2007 triumph america air box removal kit

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Triumph Bonneville America And Speedmaster The Freak Installation Instructions and Parts List

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Filed Under (Triumph) by admin on 29-10-2010

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INSTALLATION In order to install The Freak, the factory air-box must be removed. Because of it’s design, the factory air-box is not an item that is easily removed. There are several parts that must be removed in order to get the air-box out of the bike in one piece. We recommend using the following method to remove your air box without having to cut it into smaller pieces in order to get it out of the frame. 1. PARTS REMOVAL In order to gain access to the air-box, it is necessary to remove certain parts of the motorcycle to gain access to the air-box area of the frame. Removing the following parts should be the first steps you take. A. Seats – Remove both seats starting with the passenger pillion, if applicable. B. Side cover and grommets – Remove the plastic side cover on the right side (throttle side) of your motorcycle. This is the faux oil-tank cover that has the name of your bike on it. Underneath the side cover there are three rubber grommets (1 on the frame tab, and two on the air-box) that support the side cover. Remove the two that are on the air-box and leave the one on the frame. You will attach the two that you removed to the right side bracket in Section 4C . C. Faux air filter covers – On the right side of the bike, remove the chrome faux air filter covers, by removing the one allen head screw that holds it onto the air-box. On the left hand side (clutch side) remove the faux air filter cover in the same manner, you removed the one on the right. D. Plastic shrouds – on the left side, remove the black plastic air-box shroud, by removing the two allen head screws holding it in place. Then remove the plastic shroud covering your fuse box (this is the piece that surrounds your ignition terminal next to the battery). E. Battery – Remove the battery by unscrewing the torx-head bolt that holds the chrome bracket in place. Remove the chrome bracket and the black plastic cap. Tilt the battery out of the box with the top towards you. Disconnect both battery terminal connectors, negative (-) terminal first. Remove the battery. F. Battery box – Remove the two bolts that hold the battery box to the frame. Pull the battery box out as far as you can, then remove the the ignition terminal from the battery box, by removing the two allen screws that hold it in place from the back. Next, remove the fuse box from the battery box, by pushing it out from the back. It is not necessary to disconnect any of the wiring going to the fuse box, or the ignition terminal. G. Rear fender – Remove the rear fender, by first disconnecting the taillight wires. Follow the wires from the tail light assembly on the inside of the rear fender (left side) towards the front of the bike until you come to the box connector. Disconnect the tail light wires at this connector, being careful not to break it. Once the wiring is disconnected, remove the 6 bolts that hold it to the struts. Have someone hold the fender for you while you are removing all of the bolts so that it does not drop once the bolts are removed. Slide the fender out the rear of the bike. 2. PREPARE THE MOTORCYCLE FOR AIR-BOX REMOVAL To remove the factory air-box without damaging it, it is necessary to lift the bike. We recommend the use of a multi-position ATV/motorcycle jack with a minimum lift height of 10″. A. Setting up the lift – Place the lift under your bike and secure your bike to the lift according to the lift manufacturer’s instructions. B. Raise slightly – Lift the motorcycle to the point where the rear springs are without tension, but NOT to where the rear tire is off the ground. C. Remove the rear springs – Take off each of the rear springs by removing the the two bolts on each spring. Once all the bolts are removed gently pull the springs out off of the studs. If they do not pull off easily, you can raise or lower the bike slightly with the lift to ease tension on the spring. Remember, you should not have the rear tire off the ground at this point. The bike should only be raised enough to relax the tension in the springs. D. Remove the mufflers – Remove the mufflers by loosening the clamp at the exhaust header, and by removing the rear foot peg hangers. If the mufflers are not removed, they can become damaged by the axles in Section 2H . E. Disconnect the carburetors – With a small flathead screwdriver, pull the retainer springs out of the channel of the carburetor intake tubes (the two large black tubes coming from the air box into the back of each carburetor), and simply push them towards the air box off of the carbs

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2009 Kawasaki ULTRA 250X/ 260X FUEL INJECTION CONTROLLERS And REGULATORS INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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The R&D high performance Air Filter Kit will improve acceleration and top speed performance by increasing air flow and reducing air temperatures that enter directly into the Ultra 250X’s air plenum box area. The O.E.M. air plenum box on the Ultra 250X is a great design that will flow plenty of air. However, the air that feeds the plenum box is heated by the engine. R&D has created an easy to install “flat filter” that installs directly in place of the large center access inspection cover located directly under the main glove box. The R&D Flat Air Filter insert will allow unrestricted fresh and cool air to enter the air plenum box area which will add power you can feel and a nice high performance tone. The R&D Performance Filter Kit also features two filters, one for each of the surge and blowoff protections valves. The O.E.M. surge valve recycles compressed hot air back into the air box plenum at idle and under deceleration conditions. The R&D surge and blowoff valve filter kit removes the air recycling hoses which will keep the hot air from entering the air plenum box reducing the engines intake air temperatures. The R&D Ultra 250X Air Filter Kit offers great performance tips on how to remove the restrictive air vent hoses which will further reduce the under seat ambient air temperatures. The R&D Filter system does not remove or alter the O.E.M. plenum box in any way, therefore there are no questions to be answered regarding water ingestion

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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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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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YAMAHA V-Star 650 BIG AIR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 21-01-2012

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Remove fuel tank and air filter assembly per Yamaha service manual procedures. 2. Remove the air silencer box under the tank. 3. Install supplied BA-2410-00 Needle/Jet kit according to the instructions in the jet kit package being sure to use the Jets and Needle Slot setting called out for the external BAK filter assemble. 4. Reinstall the air silencer box under the tank. 5. Remove the rubber boot from the stock air box. It is glued-in from the factory, but will come loose if gently persuaded. See photo #1 Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Barons bears no responsibility on installation costs associated with this product. © 2010 Barons Custom Accessories 7401 Slater Ave. Huntington Beach, CA 92647 (714)274-4065 – Ph. (714)848-0718 – Faxwww.baronscustom.comtech@baronscustom.com Page: 2 BA-2011-00/03/06/07/13/13B BIG AIR KIT – YAMAHA V-Star 650 6. Install the stock rubber boot into your new Baron air filter backing plate with the supplied glue. Squeeze glue liberally into sealing groove in stock rubber boot. See photo #2 Allow glue to set up and dry prior to mounting onto bike

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2009 TRIUMPH DAYTONA 675 Triumph/ Arrow Race Rearsets

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Filed Under (Triumph) by admin on 12-11-2010

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race harness kit, air funnel kit, racing oil pump gearing kit, adjustable camshaft sprocket kit, manual camshaft tensioner and blade kit, a reusable engine cover gasket set and racing cylinder head gaskets. Here’s a closer look at the new racing parts and their associated performance improvements: TRACS – Triumph Race Calibration Software TRACS ( T riumph Ra ce C alibration S oftware) is a new computer program that allows racers to tune Triumph’s programmable race ECU from a laptop PC. Developed by one of Triumph’s most experienced EFI calibration engineers, the programmable ECU and software was created for the growing number of competitors that are riding Triumph motorcycles at the track. The new software provides racers with quick access to a wide range of adjustments that can be downloaded to the race ECU in about 35 seconds for tuning during testing, practice and qualifying sessions. Features include: Fully programmable fuel mapping (500rpm increments, for individual cylinders). Fully programmable ignition mapping. Switchable wet and dry maps. Adjustable pit lane speed limiter and speedo calibration. Adjustable quickshifter cut duration (adjustable at low, mid and high RPM) Adjustable rev limiter up to 15,000rpm. New software strategies to improve throttle progression. Optimized software to run faster to cater for the higher RPMs involved in a race environment. Ability to save multiple maps within the memory of the PC. Ability to update an existing 2007/2008 Race ECU to 2009 specification and functionality.* (*Not all features will be available if using the 2007/08 Race harness.) Exhaust – Triumph/Arrow Titanium “Stage 3″ System Triumph has continued to collaborate with Italian race exhaust specialists Arrow Special Parts to develop a new, full titanium racing exhaust system. This system complies with current FIM regulations, works as part of the factory race kit, and offers a significant weight reduction and considerable power gains.

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TOYOTA TUNDRA 2007 COLD AIR INTAKE REMOVAL And Installation

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Filed Under (Toyota Manuals) by admin on 26-09-2011

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Removal Procedure: 4.7L V8 OE Air Inlet System (a) Remove the two 10 mm cap nuts and throttle body cover (Fig. 4-1). (b) Remove air cleaner hose assembly. (1) Disconnect the vacuum hose and No. 2 ventilation hose (Fig. 4-2).
(2) Loosen the two 10 mm hose clamps and remove the air cleaner hose (Fig. 4-2). 5. Removal Procedure: 5.7L and 4.7L V8 OE Air Inlet System (a) Remove the air cleaner lid. (1) Disconnect the MAF sensor connector (Fig. 5-1).
(2) Using a clip remover, detach the wire harness clamp (Fig. 5-1). (3) Unfasten the 4 hook clamps and then
remove the air cleaner lid (Fig. 5-1). (b) Remove OE air filter and save. (c) Remove the two 10 mm bolts and air cleaner
case (Fig. 5-2)

HARLEY DAVIDSON LOCKING GLOVE BOX DOOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. Unsnap the original equipment (O.E.) left-side glove box door, and unfasten the tether by bringing the aglet end (see Figure 1, B) out through the retaining hole. Always wear proper eye protection when drilling or grinding. Flying debris could cause serious eye injury. (00402e) 2. Using an 3/16 inch (5 mm) bit positioned in the center of each snap, drill out the four plastic snaps surrounding the glove box opening. NOTE The glove box door, hinge and frame assemblies are side- specific. The assemblies install so that the tether retaining hole (C) in the door frame is to the inboard side. 3. Obtain the new left-side glove box door, hinge and frame assembly (1), a lock (2) and a tether assembly (8) from the kit. Remove the nut (3) from the lock. 4. Insert the lock through the hole in the glove box door as shown. Assemble the tether over the lock threads with the tab (A) on the inboard side of the lock, same as the retaining hole in the door frame. Tighten securely. 5. Open the left-side door, and position the door assembly at the glove box opening, lining up the holes. 6. Insert a screw (9) through each of the holes in the door frame and glove box. Install a hex nut with washer (10) onto the threads of each screw. Tighten finger-tight. NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the gaskets to the glove box door frame. 7. Clean the glove box door frame with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. NOTE The glove box gaskets are side-specific. With the paper backing facing the door frame, the oblong hole at the top of the gasket is to the outboard side. 8. Obtain the left-side gasket (6) and a hinge gasket (7) from the kit. Install the gaskets to the glove box door frame. a. The gasket liner on the large gasket is split to aid alignment. Peel one half of the liner from the adhesive backing of the left-side gasket. b. Using the frame edges and screw heads as a guide, carefully position the gasket to the glove box door frame and press firmly into place. c. Peel the remaining half of the liner from the gasket backing, and carefully position the rest of the gasket to the door frame. Press firmly into place. d. Apply steady pressure for a few seconds at all areas of the gasket to verify proper adhesion. e. Peel the liner from the hinge gasket. f. Carefully position the gasket to the door frame above the hinge, and press firmly into place.

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2002-2004 TRIUMPH BONNEVILLE AMERICA/ SPEEDMASTER CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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A.) REAR WHEEL REMOVAL- PAGE 14-16 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 12 mm bolt from rear seat section—if you have a pillion pad remove it first by removing the 8 mm bolt, slide forward and lift free of seat catch. Take a position where you can see what you are doing or you will scratch your painted surface. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-14 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 side allen head mount bolts and 2 12mm hex head top front mount bolts– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-11 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove the 12mm rear tank-mounting bolt. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface. E.) REMOVE SIDE COVERS PAGE 15-10 and 9-15 Triumph Motorcycle Service Manual 1.) Loosen and remove left side cover screws on the air filter facade— lift slightly to disengage top mounts and remove—set aside in a safe place to prevent damage to painted surface. 2.) On right side cover simply and gently pull bayonet fittings from rubber slip mounts. 3.) Secure these rubber mounts and remove for later re-assembly with the Bonneville Performance brackets.

Daytona 675 Motorcycle Race Kit Installation Manual

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Filed Under (Triumph) by admin on 29-10-2010

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Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Fit the chosen race kit cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Caution The use of the following race kit cylinder head gaskets will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. Item Description Qty 1 Head gasket (t = 0.65mm) 1 1 Head gasket (t = 0.60mm) 1 1 * Page 7 of 29 © Triumph Designs Ltd 2007. Cams, Valve Spring & Sprocket Kits Parts Supplied Camshaft Inlet Kit – A9618055 Camshaft Exhaust Kit – A9618056 Valve Spring Kit – A9618058 Camshaft Sprocket Kit – A9618057 Warning The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of the Camshaft, Valve spring & Sprocket race kits detailed below will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. 5 5 4 1 3 2 4 3 Item Description Qty 1 Cam assy, inlet, race 1 Item Description Qty 2 Cam assy, exhaust, race 1 Item Description Qty 3 Valve spring, 14.4id, race12 Item Description Qty 4 Sprocket, camshaft, 34T 2 5 Socket head cap screw, Encapsulated, M6x10 4
Page 8 of 29 © Triumph Designs Ltd 2007. NOTE •The standard inlet cam is 9.25mm max lift and 258.50o duration. The race kit inlet cam is 9.25mm max lift and 268.74o duration. •The standard exhaust cam is 8.5mm max lift and 246o duration. The race kit exhaust cam is 8.5mm max lift and 262.21o duration. •The race kit valve spring must be used in conjunction with the standard spring platforms and retainers. The fitted length of the race springs is the same as the standard spring. 1. The race kit valve springs should be assembled in the same manner as the standard valve springs. Follow the procedure detailed in section 3 of the Daytona 675 service manual. Ensure the springs are installed with the close wound, colour coded end of the springs facing downwards, towards the piston. 2. The race kit camshafts should be assembled in the same manner as the standard camshafts. Follow the procedure detailed in section 3 of the Daytona 675 service manual. 3. The race kit cam sprockets should be mounted and secured to the camshafts using the slotted holes in the sprocket. The slotted holes allow adjustment of the valve timing. The circular holes in the sprockets are for Triumph service tool T3880102 and should not be used to mount the sprockets to the camshafts. NOTE •No timing marks are included on the race sprockets. Race engines will typically have different depths skimmed off the cylinder head and, therefore require specific individual timing. 4. The camshafts should be timed using cam degreeing equipment which typically consists of a degree wheel, pointer, dial indicator and piston stop. Optimum cam timing will depend on the exact specification of the engine, but a recommended starting point is 104o IMOP (Inlet Maximum Opening Point) and 104o EMOP (Exhaust Maximum Opening Point). 5. Always check the inlet and exhaust piston to valve clearance for the timing selected to use, before running the engine. You must ensure both clearances are adequate. As a guide, the standard nominal piston to valve clearance is 1.3mm inlet & 1.5mm exhaust

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