KAWASAKI Undertail Installation AND Removal instructions

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Filed Under (Kawasaki) by admin on 26-04-2012

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1- MASKING TAPE 2- DRILL 3- PHILLIPS SCREWDRIVER 4- HAND SAW BLADE OR DREMMEL 5- DRILL BIT # 3/16 (TABS – AREA NEAR LENSES ) 6- DRILL BIT # 15/64 (NYLON SCREW RIVETS FOR THE BACK) 7- ELECTRIC TAPE WHAT COMES WITH THIS UNDERTAIL? 2 RED LED BULBS 2 SCREWS REMOVE THE REAR SECTION OF THE BODY There are plastic body connectors as well as bolts inside the tail in addition to the Allen-head bolts on the outside surface. NOTE: KEEP YOUR STOCK RIVETS FOR LATER USE. REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT

KAWASAKI 1500 9408 PRO HYPERCHARGER INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 26-04-2012

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STEP 1 Remove the seat STEP 2 Disconnect the battery positive cable to prevent sparking that could cause ignition of spilled fuel, and personal injury. STEP 3 Remove the fuel tank. IMPORTANT- Throughout this installation, we strongly recommend labeling all hoses, and the nipples they were removed from. STEP 4 Remove the intake ductwork, air inlet, right and left air cleaner housings, air cleaner, cold start components (see PIC. 1), air mass sensor, and support bracketry. The wires that were unplugged from the cold start solenoids, may be neatly bundled and tucked out of harms way and out of sight. Be sure the terminals are insulated so they cannot short to any surrounding parts. Insert plugs (3/8″ x 1/2″ socket head bolts work well) into the two hoses that connected to the cold start circuit lines. (See PIC.2.) Also unplug the crankcase breather hose from the right angle fitting at the bottom of this enclosure, and the large diameter hose from the fresh air injection valve. (Don’t forget to label.) The fuel drain hose will not be re-used. PIC.3 shows what you’ll have left when all components are removed. STEP 5 From the hardware kit, find the front and rear support tabs and the four M6 x 1.0 x 16mm socket head cap screws. Install the support tabs to the threaded holes in each cylinder, and to the holes in the throttle body as shown in PIC.4. STEP 6 From the hardware kit, find the M6 x 1.0 x 16mm hex bolt and lock tab washer. Also find the intake gasket (oval shape with two large holes) and the manifold adapter body. See PIC.5. Screw the air temperature sensor into the back of the manifold adapter body. Place the intake gasket over the mouth of the throttle body so all holes line up. Insert the M6 hex bolt through the lock tab washer, and secure the adapter body to the throttle body, again making certain all holes line up perfectly. Tighten the hex bolt, but do not bend the lock tabs yet

Kawasaki Vulcan 900 Installation and Removal Manual

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Filed Under (Kawasaki) by admin on 25-04-2012

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1) Place motorcycle on its side stand on a firm level surface. 2) Remove saddlebags if applicable 3) Attach bracket C (left side) and bracket D (right side) to rearmost fender attachment bolt. A) If bike has no saddlebags use 3/8 spacer between bracket and motorcycle. Use new bolt provided. B) If bike has stock saddlebags use enclosed threaded rod assembly. 1) Thread rod into rear bag/fender mount 2) Place 3/8 spacer and bracket onto rod 3) Tighten down with locknut ensure locknut and rod are tight 4) Replace bags on rod and tighten NO BAGS STOCK BAGS
4) Remove rear riders pegs and attach front of bracket A(left side) and bracket B (right side) to rear foot peg mounting point. Mount foot peg to outside of bracket. Use new bolts provided. 6) Attach brackets C/D to top of rear hitch plate. 7) Attach rear of brackets A and B to TOP of hitch arms 8) Ensure hitch is square on motorcycle and tighten all bolts

Harley Davidson Honing Plates Installation Manual

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Filed Under (Harley Davidson) by admin on 25-04-2012

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Honing Plate Kits are available for the Harley Davidson Shovel Head, Evolution and Twin-Cam engines. Kits are supplied with a Base Plate, which features side clamping of the spigot area on the Jug to address the recurring problem of spigot deflection during honing. This is especially prevalent in large-bore applications and will eliminate additional clearance that would be necessary to achieve correct piston to cylinder wall clearance. The Plate allows the user to hone straight, round bores through the full length of the Jug. The Plate also has tapped holes in the bottom surface to facilitate clamping onto most honing machines. The Shovel/Evolution Kit is supplied with the above Base Plate machined with a dual bolt pattern to accept both Shovel Head and Evolution Jugs. Two Honing Plates are included, to accommodate each engine type. A Hardware Kit containing all the fasteners needed to simulate the assembled engine condition for both setups is also included. The Twin-Cam Kit is supplied with the above Base Plate machined with the bolt pattern to accept the Twin-Cam Jug and one Honing Plate. A Hardware Kit containing all the fasteners needed to simulate the assembled engine condition is also included.

Harley-Davidson Standard Seat Installation Instructions

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Filed Under (Harley Davidson) by admin on 24-04-2012

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Step 1 – Remove the original seat and place it bottom side up next to your new custom replacement seat. Step 2 – Remove each bracket from your original seat and install it in the corresponding location on your new seat, using the 1/4-20 bolts provided. Place the new bolts through the brackets and into the threaded jacknuts in the new seat bottom. Repeat until all hardware is transferred. Step 3 – Check all fasteners for tightness, 10-15 ft/lbs is recommended, do not over-tighten. Step 4 – Remove rubber bumpers from your original seat and move them to your new custom seat. In some instances we have already installed bumpers that are needed, but some models require the special specific bumpers from your original seat for proper tolerance and fit. The stock bumpers are easily removed by twisting and pulling at the same time. Reinstallation requires drilling a hole of the same diameter as the original into the new seat pan. Rubber bumpers are most easily installed using either water or silicone spray as a lubricant.
Step 5 – Reinstall the seat on the motorcycle. Check to make sure the seat fits properly. The new seat will be more firm than the original seat and will break-in over time to provide greater comfort. During the break-in, the seat will also settle-in, or lower, about ½ to one inch. Older seats may seem substantially lower because of the worn-out, compressed foam that has deteriorated with time on your original seat

Harley-Davidson CUSTOM FIT SADDLEBAG INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 24-04-2012

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INSTALLATION INSTRUCTIONS 1. It is anticipated that the smooth back side of the bags will be drilled to facilitate mounting, and that you will fabricate mounting brackets, spacers or supports. Mounting bolts with then pass thru the bags and, using the supplied fender washers, be secured to either your fabricated brackets, fender or fender struts. Most installations utilize the fender struts and their fender mounting locations for connecting the saddlebags to the motorcycle. Other locations can also include turn signal or top shock mounting points. Mount points should be as far apart as possible and use the fender washers supplied to provide a stable mount base and spread the mounting load and stress over the largest area possible. The bags can also be mounted utilizing aftermarket saddlebag support brackets and securely attaching the saddlebags to these brackets. 2. The saddlebags must be securely mounted to the motorcycle so that they can support any load that you intend to carry (less than 10 pounds per side) and so the bags clear all moving or suspension components thru the full suspension travel, even when the bags are fully loaded. Be expecially careful that the cantilevered bottom inside edge of the bag, and all other surfaces, clear all components such as shocks, swingarm, brake calipers, brake rods and lines, chain guard, etc. after installation. 3. Inspect the bags immediately after first use to determine that the bags are not interfereing with moving components. Inspect weekly thereafter to be certain that the bags are not contacting moving parts and that the bags are not developing cracks as a result of inadequate mounting support. 4. If the installed bags obstruct the original factory supplied side reflectors, please contact Saddlemen to purchase self-adhesive reflectors, which must be installed where they are clearly visible from the side of the motorcycle. LOCKABLE BUCKLES FEATUREDrifter and Desperado models feature leather straps with hidden lockable buckles. Once locked, bags cannot be opened. Cruis’n models feature lockable twistlocks, with small padlocks included.

Harley-Davidson Electronic Ignition Module Installation instructions

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Filed Under (Harley Davidson) by admin on 23-04-2012

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Step 1: Switch main dashboard switch to “off” position (Ignition& light switch) Step 2: Disconnect negative (ground) cable from the Battery Step 3: Remove the Condenser and Breaker points from the circuit breaker timing base. Step 4: Disconnect advance/ retard cable from timing base Step 5: Remove timing base from timer shaft and housing (see your manual for instructions) Step 6: Remove circuit breaker wire stud or circuit breaker to coil wire assembly from timing base Step 7: Remove circuit breaker wire from Ignition coil, and mark terminal on coil with piece of tape. Step 8: Install the Electronic Ignition Module on the timing base. Mount this short black wire to one on the timer base screws by keeping some slack in this wire so the timing base can turn free. Solder the flag terminal to this short black wire and mount it under the timer to motor bolt. This way of mounting provides a much better grounding. Do NOT use the screws (number 1 or 2 screws from picture below) from the timing base!!!! Step 9: Now three wires pass this hole via the rubber grommet. Figure 1 Figure 2 Step 10: Reinstall the timer base on the timer shaft housing, and keep some slack in the wires before protruding the hole in the timer shaft housing, and secure with ground spring and cover retainer. Reconnect the advance/retard cable to the timer base. Step 11: Route the two long wires to the ignition coil. Check in the HD service manual for a proper route to the ignition coil. (Keep away from hot surfaces like exhaust systems). Cut the wires to the exact length necessary for mounting. Step 12: Determine the exact length of the wire loom. Keep in mind that one end of the loom enters the timer shaft housing by 1cm. Cut the loom to the proper length. Step 13: Insert both wires in the loom. Strip both wire ends and solder the two flag terminals on the wires. Step 14: Connect the red wire to the ignition coil, on the terminal where the 6 or 12 volt is supplied to. This terminal has at minimum one wire connected which runs to the main switch. Step 15: Connect the black wire to the ignition coil on the terminal which is empty, and has piece of tape on it. (Old place where the circuit breaker wire was connected to) Step 16: Install the trigger rotor on the timer shaft cam, and tighten the hex screw by using the hex key tool. Do not over tighten the screw! Step 17: Check for clearance between trigger rotor and Electronic Ignition Module. Appropriate clearance is between 0,5mm and 1,5mm . Minor adjustments can be made by unlocking the two screws and slightly shift/move the Electronic Ignition Module. Check if the rotor moves free. Timing instructions: Remove the spark plugs from the engine, but keep them connected to the spark coil cables and engine ground. This enables normal operation of the spark, and prevents unwanted engine firing on compression stroke. See service manual or handbook for timing instructions of your model Step 18: Reconnect the negative (ground) cable to the battery. Step 19: Switch main power to “on” position. The red light in the Electronic Ignition Module might already light up. If not, turn the kick starter slowly. The red light is on while charging (closed points)the Ignition coil, facing solid metal of the trigger rotor. The light goes off (open points) when the end of the solid surface of the trigger rotor passes the centre of the Electronic Ignition Module. At that point a spark is generated by the coil

HARLEY DAVIDSON ULTRA CLASSIC AND ELECTRA GLIDE CLASSIC TOUR PACK ADJUSTMENT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-04-2012

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1. Open the Tour Pack and remove all of the contents. 2. Remove map bag and inner pack liner. Pack liner comes out quite easily once map bag is removed. 3. Remove the 4 bolts inside the tour pack that are located on top of the metal support plate that hold the tour pack to the luggage rack. Have your assistant hold the pack in place before removing the last bolt. 4. Gently tip the tour pack forward to expose the supporting luggage rack under the pack. 5. While your assistant holds the pack up, place the two adjusting bars on top of the supporting luggage rack. Use the 4 flat head screws supplied with the kit to mount the bars snugly to the support rack (see fig. 1). 6. Reposition the tour pack over the threaded holes in the adjusting bars at the 2″ or 3″ position and bolt it in place snugly (see fig. 2). 7. Replace the trunk liner and map case and the installation is complete

HARLEY DAVIDSON EDITION F 150 LIGHTNING HIGH PERFORMANCE INTAKE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 22-04-2012

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Turn off ignition and remove negative battery connection. 2. Loosen the hose clamp on the OEM intake. 3. Disconnect the MAF sensor off intake 4. Pull out air temp sensor and then pull out intake unit. 5. Install NPT hose barbs in the cold air intake with the 1/4″ in the center position. 9.Connect the hoses to the S&B intake tube 6. Put the 4.5x2hose adapter with #72 hose clamps on the S&B tube . 10. Install the S&B intake on the throttle body, push the air temp sensor into the tube 7. Locate the three vacuum hoses 11. Remove the air box grommets and use the 1/4″-20″ speed nuts 8. Place the small sections of 5/8″ hose on the vacuum hoses. 12. Install the hose adapter onto the MAF sensor assembly

Harley-Davidson feuling Adjustable Pushrods Installation Instructions

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Filed Under (Harley Davidson) by admin on 22-04-2012

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1. Refer to the proper factory service manual for your model and year of engine, for removal of existing pushrods. 2. The Feuling pushrods are designed with a small adjustment parameter for rigidity creating maximum lift – These are not quick install pushrods and may require the removal of the lifter blocks and or loosing of the breathers/rocker arms supports. When loosening the rocker arm supports always remove the breather bolts first. 3. Clean and inspect each new Feuling pushrod including center oil hole 4. Feuling pushrods are marked Intake and Exhaust. The shorter pushrods are Intake and the longer pushrods Exhaust 5. Feuling recommends using new O-rings and gaskets where applicable to prevent oil leaks
6. Always pump up hydraulic lifters before installing them. Use an oil squirt can to fill the lifter with oil through the feed hole on the side of the lifter, push oil through the feed hole until the air bubbles are gone. If needed work the oil back and forth through the feed hole and pushrod seat with the squirt can. Light weight oil can be helpful. 7. Assemble and adjust one cylinder at a time, the servicing cylinder needs to be on TDC of compression stroke so the cam lobes are at their lowest point 8. Install pushrods into proper locations with the adjusting side of the pushrod down, towards the lifter. Slide the pushrods through the pushrod covers up into the rocker housing and set the pushrod on the seat of the lifter. We recommend filling the pushrods with oil then maneuver the pushrod up into the rocker arm seat. 9. Torque rocker arm housings and breathers to factory torque spec’s 10. See the instructions for your lifters for the proper adjustment. All Feuling hydraulic lifters run best at . 090″ – . 100″ of crush.