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…

LEGGERE DI PUI

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

  1. 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.
  2. 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 232020) 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