off the bulb. Lay it aside

Locate the locking ring on the back of the headlight assembly. Turn the lock ring 1/8 of a turn counterclockwise to release the lock from the headlight assembly. Remove the lock ring and set it in a safe place.Remove the headlight bulb from the headlight assembly, pulling it straight back toward the engine. Discard the old bulb, unless you are reusing the bulbs in the Jeep.Insert a new bulb into the headlight assembly. (Be careful not to touch the glass when handling the bulb. The oils from your hands can cause it to overheat and shatter.)Install the headlight lock ring onto the headlight assembly and turn it clockwise 1/8 of a turn to lock the bulb into the assembly. Connect the wiring harness connector to the new bulb, ensuring that it seats completely on the bulb.Move to the opposite headlight and repeat the process to replace the second bulb. Turn on the lights to verify they are working correctly.

Jan 13, 2011 | 1993 Jeep Cherokee Country

1 Answer

My handlebars move up and down on my 2000 Road King. The mechanic says I need to replace the "bushings" and it is a big, 2 hours labor, to replace them. Can it be done by me with my limited motorcycle...

Well, I can't answer your question because I don't know the level of mechanical ability you have. But, there is nothing that is super exotic about replacing the bushings on the risers. It depends on the type of bushings that are in the upper triple tree. Some bushings simply push out and others are "pressed" in. By "pressed" in, I mean you can drive them in with a hammer if you use the proper precautions to keep from damaging them and you get back in the proper position.

Basically, all that has to be done is to remove everything that is in the way of accessing the bushings. You need to remove any windshield, fairing, nachelle, headlight, handlebar riser cover, and remove the nuts or bolts from the risers. Replace the bushings with either replacement bushings like they came from the factory or urethane bushings to give a more firm feeling to the handlebars.

Good Luck

Oct 18, 2010 | 2000 Harley Davidson FLHR-FLHRI Road king

1 Answer

I am trying to change a headlight. I can't can not

The headlight assembly (1993 Grand Caravan) is held in place with three plastic "wing nuts" that rotate on the ball-end (front end) of the adjusting screws. One "adjusting screw" (the one on the bottom, inboard side) is not for adjusting, just for mounting. The other two adjusting screws take a torx T15 in the front end of the screw.
Removing the headlight assembly is somewhat of a trick - it seems like it takes a special tool to reach the "wing nut" and turm it 1/4 turn (90 degrees) CLOCKWISE (so the "wings" are vertical). When all three of these mounting "wing nuts" have the wings vertical, the headlight assembly just pulls forward and off these mounting nuts. Place the new assembly back over the "nuts", turn the 3 "wing nuts" another quarter turn, and the new unit is mounted. Probably not even a need to re-adjust the headlights, but you should check.
The PROBLEM, is that it appears to take a special tool to reach and turn these wing nuts without breaking them (yes, the old ones get brittle). I tried a socket (did not work), and then long needle-nose pliers (broke one wing nut), then a 1/2" open-end wrench (which at least worked). However, pushing the new assembly back over the wing nuts, I broke another wing nut. So, I broke 2 of the 6, and one was broken when I started.
Now I need to find replacements for these "wing nuts" ... any ideas where to get them?
Of course I can use some washers, some nuts to fit the fine-threaded adjustment screw, and some sort of bushing (maybe cut a short piece of rubber tubing to fit over the adjustment screw). Place double nuts (second nut to lock the first in place) and a washer, then the bushing onto the adjusting screw, then the headlamp assembly onto the bushing, then add another washer, and two more nuts (not too tight) to lock it onto the adjusting screw (which must still be free to rotate). Repeat for each of the 6 mounting points. I have not tried this yet, but ... it should work.

Fabricate a tool to turn the "wing nuts" using a piece of 3/8 inch ID tubing which you file or cut 1/8 inch by 1/8 inch notches on each side of a diameter line.

Apr 22, 2010 | 1993 Dodge Caravan

1 Answer

Loose handle bars

Usually you do have to remove the entire fairing. The Loosness that you feel in the handlebars is due to the rubber bushing that the handlebars are mounted in. These bushings are designed to absorb vibration. Over time, they get mushy. You must gain access to the upper triple tree which not only involves the removal of the fairing , it could require the removal of the headlight nachelle as well. Good Luck.

Mar 29, 2010 | 2000 Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to get acsess to my handlebars to tighten

You must remove the Nachele to get to the handlebar risers. They are bolted through the top triple tree. Of course, you must also remove anything that prevents you from gettng the nachelle off such as windshield, fairing, and headlight. Note: Sometimes if you turn the front end fully to one side, you and get to the large nut or bolt from the bottom side without removing he nachelle. Turn the front end to the other direction to get to the other nut or bolt.

Now, keep one thing in mind, the handlebar risers are mounted in rubber bushings. This is done to reduce handlebar vibration. Harley has used this vibration dampening system for years on their big twin bikes. Your handlebars may not be "loose" but move due to the rubber mounting. Before I went to tearing my bike apart, I'd feel of some other bikes handlebars first and compare it to what yours feel like.

You can get more firm bushings for the handlebars. Matter of fact, you can get steel bushings that eliminate the rubber mounting.

Go to this site and check out page 990 It is the V-Twin manufacturing catalog and shows the handlebar riser bushings. Good Luck

Jan 31, 2010 | 2005 Harley Davidson FLHT - FLHTI Electra...

1 Answer

My handle bars are loose on my 2005 Harley Roadking FLHRI, how do I tighten them. Do I need to remove the headlight assembly?

They're probably not loose. The movement you're feeling is probably in the rubber bushing that the handlebars are mounted in. Harley has used rubber bushings for years to isolate the handlebars from as much engine and road vibration as possible.

On your "cruiser" bikes like your roadking, the bushing are quite soft to dampen the vibration to a greater degree. The bushing on the Softail may not be as soft. The good news is that they aren't difficult to replace with a firmer set. You will have to take the headlight nachelle off to gain access to the nuts or bolts that hold them in place. You can order aftermarket bushings that are more firm or you can even get solid steel bushings to eliminate the movement to the degree that you want.

Jan 08, 2010 | 2005 Harley Davidson FLHR - FLHRI Road...

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