2009 flstc triple tree dissassembly diagram

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Daytona 675, Street Triple Street Triple R Fitting Instruction

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

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remove the original gear selector rod from the motorcycle. Note: The ball joint and locknut on the transmission linkage have a left hand thread. This is identified by either a machined ring on the gear selector rod on Daytona 675 or on the ball joint on Street Triple and Street Triple R. 1. Front ball joint 2. Locknut 3. Gear selector rod 4. Machined ring, left hand thread identification 5. Machined ring, left hand thread identification (StreetTriple and Street Triple R) 6. Remove the front and rear ball joints and front locknut only from the gear selector rod. Retain the locknut and both ball joints for re-use. Retain the gear selector rod if the motorcycle is to be returned to its original condition. 7. Remove the plastic end caps from the quickshifter assembly. 8. Screw the locknut on to the rear of the quickshifter assembly (right hand thread) leaving 8mm of thread exposed. 1. Quick shifter assembly 2. Locknut 9. Screw the rear ball joint (right hand thread) on to the rear of the quickshifter assembly until it contacts the locknut. Unscrew the ball joint, only enough to achieve the correct orientation in relation to the quickshifter cable, as shown below. Finger tighten the locknut at this stage. 1. Ball joint 2. Quickshifter assembly 3. Locknut 4. Quickshifter cable 10. Fit the locknut and front ball joint (left hand thread) to the front of the quickshifter assembly Screw the locknut and ball joint on to the quickshifter assembly to achieve a dimension between the ball joint ends of 203.5 mm. Ensure that the ball joint is in the correct orientation to the quickshifter cable, as shown below. Finger tighten the locknut at this stage. 1. Ball joint 2. Quickshifter assembly 3. Locknut 4. Quickshifter cable 12. Route the quickshifter cable through the gear selector rod aperture in the frame, as shown. 1. Quickshifter cable 2. Gear selector rod aperture 13. Locate the quickshifter assembly in position, through the frame with the sensor at the rear and the cable at the top. 1. Quick shifter assembly 2. Sensor 14. Attach the front ball joint to the transmission linkage. 1. Ball joint 2. Transmission linkage

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HARLEY DAVIDSON CHROME DYNA TRIPLE TREE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION NOTE The components in this kit install exactly as the OE (Original Equipment). 1. Refer to the applicable Service Manual for steering head removal procedures. 2. Refer to the applicable Service Manual for steering head installation procedures. SERVICE PARTS 1 5 4 3 2 is05169 Figure 1. Service Parts: Dyna Chrome Steering Head -J02511 1 of 2 Table 1. Service Parts Table Part Number Description (Quantity) Item 48365-48A Steering head bearing dirt guard 1 4307 Socket head cap screw 0.38-16 x 1.5 in. 2 4306 Socket button head cap screw 0.38-16 x 1.5 in. 3 46183-99 Bracket, upper fork, chrome 4 45503-02 Lower triple clamp assembly, chrome 5 45611-86 Retaining ring (not shown) 6

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HARLEY DAVIDSON GLOSS BLACK TRIPLE TREE COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Refer to the service manual to remove the front panel, side panels and trim strips. Save all hardware to install the new panels from the kit and trim strips. 2. See Figure 1 and Table 1. Install new panels from the kit and trim strips (D). 3. Tighten screw (A), three places, to 20-30 in-lbs (2.26-3.39 Nm) Tighten screw (B), two places, to 12-17 ft-lbs (16.3-23.0 Nm) Tighten screw (C), four places, to 8-12 ft-lbs (10.8-16.3 Nm) . If installing on a motorcycle with a light bar or windshield, refer to the appropriate service manual or instruction sheet for torque values.

HARLEY DAVIDSON LOWER FORK BRACKET (TRIPLE TREE) COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation 1. For models equipped with air baffle: See Figure 1. Remove and discard the two hex screws (2) and flat washers (3) holding the baffle (1) to the fork stem and bracket assembly(4). Retain the baffle for later reassembly. For models not equipped with air baffle: Remove and discard the two plugs from the rear of the fork stem and bracket assembly (4). 2. Remove and discard the hex socket head screw (6) holding the brake line manifold (5) to the underside of the fork stem and bracket assembly. 3. Place the lower fork bracket cover into position covering the brake line manifold. Attach the cover (and the baffle, if so equipped) to the fork stem and bracket assembly with the two 1/4″ self-tapping hex screws from the kit. Tighten securely. 4. Install the 5/16″ self-tapping hex socket screw through the cover and brake line manifold into the stem and bracket assembly. Torque to 10-15 ft-lbs (13.6-20.3 Nm). 5. Verify that the throttle and clutch cables are routed properly and do not interfere with steering the vehicle. After disturbing the brake system, BEFORE moving motorcycle, you must pump brake fluid until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brake will not be available to stop the motorcycle which could result in death or serious injury. After disturbing the brake system, always test motorcycle brakes at low speed. If brakes are not operating properly, or braking efficiency is poor, testing at high speeds could result in death or serious injury

Harley Davidson 2004-Up Sportster EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Installation Notes • Remove front fender, wheel, brake caliper, and fork tubes. • Remove all components attached to stock triple clamps, then the triple clamps themselves. • Remove upper and lower bearings including race. • Install new steering stem bearing races into neck. • Install new upper steering stem bearing with seal into neck. • Install Top and Bottom triple clamps into neck and snug steering stem bolt with washer. • Remove fork tube cap from both forks. • Install fork extensions with o-ring into fork tubes and tighten until fully seated. • Install fork tube caps with o-rings and tighten (see torque table). • Slide fork tubes into triple clamps until the top of each tube cap extends 0.42-0.50 in. above top surface of upper triple clamp. • Tighten 3/8-16 x 1.5″ bolts on upper triple clamp (see torque table). • Tighten steering stem bolt (see torque table). • Tighten pinch bolts on lower triple clamp (see torque table). • Install front wheel assembly and front brake caliper. • Install front fender. Item # Part Description Torque Spec (Lb. Ft.) – Fork Tube Cap 22-58 8 Bolt, Steering Stem, SP 30-35 11 3/8 – 16 X 1.5″ Socket Head Cap Screw 30-35 EZ-Steer Maintenance The bearings in your EZ-Steer rake kit are normal wear items, not subject to replacement under Champion’s one year Limited Warranty for the product. Failure to follow your motorcycle manufacturer’s recommendations for periodic OEM triple-tree maintenance will accelerate the wear on these bearings. Checking/adjustment of the steering stem nut torque with the front end lifted, in accordance with your motorcycle manufacturer’s recommendations, is important to reliable bearing service. Windshield Notes Please note that this EZ-Steer kit accommodates all known windshield types with the exception of a minor modification to Quick Release Compact Windshield, example part no. 58063-04. You will need to oblong the lower bolt holes as shown in figure

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RESTYLED 2009 TOYOTA RAV4 DEBUTS NEW FUEL-EFFICIENT FOUR-CYLINDER ENGINE AND ADDS NEW SAFETY, CONVENIENCE AND USER TECHNOLOGY FEATURES

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Filed Under (Toyota Manuals) by admin on 17-09-2011

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Toyota has restyled its popular RAV4 compact sport utility vehicle for 2009. The new standard 2.5-liter four-cylinder engine is more powerful than the previous 2.4-liter engine and is more fuel efficient. In addition, all RAV4 models feature interior upgrades and a comprehensive new Sport Appearance Package is available for the 4WD V6 model. All RAV4 models receive enhanced safety and security features with standard front seat active headrests and an engine immobilizer. Comfort, convenience and user technology are also significantly enhanced in 2009 RAV4 models. The Limited grade adds a new standard Smart Entry system that allows the driver to open the vehicle by simply carrying the key fob and grasping the door handle. The Sport and Limited grades offer an available new rear backup monitor. Integrated satellite radio is newly available for 2009, and the Sport and Limited grades offer a new low-cost navigation system. All RAV4 models gain new standard seat fabric, and the Sport grade exclusively offers a new, unique Charcoal leather option.

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2009 TOYOTA RAV4 DEBUTS NEW FUEL EFFICIENT FOUR CYLINDER ENGINE AND ADDS NEW SAFETY

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Filed Under (Toyota Manuals) by admin on 01-10-2011

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Toyota has restyled its popular RAV4 compact sport utility vehicle for 2009. The new standard 2.5-liter four-cylinder engine is more powerful than the previous 2.4-liter engine and is more fuel efficient. In addition, all RAV4 models feature interior upgrades and a comprehensive new Sport Appearance Package is available for the 4WD V6 model. All RAV4 models receive enhanced safety and security features with standard front seat active headrests and an engine immobilizer. Comfort, convenience and user technology are also significantly enhanced in 2009 RAV4 models. The Limited grade adds a new standard Smart Entry system that allows the driver to open the vehicle by simply carrying the key fob and grasping the door handle. The Sport and Limited grades offer an available new rear backup monitor. Integrated satellite radio is newly available for 2009, and the Sport and Limited grades offer a new low-cost navigation system. All RAV4 models gain new standard seat fabric, and the Sport grade exclusively offers a new, unique Charcoal leather option.

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2008-2009 Kawasaki Versys Adjustable Windshield Mount Installation Instructions

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

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1. Remove the plastic covers (bodywork) on each side of the bike. There are six screws per side that can be removed using the 4mm Allen wrench provided. Once all the screws are out, the panels pull off. There will be a little bit of resistance because of a post being held on the back of the panel, but it will pop out by pulling straight away from the frame. 2. Remove the windshield from the factory brackets. 3. Remove the four (4) bolts that hold down the factory windshield brackets. You will need an 8mm socket or open-end wrench. The MadStad Adapter Plate The diagram below shows the Adapter Plate. Please review this diagram before proceeding.
3 Mount the Brackets to the Adapter Plate Insert the M6 x 12mm button socket screws washers through the adjustable bracket, stiffening plate and base plate mounting holes as shown below. Attach them in either the narrow (Versys) or wide (Suzuki V-Strom) positions as shown in the diagram on page 2. Use the lock nuts underneath to tighten the brackets to the adapter plate

Triumph TT 600 Installation instructions

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

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1) It is essential to use Blue Loc-tite on all setscrews and bolts or they will come loose. 2) Remove the stock 30mm nut AND washer , that holds the top triple clamp tight and discard them. 3) Install the new aluminum nut supplied in the kit with the Hex drive facing up and torque to 45 ft. lbs. or more. 4) Install the new “triple clamp damper mount” (TC mount), the part with 6 set screws in it , over the main triple clamp nut with the “machined register” (lip) indexing over the back of the triple clamp (see photo below). Tip to save time: Before installation, using Loc-tite, start all the setscrews first, until flush with the inside bore. 5) Be sure this damper mounting bracket is setting flush on the triple clamp surface all the way around. This part is machined precisely to fit over the stock triple clamp. Due to the fact the stock triple clamp is cast, they could vary is size. Remove or trim around any obstructions that might prevent the TC mount from sitting down flush such as carbon fiber deco plates. 6) Loc-tite and engage the setscrew at the 12 o’clock (front) position first so it pulls the “register up against the back of your triple clamp. Do not tighten this setscrew, just snug it enough to secure the position of the TC mount. 7) Loc-tite and tighten the remaining setscrews evenly until they make contact with the groove and are secured tightly. It’s a good idea to check the setscrews after the first ride as they will seat into their final position and need re-tightening. 8) Tip to save time: Before installation, using Loc-tite start all the setscrews first, until flush with the inside bore. 9) (Note: You must use some heat to compromise the Loc-tite before trying to remove the setscrews or the small Allen head setscrews can be stripped easily). 10) Remove the stock front fuel tank retaining bolt and washer. You must use the longer 6×30 bolt provided . 11) Retain the rubber bushing and the spacer-washer that fits inside the rubber bushing for your tank mount. 12) The gas tank mounting hole is actually off-center from the factory on this bike, by only 1mm or so, so our frame bracket has a slot instead of hole so you can make fine adjustments in the alignment of the frame bracket. 13) Install the frame bracket so the “feet” that contact the frame are positioned to match the frame. View the photo below to see how it should look and remain straight with the front edge of the gas tank. There is a front and back to this part. 14) We’ve machined this frame bracket precisely to match the Triumph frame, so as the bolt tightens up it will pre-load the frame bracket just enough to secure it tightly to the frame. 15) Remember, under heavy braking your entire body weight is pushing the tank forward. Until you have verified sufficient clearance between the tank and the frame bracket, put something between the tank and frame bracket to protect the tank. Each bike will vary as to how much movement there actually is under heavy braking 16) Grease the tower-pin lightly and drop it in the tower-pin hole. It is designed to “float”. Keep the hole and shaft portion of the tower pin greased for easy movement. 17) Install the stabilizer using (2) 6×20 Allens. The link arm slot aligns with the flats on the tower pin. 18) Read your damper manual for initial settings on the controls.

1996-2003 KAWASAKI ZX7R INSTALLATION INSTRUCTIONS

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

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1) It is mandatory to use blue Loc-tite on all bolts. We promise they will come loose if you don’t. 2) Remove the large nut and washer that holds your triple clamp on. Install the new nut that we provide which has HEX drive facing UP. You will NOT use the stock washer. 3) Torque the new nut to your factory recommended setting as they vary. Normally a minimum of 50-80 ft lbs. 4) Install the new triple clamp damper mount (TC mount) over the new triple clamp nut with the “machined register” (the small knub) indexing into the matching groove on the top, back of your stock triple clamp. The knub insures the mount cannot spin should the damper try to loosen the main nut. 5) Be sure this TC mount is setting down flush on the triple clamp surface all the way around. This part is machined precisely to fit over the Scotts triple clamp nut. The groove machined into the nut is positioned so once the set screws are tightened, it will suck the TC mount down against your triple clamp. Remove any obstructions that would not allow the TC mount to sit flush against your stock triple clamp surface. 6) Tip to save time: Before installation, using Loc-tite start all the setscrews first, until flush with the inside bore. 7) Using blue loc-tite on the setscrews, run them all in against the nut equally and then proceed to tighten each one making your way around until they are all equally tight. They should be checked after the first ride as normally they will settle into the groove in the nut and require tightening. 8) (Note: You must use some heat to compromise the Loc-tite before trying to remove the setscrews or the small Allen head setscrews can be stripped easily). 9) Remove the two, stock-front tank retaining bolts. You will replace these with longer ones in the kit. 10) Install the new “frame bracket tower”. There is a front and back to this part, note the picture! 11) Install the longer tank bolts supplied, through our frame bracket and into your tank mounting holes. 12) Grease the tower pin and drop it in the tower pin hole. It is designed to “float” and requires no retaining devices. Keep the tower pin and hole portion greased lightly. 13) Install the damper using the (2) 6×20 Allens. The link arm slot aligns with the flats on the tower pin. 14) Read your damper manual for initial settings on the controls. The damper is infinitely adjustable and totally up to the user to find their preference. Start with softer (counter clockwise) settings. Normally where we set the unit is a good starting point, usually 8 clicks out on the base valve. 15) The base valve controls the immediate feel of damping forces exerted

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