Honda XR 400 Removal and Installation Manual

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Filed Under (Honda) by admin on 09-12-2011

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Turn Signal Switch Installation Front Wiring Connections Field Effect Transistor Installation Taillight Installation: Install the Acerbis DOT taillight over the empty well left in the stock fender using the two 5 x 20 mm bolts and 6 x 16 mm bolt found in the parts bag. Position the taillight over the previous taillight mounting well and transfer the hole locations for the top mounting holes onto the fender with a felt pen or snap punch (Photo 3) so that they are 3/8 of an inch above the edge of the taillight opening as shown in Photo 3. Drill two 3/16 inch holes for the top mounts. Attach the taillight using the top mounting screws, then pull the license plate holder down toward the bottom of the fender so that the taillight is pulled as horizontal as possible. Transfer drill a 1/4” hole at the bottom mounting location with the taillight in this position. When installing the bottom license plate mount bolt, make sure to install the 6 x 16 mm bolt from the bottom up to minimize the opportunity for the tire to grab it. Run the taillight
wires along the left frame rail using the stock wire clamps to support it. 8. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean,
durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5, 3-3/4 inches back from the front edge (pointed tip of fender where it meets the side panel) and 2-3/4 “ up from the bottom edge Brake Light Switch Installation

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2000-2001 Honda CBR 929 RR Power Commander installation

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Filed Under (Honda) by admin on 09-12-2011

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Remove the main seat. 2) Open the passenger seat hatch. 3) Remove the fuel tank mounting bolts. NOTE: The fuel tank does not need to be removed in order to install the PCII. If you choose to remove the fuel tank to aid in the installa- tion, then all fuel must be drained prior to disconnecting the fuel lines. 4) Locate the main injector harness connector. It is on the right side of the chassis near the fuel hose fitting on the throttle bodies. 5) Disconnect the injector harness connector. 6) Plug the male connector from the PCIIIr into the female connectorm on the main harness (Fig. A). 7) Plug the female connector from the PCIIIr into the male connector from the stock injector harness (Fig. B). 8) Locate the small, red, 2 pin connector (Fig. C) from the crank position sensor. Match the corresponding connectors from the PCIIIr, in-line of the stock wiring harness (Fig. D). 9)Route the harness from the PCIIIr under the fuel tank towards the tail section. 10) Reinstall the fuel tank, make sure not to pinch the PCIIIr harness. 11) Attach the ground wire from the PCIIr to the negative terminal of the battery. (Fig. E) 12) Route the PCIIIr and wiring under the rear seat subframe. Attach to inner fender below passenger seat using supplied velcro (Fig. F). 13) Reinstall the main seat

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2002-2007 HONDA VFR 800 NSTALLING GALFER BRAKE LINE KIT

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Filed Under (Honda) by admin on 08-12-2011

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Remove the clutch fluid from the master cylinder on the left clip-on. Remove the fluid from the clutch line and slave cylinder. This factory line is NOT attached along the inner frame spar so here is a little trick that made this a 20- minute job including the bleed: 1. Remove the banjo bolts from the master cylinder and the clutch slave ends. 2. With a nice heavy wire tie, attach the slave end of the new braided line to the lever end of the factory line. Snip off the tail of the wire tie. Wrap this “joint” with electrical tape. 3. Pull from the factory slave end until you get the braided line end to the clutch slave. If it gets caught on something, try turning the end you are pulling
from.4. Remove the tape, carefully cut off the wire tie, install new sealing washers and bolts at both ends and torque to 17-21 foot/lbs. maximum. Bleed the clutch

HONDA BRAVO Engine Owner and INSTALLATON

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Filed Under (Honda) by admin on 08-12-2011

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The focus of this manual is HOW to operate and service the equipment safely. It is not possible to cover every con-
ceivable situation you can face when using this mower. Therefore use this product only in a manner described in
this manual. Operation or handling the machine in any other manner can lead to serious injury or death. if a
situation is not described in this manual it should be considered dangerous ~ and not be done. If you are unfamiliar with this product make sure that you carefully understand how it functions and practice all operations and handling before putting the machine to use. Familiarize yourself in the presence of an experienced operator. Avoid all situations that are beyond your capability. If you still feel uncertain about the operating procedures after reading these instructions DO NOT operate the machine until you have consulted an experienced operator

Honda Shadow Backrest Kit Installation Manual

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Filed Under (Honda) by admin on 07-12-2011

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Install the right and left brackets, leave screws loose to allow brackets some movement for ease of backrest installation. Install the ackrest as shown, if optional carrier is also purchased, use the longer flange bolts provided. Note the backrest goes inside of the brackets, and carrier rack (optional) will go outside of the brackets when installed. Tighten all nuts and bolts to the torques specified

HONDA VTX 1300 Retro BIG SHOTS EXHAUST SYSTEM INSTALLATION

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Filed Under (Honda) by admin on 07-12-2011

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Check condition of stock exhaust gaskets. Replace if damaged or worn. 2. Install and tighten supplied mounting bracket (stamped
346-P) in the original mounting bar location, using two M10x40 flange bolts, nuts, and washers (supplied) (Figure 1). 3. Install and tighten rectifier using M6x30 flange bolt, nut, and washer combinations (supplied)(Figure 1). 4. Place heat shields on a non-abrasive surface such as a blanket or carpet. Using a felt tip marker, mark the outside surface of front and rear heat shields with the location of the mounting clips welded inside(Figure 2). 5. Install each heat shield over its respective head pipe (Figure 3). 6. Install each hose clamp by feeding tail end of clamp into heat shield clip. Take note of clamp screw head direction (Figure 2 & 4). Screw head should be ccessible when system is installed on motorcycle for adjustment purposes. Use #20 hose clamps for head pipe areas and #28 hose clamps for muffler areas. Note: Prior to tightening hose clamps, align end caps so that slash ends are even.

HONDA XR 250 1996 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 06-12-2011

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, side panels, radiator shrouds, and gas tank.
If you are color blind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 3. Unplug the green and blue taillight wires from the stock wiring harness, remove the taillight lens, and remove the taillight socket and wiring. 4. Unplug the headlight from the stock wiring harness and remove. 5. Remove the kill switch. Unplug the black/white wire and the black wire from the connector near the base of the odometer. AC Regulator Unplug taillight here Photo 1 6. Locate the AC voltage regulator found mounted on the front top edge of the airbox as shown in Photo 1. Unplug the regulator from the wiring harness and remove regulator (Leave the U-bolt
attached to the airbox and save the bolt for a later step)

HONDA CB 90O C CYLINDER HEAD PISTON REMOVAL and INSTALLATION

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Filed Under (Honda) by admin on 05-12-2011

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108 CYLINDER/PISTON PISTON/PISTON RING INSPEC- TION I Inspect the piston ring-to-groove clearance. NOTE Mark the rings so that they can be returned to their original locations. Inspect the pistons for damage and cracks; ring grooves for wear. Insert each piston ring into the cylinder, and inspect the end gap

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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2007-2008 HONDA CBR 600RR DUAL CANISTER SLIP- ON INSTALLATION

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Filed Under (Honda) by admin on 04-12-2011

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INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR CENTERSTAND OR SERVICE TABLE. 3. REMOVE BOTH THE FRONT AND REAR SEATS. 4. REMOVE THE 4 BOLTS HOLDING THE TAIL
FAIRING TO THE SUBFRAME AND REMOVE THE TAIL FAIRING. REMOVE 5. REMOVE TRIM PLASTIC JUST ABOVE RIGHT SIDE FOOTPEG. (REMOVE THE ONE BOLT AND UNCLIP) TRIM PLASTIC UNCLIP REMOVE 6. REMOVE LOWER FOOT PEG BRACKET AND REMOVE THE HEAT SHIELD BOLT. ALLOW THE FOOT PEG BRACKET TO HANG BY THE HOSE AND WIRES

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