2002 honda shadow 1100 spirit coolant hose

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Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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HONDA VTX1300 AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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1. Remove the rider and passenger seats, left chrome side cover & original horn located at the top of the radiator. 2. Locate the supplied black horn mounting bracket and supplied smaller hose clamp. Notice the slight twist in the bracket. Using 2 adjustable wrenches or a vise and one wrench remove the twist from the bracket. Route the hose clamp thru the bracket. (As shown in photo 1A) 3. Install the bracket on to the left frame tube, (As shown in photo 1A) and tighten securely. Bolt the supplied horns to the bracket using the supplied bolt, lock washer and nut, (As shown in photo 1) and tighten securely. Install the supplied trumpet covers (As shown in photo 1B) by flexing the spring clips over the trumpets. Check that they fit securely. If not remove covers, make sure the center screw is tight and bend spring clips in towards center of covers and re-install. Using a blade screwdriver pry the two supplied hoses with the “Y” connector off of the air horns cut a new piece of hose 3 ½” long from the hose and replace the short hose on the “Y”. Re-install the “Y” hose assembly with the short hose going on the long or upper trumpet. (See photo 1C) Re-route the original horn wires. (As shown in photo 1D) 4. From the supplied wire cut 2 pieces 28″ long. Strip ¼” of insulation from both ends. Crimp 2 supplied male terminals to one end and 2 supplied female spade terminals to the other end. Plug the male ends into the original horns wires. (As shown in 1D) Attach the remaining air hose to the “Y”. Tape the hose and wires together every 6-8″ using electrical tape to make routing easier and neater. Route the wires and hose up under the fuel tank, over the cylinder heads coming out between the frame rails at the rear of the fuel tank. (See photo 2A) Locate the supplied relay and plug the 2 wires from the original horn onto terminals 85 & 86 on the relay. (See wiring diagram on back of last page of instructions) This will be the 2 outer terminals that are parallel to each other. Locate the supplied fuse, holder & wire assembly. Crimp a supplied fork terminal to one end and a supplied female spade to the other. Attach the spade terminal to one of the remaining outer relay terminals. (#30 or 87 on wiring diagram) Remove the 3 Phillips screws from the battery top cover. Remove the cover and attach the fork end of the fuse wire to the positive (+) terminal. Re-install the battery cover. 5. Cut a wire 9″ long and strip ¼” insulation from each end, crimp a fork to one end and a female spade to the other. Attach this wire to the compressors negative (-) terminal. Cut another wire 18″ long and strip both ends. Crimp a female spade to both ends. Attach this wire to the compressor positive (+) terminal. Route the air hose out under the left side cover as shown in photo (3). Hold the compressor in place against the frame tube. Note: Looking at the large end of the compressor the space between the hose fitting and the bolt mounting flange forms a “V” shape. This is where the compressor should rest against the frame. Next loop the hose around to the compressor hose fitting and trim the hose to the desired length. Attach the hose to the compressor. Secure the compressor to the frame using 2 large supplied cable ties as shown. 6. (See photo 3A) Attach the compressor negative (-) wire to the bolt on the frame (As shown in photo 3B) Route the compressor positive (+) wire along the side up to the relay and attach to the remaining outer terminal 87 or 30. Cable tie the relay in place. (As shown in photo 2B) Use several of the supplied short cable ties to secure the compressor wires to the air hose (As shown in photo 3) as wells as any other loose wire or hose.

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Honda Shadow A.C.E. v. Yamaha V-Star 1100 Middleweight Import Cruiser Shootout

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Filed Under (Tips and Review) by admin on 25-11-2010

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You want a big cruiser but you don’t need a large 1500 cc behemoth that weighs close to half-a-ton fully loaded. You want something you can cruise down the boulevard on but you want to be able to handle a corner or two. You want classic styling but you insist on reliability as well. If these are your guidelines, then Honda and Yamaha might have what you’re looking for in the guise of the Honda Shadow American Classic Edition and Yamaha V-Star 1100. Shadow ACE 1100 The ACE and V-Star have a few things in common: Both sport requisite V-twin powerplants (75° for the V-Star and 45° for the ACE) and both possess typical Japanese refinement. Aside from these similarities, the two rides are very different machines. While both machines are shaft driven, the ACE uses the shaft housing as the swingarm. Although this arrangement is effective, it’s a bit lacking style-wise. However, the whitewall tires and the classic fenders and tank help to create a traditional design that turns heads when you’re out and about. The V-Star uses a different approach, utilizing a pivoting sub-frame design with a hidden mono-shock that keeps the lines fluid and consistent with the rest of the bike. Although this beast isn’t equipped with whitewall tires, it still cuts a graceful, glittering profile. The only flaw we noticed was the small headlight that

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HONDA VTX 1800 AIR HORNS AHVTX INSTALATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-12-2010

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1. Remove the right and left frame side covers and the seat. 2. Unplug and remove the stock horn located behind the left foot peg. Re-route the horn wires up over the front cylinder head and to the rear. Next cut two pieces of wire 36″ long, strip both ends ¼”, crimp two male spade terminals to one end and two females to the other ends. Attach these wires to the stock horn wires and route them over the rear cylinder and behind the frame tube. The end of the wires should come out near the center of the left side cover area (see photo 1 A). Connect these two wires to the relay terminals 85 & 86 (these will be the two that are parallel to each other see wiring diagram for terminal identification). 3. Using a blade screwdriver pry the two hoses with the “Y” connector off of the air horns. Cut a new piece of hose 2 ¾” long, replace the old short hose on the “Y” with this. Re-install the “Y” hose assembly onto the horns with the short hose on the long trumpet, route the hoses behind the horns and connect the long hose to the short horn (see photo 2A). 4. Remove the upper 8mm (12mm wrench size) motor mount bolt (see photo 2B). Install the horn assembly using the 8 x 55mm bolt and spacer tube provided. If the motorcycle is fitted with Honda line tubular radiator or engine guards the above mounting will not work. You will need instead to locate the “J” shaped bracket and small hose clamp provided in the hardware kit (see photo 2 on instructions of multi -application instruction sheet). Thread the hose clamp thru the bracket and attach to the frame or Honda line guards as shown ( see photos 2&3 ) tighten the hose clamp securely using a socket or wrench. Attach the horn set to the “J” bracket using the 5/16 x ¾” bolt, nut and lock washer provided. Position the horns so that they are angled down just slightly then tighten the bolt securely. Attach the remaining air hose to the “Y” connector, route the hose up over the top and to the rear of the engine. Cross the hose over to the right side of the rear cylinder head, then behind the electricals of the right side cover and coming out as shown ( see photo 3 A & B ). 5. Remove the center relay from its mounting bracket by lifting it upward and re-attach it lower and at an angle as shown (see photo 3C) using a small cable tie. Route two long cable ties thru the hole in the relay mounting bracket as shown (see photo 3D). Next cut a 16″ wire, strip both ends, crimp female spades to both ends. Attach this wire to the compressors pos (+) terminal. Cut an 8″ wire, strip both ends, crimp a female spade to one end and a fork terminal to the other. Attach this wire to the compressors neg. (-) terminal. Cable tie the compressor securely in place as shown (see photo 4). Route the hose to the compressor making sure there are no tight bends or kinks cut the hose to the desired length and attach it to the compressor. Route the neg. (-) wire with the fork terminal up and attach it to the 10 mm bolt as shown (see photo 4A) . Route the pos. (+) wire over to the relay on the left side of the motorcycle and attach it to terminal 30 or 87 on the relay (see wiring diagram)

2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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HARLEY DAVIDSON XL PREMIUM OIL COOLER KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Refer to Owners Manual to drain engine oil and remove oil filter. 2. See Figure 1. Remove oil feed hose (1) from oil pump. 3. Remove oil feed hose fitting from engine crankcase. Discard oil feed hose. INSTALLATION 1. See Figure 2 and Table 1. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to oil pump. 2. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to crankcase. 3. Tighten fittings to 55-65 in-lbs (6.2-7.4 Nm) . 1 2 3 1 is04015 1. Fitting 2. Oil Hose Cooler Supply 3. Oil Hose Cooler Return Figure 2. Oil Hose Cooler Return and Supply Assmeblies 4. Loosely install oil cooler return hose assembly (3) to crankcase fitting. 5. Loosely install oil cooler supply hose assembly (2) to oil pump fitting. 6. See Figure 3 for proper oil hose routing. The oil supply hose (1) should be the upper hose and the oil return hose (2) the lower hose 1 2 is04018 1. Oil Supply Hose 2. Oil Return Hose Figure 3. Oil Cooler Hose Routing 7. Remove two existing clips holding the clutch cable and wire harness from the left frame downtube. 8. See Figure 4 and Table 1. Position oil cooler clamps (7) in approximately the same position as the clips that were removed from the frame downtube. 9. Loosely attach oil cooler (4) to the clamps (7) using screws (9) and nuts (8). 10. Attach oil return hose (3) to the inboard connection of oil cooler (4) with worm clamp (5).

2003 Honda Shadow Spirit 750 VT 750DC Custom speedometer dial installation

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Filed Under (Honda) by admin on 06-11-2011

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DO NOT REMOVE THE 3 PHILLIP SCREWS ON THE BACK OF THE SPEEDOMETER. This will unscrew the circuit board and the main components inside the speedometer, and possibly damage it. Just leave those 3 screws alone. They won’t make your customization any easier if they are removed. This is the hard part. Turn the speedometer face down on a soft towel on a sturdy table, bench, etc. I used a regular flat screwdriver to do this step. There is a chrome metal ring holding the glass on the speedometer. It is factory sealed. On the bottom side of this ring start prying with a flat screwdriver under the bottom lip of the metal ring. This will be a slow process (patience, patience, patience) so don’t get in a hurry and ruin the wife’s kitchen table like I did. Go around the metal ring with a flat screwdriver prying it up as straight as you can. It’s easier doing this every millimeter or two. I had to do this about 3 times all the way around the ring. After you pry the lip of the ring up all the way around enough to loosen it up considerably, gently pull the ring off of the speedometer. The glass should come off with it. Put the glass with the chrome ring aside for later. You might want to use a soft lint free towel to rest it on

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1998 Honda Shadow Aero Specifications And Review

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Filed Under (Honda) by admin on 24-11-2010

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can fix it – let us help. The color combo that would have been featured here, had we not got rained on. As light as the morning precipitation was, a rainsuit seemed silly, and surely jeans and a leather jacket would be enough. However, at the crest of the peninsula, El Nino let his wrath be felt. A full-on downpour of Florida- like proportions dropped from the sky, without the benefit of gulf-stream warmth. Suddenly, wearing geeky-looking Gore-Tex seemed like a very good idea. Riding through six inch deep floodwaters at about 15 mph, the Aero kept a very even keel. The floorboards (first ever on a Honda) kept the feet drier than they would have been otherwise. After a brief stop at a military museum, we headed back to Honda’s HQ for a van ride to lunch at Hollywood’s House of Blues. Detail 101: Witness the huge chrome headlight/speedo assembly, with matching idiot lights set into the triple clamp. We couldn’t form much of a riding impression from our rain-soaked 30 mile jaunt, but we liked what we found. If you’re a big fan of the ACE 750, you’ll be a big fan of the Aero. Although the styling is not ground-breaking, it isn’t a carbon copy of you-know-who (hint: They’re based out of Milwaukee). The detail on the Aero is beautiful, with tasteful chrome accents and well-finished pieces. We hope to get the big 1100 back for a full test against Suzuki’s new Intruder 1500LC, Harley’s new Road King Classic, and all the other cruiser big boys some time this spring, after El Nino goes away … Manufacturer: Honda Model: 1998 Shadow Aero Price (two-tone): $9,995.00 Engine: liquid-cooled 45 degree V-twin, single crank pin Bore and Stroke: 87.5 x 91.4mm Displacement: 1099cc Carburetion: Two 36mm CV Transmission: 5 speed Wheelbase: 66.1 in Seat Height: 28.5 in Fuel Capacity: 4.2 gal with .8 gal reserve Claimed Dry Weight: 623 lbs

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HONDA VT1100 SHADOW EXHAUST SYSTEM Installation Manual

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Filed Under (Honda) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header nuts from the exhaust port on both front and rear cylinders. The nuts will be reused during installation. 2. Remove the mounting bolts/nuts located below the lower muffler. Carefully remove the entire system and set it aside. Note: The system is heavy so have someone assist you. 3. Remove the muffler mounting bracket from the frame but save the two bolts for reuse. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Remove the bar bracket from the box. Hold the bar bracket in front of you with the four hole bracket positioned to the right hand side and pointing down. Mount one muffler to the bracket on the left hand side of the bar using two of the 5/16″ bolts (supplied) and leave them loose. Be sure the small end of the muffler is pointing to the right hand side. 3. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. 4. Slide a new flange onto each header tube. Note: The two smaller holes in the header flanges are offset from the large hole. If the small holes do not align with studs at the exhaust port, spin the flange on the pipe one half of a turn and try again. Refer to Figure 1. 5. Place the head pipe into the heat shield, unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Wrap the hose clamp around the head tube and give the screw three to four turns, leaving heat shield loose on the head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike

HONDA SHADOW AERO 750 STRAIGHTSHOT HS EXHAUST SYSTEM

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Filed Under (Honda) by admin on 03-11-2011

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Install mounting bracket (stamped 359-P) in the original bracket mounting position, using two 10mm bolts and
one 10mm nut (supplied)(Figure 2). 2. Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark the outside edge of each heat shield to show location of hose clamp mounting clips (Figure 3). 3. Slide flanges onto head pipes and lay head pipes into
heat shields. Loosely install hose clamps by feeding tail end of clamp into heat shield clips (Figure 3). Take note of screw head direction (Figure 4). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Use #20 hose clamps for head pipe areas and #28 hose clamps for muffler areas.
4. Using stock nuts, carefully install head pipes into exhaust ports (Assistance may be required). NOTE: Do not tighten at this time.

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