Technical information
Tech tips
For correct piston play, bore sizes and wear limits refer to the OEM service manual. If you are using special pistons and/or cylinders follow the manufacturer instructions for bore sizes.
Il systema CAN bus è presente su tutti i modelli…
The following information and instructions are for your use, so your warranty will by in effect. No warranty can be in effect if these instructions are not followed. Whenever any component of a generator charged electrical system is serviced it is necessary to re-polarize the complete system, making sure it has the correct polarity so the system will charge in the right direction. If the system is put into service with the wrong polarity it may result in burned relay points, a dead battery and damage to both the regulator and generator.
Instructions
- To polarize a generator system with a mechanical regulator, momentarily connect a jumper wire of adequate gauge (a battery cable is ideal) between the “bat” and the “gen” terminal on the regulator after all wires have been properly connected and before starting the motor.
- To polarize a generator system with electronic regulator/ rectifier. Before mounting the generator of the vehicle, place the generator on a non conducting work surface (like a wooden bench) and connect the positive terminal of a battery to the armature terminal of the generator. Then momentarily “flash” the negative battery terminal to the generator field terminal.
The oil system of Harley-Davidson changed between the Evolution and Twin Cam models. On Evolution models the oil filter system is in the return section and uses a 30 micron filter. On Twin Cam models the oil filter system is on the pressure side and uses a 10 micron filter. Oil filters can not be changed over!
The zinc-chromate primer finish, on some of our tanks, is provided for protection of the tanks during shipment and storage. It is not recommended as a primer finish for paint applications without proper surface preparation. As with any fuel tank, particularly one where custom paint is to be applied, all the tanks must be pressure tested, then cleaned and sealed with tank sealer (ZPN 752900 & 752903 / 752904) before painting, to protect the final finish and prevent internal rust during winter storage.
Except where mentioned differently, all exhaust systems, mufflers, dragpipes, etc. shown in our catalog, are for closed course competition or in show competition only. They will not meet legal noise standards.
Technical information
| ZODIAC PN | DESCRIPTION |
| 011308 | Fat Bob gas tank XL82-03 dashmount |
| 011474 | Quick Bob gas tankdash/base XL82-03 |
| 011561 | Sport Bob gas tank Quick-Cam cap XL82-03 |
| 011586 | Strech Sport Bob gas tank XL82-03 |
| 011601 – 011602 | Str Rubber mnt gas tank XL82-03 dashmount |
| 011612 – 011613 | Str Rubber mnt gas tank KM Speedo XL82-94 |
| 011745 | Sport Bob Aero gas tank XL82-03 |
| 012652 | Carb rep. kit Keihin carb 76-89 VITON |
| 032534 | Top Motor Mount BT 48-99 #16852-87T |
| 032536 | Heavy duty top motormount FXS/B #69013-87T |
| 049105 – 049106 | Cylinder Shovelhead front/rear |
| 049112 | Cylinder Big Bore frint. STD lenght |
| 049112_049114_049108_049109 | MODIFICATION FOR THE OIL RETURN FROM THE CYLINDER HEADS IN 1953 THRU 1984 CRANKCASES (Except Evolution Big Twin) |
| 049114 | Cylinder Big Bore rear, STD lenght |
| 049124 | Cylinder Knucklehead rear 74″(1200cc) |
| 049118 – 049127 | Aluminum Cylinder BT84-99 Black Wrinkle |
| 049130 | Aluminum Cylinder XL1200 # 16447-88 |
| 056025 | Forward Control Set XL86-90 |
| 056080 | Forward Control Kit XL91-03 |
| 056100 | Forward Controls FL 58-86 Softail 86-99 |
| 056109 | Forward Controls w/o/ pegs BT58-86 F*ST86 |
| 090205 | Fender License Bracket custom |
| 090225 | Custom Rear Bobbed Fender FXST w/o/light |
| 121158 | Allen Head Air Cleaner Insert for Evo filters |
| 144506 | Inner Clutch Hub for 1984 thru 1989 Big Twin |
| 148112 | Clutch Shell BT98-06 w/102T Ring Gear |
| 151080 | Generator HD 12 Volt Chrome finish |
| 160262 | Softail Turn Signal Bracket 88-up |
| 169165 | Speedo / Tacho Combo MPH, black face , 2:1 |
| 175122 | Extended Wire kit XL73-81 FX73-81 |
| 231311 | Cylinder XL/H/CH 73-85 Rear |
| 231731 | ACCEL Voltage Regulator BT/XL 12V10A |
| 231923 | ACCEL Regulator Delco style |
| 232284 | Hotgrips HD with single throttle cable |
| 232289 | DYNA S Electronic Ignition DS6-1 1970 to present |
| 232467 | Fournales Pan Cruise F*ST84-99 black |
| 232594 – 232595 | Andrews camshafts 21H / 26H bolt in FXD06 TC07-up |
| 232598 – 232599 | Andrews camshafts 44H / 50H bolt in FXD06 TC07-up |
| 232648 – 232650 | Andrews camshafts XL91-99 N6 /N8 grind |
| 233550 | Assortment Tray Engine/Transmission keys |
| 233552 | Assortment Box Retaining Rings 120 pcs |
| 235002 | 5 Speed Kicker Kit |
| 236386 -238387 | Bar Mount Digital Speedometer with indicators |
| 236399 | Super Ass Swingarm kit Zodiac Widetail |
| 236443 | Complete Super-Ass Swing Arm kit Softail |
| 236683 | Unilite Distributor 36-39 Big Twin |
| 236890 – 236891 | Wide-Ass Swing Arm kit FXD91-05 raw/black |
| 237223 | Wrist pin bushing tool & reamer |
| 237429 – 237446 | Brute IV belt drive F*ST90-99 / FXD90-05 |
| 239441 | Hide-Away Fork Stop kit polish stainl. |
| 237987 | AMM Dual Fire Millenium Ignition |
| 238092 – 238093 | Compufire Ignition Module Kit |
| 239790 | Altmann P3 ignition Softail 00-up |
| 239793 | Altmann P3 ignition w/o coilmount TC99-up |
| 243071 – 243073 | Shock Set chrome/black adjust Softail 00-up |
| 301738 | Chrome Lifter block cover set XL86-90 |
| 301832 | Nose cone cover with allen screws |
| 301869 | Chrome Oil Filter bracket cover BT92-99 |
| 301887 | Chrome Oil pump cover Evo BT92-99 |
| 301893 | Chrome lifter block covers XL91-99 |
| 302233 | Chrome 5-speed kick starter kit |
| 339091 | Tamer II kit XL 71-84 |
| 345276 | Chrome dash for XL95-up Q/B tanks |
| 361569 | FXST Adjustable rear footpegs mount univ. |
| 361571 | Adjustable front foot peg mount univ. female |
| 370254 | Pull-Start system BT65-88 black |
| 396025 | 250 De Luxe Swing Arm kit for FXST91-up |
| 700852 | Zodiac 6-speed Conversion kit |
| 700878 | 12mm Primary offset kit BT94-06 5-speed |
| 700889 – 700925 | 25/45 mm Primary offset kit BT94-06 5-speed |
| 700935 – 700936 | 25/45 mm Primary offset kit 94-up 6-speed |
| 700977 | Complete Zodiac 300 swingarm Kit, Twin Cam Softail 2000-2006 |
| 700996 | Swingarm + Banana 280/300 Twin Cam |
| 701151 | Pro Clutch 4-Speed Big Twin |
| 701153 | Pro Clutch 1990 -1997 Big Twin |
| 701206 | 5-Star floating brake disc 11.5″ 00-up |
| 701242 – 701243 | PosiLock in-line conector 2.0 – 5 mm / assortment |
| 701246 – 701247 | PosiTap tap-conectors 2.0 – 5 mm / assortment |
| 701249 – 701250 | PosiTwist non-inline connectors 0.2 – 1.0 – 2.5 mm |
| 701252 – 701253 | PosiSeal weaterpr.inline connectors 0.5 – 1.0 – 2.5 mm |
| 701256 – 701257 | PosiSeal weatertite inline connectors 0.5 – 1.0 – 2 mm |
| 701802 – 701804 | TPD RSDrive 300/330 Conversion kit 5-speed |
| 701958 | 25 mm Primary kit TC12-up |
| 702022 | Trci Box AIS intake override 07-up |
| 710111 – 710112 | Copper Head/Base gasket stock bore set Evolution |
| 710372 – 710373 | MMB 48 mm electronic mini speedo mph black/white |
| 710416 – 710417 | MW Digital Speedo w/MMB meter bracket |
| 710420 | MW Digital Speedo bracket for 5″ Tacho |
| 710424 – 710425 | MW Handlebar clamp w/Digital Speedo |
| 711802 | MSD Launch Control & Shift light |
| 711829 | MSD Nitro Programmable Ignition V-Twin |
| 712009 | Power Commander V for 2009 XR1200 |
| 712100 – 712101 | TPP VP Clutch 70T BT98-06 / 84T BT07-up |
| 712104 – 712105 | TPP VPC 84T BT98-up High Perf. / VPC 92T BT98-up with High Perf. spring |
| 712108 – 712109 | TPP VPC-EVO BT90-97 w/o diaphragm spring / TPP VPC 883XL91-03 150 lbs spring |
| 712112 | TPP VPC XL91-03 w/o diaphragm spring |
| 712114 | TPP VP cluch VRSC02-07 |
| 721351 | Assortment Box Main & Slow Jets |
| 721721 | Brute IV belt drive F*ST00-06 |
| 721927 – 721928 | S&S Billet Rocker Kit TwinCam 99up Chrome/Polished |
| 722051 | Crane Fireball H14-TC Ignition TC99-03 |
| 722080 | Wide Ass Swing arm kit Softail 2000-2006 |
| 722577 | RSD Frame support kit F*ST89-99 |
| 722685 | Black Fat Bubba upper fork Tube covers |
| 731448 – 731449 | Round Mini Speedometer 2-1/16″ MPH / KPH |
| 731471 | Rectangular Bargraph Mini Tachometer |
| 731485 | Individual Electronic Tacho bar mount |
| 731496 | Round Cyl. head temperature gauge 2-1/16″ |
| 731499 | Round Digital Tachometer 3-3/8″ |
| 731501 | Round Digital Oil pressure gauge |
| 731513 | Chrome Voltage Reg. XL/1200 2 Brush gen. |
| 731918 | Wire + Motor mount wiring system chopper |
| 731940 | Wire + autocancel turnsignal module/w/EQ |
| 732056.ITALIANO | Information Brochure – DIAG4BIKE |
| 733410 thru 733478 | CCCS Handlebars & Handlebar Controls |
| 736080 | “Rite on Time”V-Twin Timing Tool |
| 740089 – 740090 | Anti Rotation Device TC88A/TC96A – TC88B/TC96B |
| 741190 | Techlusion FI module EVO+TC88 thru 04 |
| 741203 – 741204 | Hitachi type starter 1.4 KW Black/Chrome |
| 741225 | TPD SuperPump Oil Pump TwinCam 99-06 |
| 741235 | Müller Power Clutch XL94-up |
| 741237 | Müller Power Clutch BT87-up |
| 741360 | Brainbox Electronic control box |
| 741399 | Brainbox Lite Electronic control box |
| 741578 | Zodiac Beam Box Light Switch |
| 741691 | Zodiac TOP FI Module F*ST06 FLH/T06 FXD06 |
| 741693 | Zodiac TOP FI Module FLH/T08-09 |
| 741695 | Zodiac TOP FI Module VRSC02-07 |
| 741698 | Zodiac TOP Module FI VRSC12-up |
| 741998 | TwinScan II diagnostics scan tool – Download software Here |
| 741699 | PS Aitail Compressor Kit FLH/T09-up |
| 743402 | Reverse gear kit 2009 thru 2013 Touring. Models with OEM or Screamin’ Eagle hydraulic clutch require additional parts kits ZPN 743403 and ZPN 743406 |
| 744135 | Sprintex SuperCharger VRSC models (use with Dynajet PowerCommander) |
| 744263 | Dakota Digital Info Center 47-03 Blue |
| 744475 | Generator HD 12 Volt Black |
| 750038 | S&S Powerkit ignition inst. kit TC99-03 |
| 750050 – 750051 | S&S Crankcase breathervalve TC A 99-02 / 03-up |
| 750348 | S&S TC Style Style Oil pump TC99-06 A engine |
| 750599 | S&S clutch w/37T sprocket BT91-93 |
| 751097 | Jim’s Forceflow Head Fan Kit |
| 751542 – 751543 | S&S EZstart Chain Drive 583 cams BT07-up / 585 cams BT07-up |
| 751546 – 751547 | S&S Easy start Gear Drive 551 cams 07-up / 570 cams 07-up |
| 751550 – 751551 | S&S Easy start Gear Drive 625 cams 07-up / 640 cams 07-up |
| 751553 – 751554 | S&S Easy start Gear Drive 551 cams BT99-06 / 570 cams BT99-06 |
| 751557 – 751558 | S&S Easy start Gear Drive 625 cams BT99-06 / 640 cams BT99-06 |
| 752088 – 752089 | S&S Cams w/Gear Kit 510G TC99-06 / 546G TC99-06 |
| 752092 – 752093 | S&S Cams w/Gear Kit 625G TC99-06 ex FXD06 / 640G TC99-06 ex FXD06 |
| 752095 | S&S 510G Gear Drive Camset FXD06 |
| ZODIAC PN | DESCRIPTION |
| 011473 | Sport Bob gas tank XL82-03 dual screw |
| 011560 | Sport Bob gas tank XL82-03 w/flush lock |
| 011583 | Streched Sport Bob gas tank XL82-03 |
| 011588 – 011589 | Strech Sport Bob gas tank XL82-03 |
| 011605 | Str Rubber mnt gas tank XL82-03 dashmount |
| 011636 | FXR gas tank + 2 single smooth top 4.2 |
| 011746 | 2″ Str Sport Bob gas tank XL 82-94 w/aero |
| 032419 | Tranny adj. kit BT 4-speed 58-85 not FXST |
| 032535 | Heavy duty top motormount FX/FXE #69018-87T |
| 049103 – 029104 | Cylinder Panhead front/rear |
| 049108 – 049109 | Cylinder Shovel big-bore 3 5/8 front/rear |
| 049113 | Aluminum Cylinder BT84-99 #16510-83A |
| 049118 – 049120 | Cylinder Knucklehead front/rear 61″(1000cc) |
| 049125 – 049126 | Cylinder Shovelhead front/rear 1340 (80 C.I.) |
| 049128 | Aluminum Cylinder 1200 cc EVO XL Black Wrinkle |
| 049131 | Aluminum Cylinder XL883 # 16446-86A |
| 056032 | Extend Forward Control FXST 87099 (Hayes) |
| 056083 | Forward Control Kit FXR82-94 |
| 056108 | Forward Controls +2″ FL/FX/FXST w/MstrC |
| 056110 | 2″Extended Forward Control Set w/o/pegs |
| 090224 | Custom Rear Bobbed Fender FXST models |
| 090226 | Fenderstrut end caps (pair) |
| 131170 | Seal & Bearing Maintenance Tool (26 piece) |
| 148060 | Caliper Anti Vibration Kit #41670-73 |
| 150035 | Starter Solenoid Repair Kit for All Models 1965-1988 (except 1981-1988 XL Models) |
| 160185 | Pyramid Style license plate holder H-D |
| 162249 | Bullet Light Mounting Kit |
| 169383 | Pro-Max Digital 300 km/h Speedo / Tacho , 8000 rpm |
| 231310 | Cylinder XL/H/CH 73-85 Front |
| 231459 | Jim’s Hydrosolid tappet BT84-99 XL86-90 |
| 231904 | ACCEL Voltage Regulator XL1200 2-brush |
| 232192 | Fournales Pan Cruise shocks 00-up Black |
| 232288 | DYNA coil 3 Ohm 12 Volt angled tower |
| 232290 | DYNA S Electronic Ignition DS6-2 1970 to present |
| 232468 | Andrews camshafts N3 XL05-06 |
| 232596 – 232597 | Andrews camshafts 31H / 37H bolt in FXD06 TC07-up |
| 232644 – 232646 | Andrews camshafts XL91-99 N2 / N4 grind |
| 232652 – 232654 | Andrews camshafts XL91-99 N9 / NV grind |
| 233551 | Assortment Tray with 120 pcs tab wash |
| 234862 | Mikuni HS40 Carburetor only |
| 235474 | 5-Star Floating Disc 11.5″ 1984-1999 |
| 236388 | Individual Classic Speedo for Bar mount |
| 236442 | Complete Super-Ass Frame Kit |
| 236682 | Unilite Breakerless Ignition Kit BT70-78 |
| 236889 | Rear Engine Mount Twin Cam |
| 236986 | Electronic Speed correction module |
| 237379 | Forward Control set FXST 84-99 w/o pegs |
| 238766 – 238779 | FXD91-05 Swing Arm kit raw/black |
| 239785 | Curve key kit Pro with manual (key 1-9) |
| 238090 – 238091 | Compufire Ignition Module Kit |
| 239788 | AMM Single Fire Millenium Ignition |
| 239792 | Altmann P3 ignition FXD99-up |
| 243067 | Chrome Adjustable shocks Softail 89-99 |
| 291266 | Tamer Clutch kit BT41-84 |
| 301739 | Shovelhead Lifter base chrome cover set |
| 301833 | Chrome slip-on cam cover plain BT74-99 |
| 301877 | Slotted Frame covers for Softail models |
| 301888 | Transmission shift lever cover chrome 85-up |
| 302231 | Chrome 6-speed kick starter kit |
| 752098 – 752099 | S&S Cams w/Gears 625G FXD06 TC07-up / 640G FXD06 TC07-u |
| 345127 | Mounting kit for Fat Bob tanks |
| 345287 | Front Mount assembly Sprtster tank 011308 |
| 361570 | FXR/FLSTC Adjustable foot peg mount |
| 370252 – 370253 | Pull-Start system BT65-88 polished/Chrome |
| 370314 | Mini push button switch 5/16 UNF |
| 700645 | Oil Thermostat |
| 700853 | Zodiac 6-speed Builders kit |
| 700879 | 12mm offset kit FLH/T00-06 |
| 700942 | Complete 250 Swingarm kit Evo Softail |
| 700978 | Complete 280 Swingarm kit Evo Softail |
| 701120 | 55mm Primary offset kit BT94-06 5-speed |
| 701152 | Pro Clutch 1984 -1989 Big Twin |
| 701154 | Pro Clutch 1998 -1999 Big Twin & 1999 – 2006 Twin Cam exept 2006 FXD |
| 701240 – 701241 | PosiLock in-line conector 0.2 – 1.0 – 2.5 mm |
| 701244 – 701245 | PosiTap tap-conectors 0.2 – 1.0 – 2.5 mm |
| 701248 | 25 pack Posi Twist connectors 0.2 – 1.0 mm |
| 701251 | PosiTwist non-inline connectors assortment |
| 701254 – 701255 | PosiSeal weaterpr.inline connectors 2.5 – 4.0 – 3.5 – 5 mm |
| 701258 – 701259 | PosiFuse Fuseholder + connector bl./round fuses |
| 701950 | 25 mm Primary kit TC07-11, FXD06-11 |
| 702020 | Trick Box AES open/close/override module |
| 702024 | Ignition Coil TC99-06 XL04-06 carburated |
| 710370 – 710371 | MMB 48 mm electronic mini speedo kmh black/white |
| 710414 – 710415 | MW Handlebar mount Digital Speedo |
| 710418 – 710419 | MW Digital Speedo bracket for 3-3/4″ Tacho – 3.75″ Tacho |
| 710422 – 710423 | MW Handlebar clamp w/Digital Speedo |
| 711596 | Lowering kit FLH/T02-08, not for FLHX/RS |
| 711803 | MSD Pulse Ignition |
| 711994 | Auto Tune kit for use w/PowerCommanderV |
| 712016 | Dynojet Power Vision |
| 712102 – 712103 | TPP VP Clutch 92T BT98-up H.Perf. / VPC 70T BT98-06 + High Perf. spring |
| 712106 – 712107 | TPP VPC-EVO BT90-97 with 190/240 lbs spring |
| 712110 – 712111 | TPP VPC 1200XL91-03 190 lbs spring / TPP VPC High Perf. XL91-03 240 lbs spring |
| 712113 | TPP VP BDL cluch for EVO and EVB series |
| 720485 | Camshaft remove & install Tool TC8 |
| 721720 | Pro Clutch – Sportster & Buell |
| 721891 | Oil themostat TwinCam 1999 – 2000 |
| 722005 | Switch Relay unit-headlight |
| 722077 | Super Ass Swing arm kit F*ST00-07 |
| 722234 | Fat Bubba upper fork Tube covers |
| 722660 | LCD Rockerbox Left m Speedo 84-99 polish |
| 730603 | Dynatek DSPT-1 ignition XL04-up |
| 731466 | Rectangular Adj. Mini Speedometer KPH |
| 731476 – 731477 | Retangular Oil temperature gauge 0-400 F / 0-200 C |
| 731494 – 731495 | Round Digital Speedometer 3-3/8″KPH / KPH+MPH |
| 731497 – 731498 | Round Oil Temperature gauge2-1/16″ C+F / 0-400F |
| 731500 | Round Digital Voltmeter |
| 731512 | Black Voltage Reg. XL/1200 2 Brush gen. |
| 731556 | Electronic Ignition System XL71-78 |
| 731919 | Wire + Motor mount wiring system w/autoca |
| 732053 | Information Brochure – Parallel Diagnostics |
| 733007 | Supertrapp V-5 2:1 slip-on VRSCA/B02-06 |
| 734408 – 734409 | CCCS Cooling Stabilizer CLR/BLK FLH/FLT99-08 |
| 736095 | S&S electric compression release valves |
| 740577 | Cont. 3 switch hsng black hyf/clutch L/H |
| 741203 – 741204 | Hitachi type starter 1.4 KW Black/Chrome |
| 741205 – 741206 | Prestolite type starter 1.4 KW Black/Chrome |
| 741225 | TPD SuperPump Oil Pump TwinCam 99-06 |
| 741236 | Müller Power Clutch XL86-93 |
| 741341 | Spyke Firstrike compr. release Shovel |
| 741393 | TFI module GEN III all TC96 models 07-up |
| 741469 | Transmission Speedo adapter no plug |
| 741690 | Zodiac TOP FI Module BT95-98 TC99-05 |
| 741692 | Zodiac TOP FI Module F*STC07-11 FXD07-11 FLH/07 |
| 741694 | Zodiac TOP FI Module XL07-up |
| 741696 | Zodiac TOP FI Module VRSC08-11 |
| 741717 | Zodiac TOP Module F*ST12-up FXD12-up |
| 743400 | Reverse Kit for 5-Speed Big Twin models |
| 743401 | Reverse gear kit 2006 to present Dyna, 2007 to present Softail and 2007 thru 2008 Touring |
| 743407 | Reverse gear kit 2014 to present Touring. Models with OEM or Screamin’ Eagle hydraulic clutch require additional parts kits ZPN 743403 and ZPN 743406 |
| 744240 – 744241 | PanCruise KompressorSuspension F*ST84-99 / F*ST00-up |
| 744266 | Dakota Digital Info Center 04-up Red |
| 744602 | Ohlins fork leg set Stock Softail lenght |
| 749502 | Installation instruction Mini (Headlight) Switch-relay |
| 749510 | Installation manual of the Rear Light US |
| 750040 | S&S Powerkit ignition inst. kit SSW Plus Engines |
| 750054 | S&S HVHP Oil pump kit universal cover |
| 750577 | S&S Powerkit ignition inst. kit TC04-05 |
| 750689 | Roller chain upgrade kit TC88 99-01 |
| 751540 – 751541 | S&S EZstart Chain Drive 551 cams BT07-up / 570 cams BT07-up |
| 751544 – 751545 | S&S EZstart Chain Drive 625 cams BT07-up / 640 cams BT07-up |
| 751548 – 751549 | S&S Easy start Gear Drive 583 cams 07-up / 585 cams 07-up |
| 751552 | S&S Easy start Gear Drive 675 cams 07-up |
| 751555 – 751556 | S&S Easy start Gear Drive 583 cams BT99-06 / 585 cams BT99-06 |
| 751559 | S&S Easy start Gear Drive 675 cams BT99-06 |
| 752090 – 752091 | S&S Cams w/Gear Kit 570G TC99-06 / 585G TC99-06 ex FXD06 |
| 752094 | S&S Cams w/Gear Kit 675G TC99-06 |
| 752096 – 752097 | S&S Cams w/Gears 570G FXD06 TC07-up / 585G FXD06 TC07-up |