150cc buggy reverse cable installation instructions

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HARLEY DAVIDSON DIAMONDBACK “LE” CHROME SERIES CLUTCH CABLE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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CLUTCH CABLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery or main fuse following the instructions in the appropriate Service manual. 2. When performing cable disassembly procedures, make careful notes as to the existing cable routing and existing cable strap locations. New straps can be installed in the same locations. 3. Remove the clutch cable following the instructions in the appropriate Service Manual. 4. If installing different handlebars, install them now (refer to the appropriate handlebar instruction sheet) and measure the change in distance that will be required from the end of the cable housing to the clutch lever. Install proper length clutch cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00448b) 5. Compare the additional required length to the cable provided in your kit. If the cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. CLUTCH CABLE INSTALLATION Sportster and Softail Models Do not over-tighten clutch cable threaded end fitting. Use recommended torque values. Damage to threaded fitting can lead to loss of transmission fluid, which could result in loss of control and death or serious injury. (00449c) -J04568
NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. 1. See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing the O-ring onto the threaded portion of the clutch cable end. 2. Install the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). 3. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet. FLTR Models with Fairing Lowers 1. See Figure 1. Carefully twist the clutch cable around the coiled opening in the clutch cable guide (2) with the eyelet toward the left handlebar. 2. Route the clutch cable assembly down from the clutch cable clamp while crossing to the right side of the vehicle. Run the cable between the inboard side of the right frame downtube and the outboard side of the voltage regulator. 3. The clutch cable clamp, mounted on the engine guard, has two fingers, an upper and a lower. Feed the cable assembly under one finger and over the other. 4. Finish the installation of the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). NOTE See Figure 2. Adjust the clutch cable clamp to 2.25 ± 0.25 in. (57.15 ± 6.35 mm) as measured from the inside lower left fairing mount to the clutch cable clamp. 5. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet.

HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 4. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

Yamaha XV-1900 Braided Stainless Steel Thottle Cables Installation Instructions

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Filed Under (Yamaha) by admin on 30-12-2011

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Please read and understand these instructions completely before installation to avoid injury or damage to the motorcycle or accessory. IMPORTANT: Dealer installation is recommended. The installer should have the service manual for the motorcycle , as well as a good understanding of motorcycle service and repair techniques. Dealer: These instructions contain important information for future reference and must be given to the customer. 1. Parts List: Item Part Name Part Number Description Qty 1 Throttle Cable Set 07-1083 1 2. Preparation: a) Before installation, lubricate cable with an appropriate cable lube such as Motion Pro Cable Lubricant (P/N 15-0002) b) Securely place motorcycle on side stand 3. Installation: Refer to vehicle service manual for installation instruction and adjustment procedures. NOTE: Notice how original cable routed before removing it. Install the accessory cable in the same way. If unsure or original cable routing, refer to the cable routing diagram in the service manual. WARNING ∞ Before starting the engine, be sure the throttle operates smoothly and check that throttle body is fully closed when throttle is released ∞ After starting the engine, turn the handlebar to the right and to the left to be sure the throttle operation is not affected ∞ Improper installation could result in great bodily injury or death 4. Maintenance: Check throttle operation before each ride. Follow Periodic Maintenance procedures in the owner’s manual for adjustment and lubrication. 5. Care and Cleaning: See your Owner’s Manual