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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

HARLEY DAVIDSON XL BRAIDED FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Drain the brake fluid following the instructions in the service manual. Dispose of waste properly. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Disconnect the battery, negative (-) cable first or remove the main fuse. Follow the instructions in the service manual 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Discard sealing washers, but save bolt for installation. 4. Remove bolt and two sealing washers to disconnect brake line fitting from front brake caliper. Discard sealing washers, but save bolt for installation. 5. Carefully make note of brake line routing, then remove existing brake line. NOTE This kit contains clamps and cable straps to either replace the original equipment clamps and cable straps being removed or to add additional brake line support. INSTALLATION Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 1. Position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Small ID washers are for caliper end, large ID washers are for master cylinder end. 2. Insert bolts (removed earlier) through washers and fittings. 3. Hold new braided brake line in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the same orientation as the stock banjo fitting. 4. Verify there is no twist in the brake line. Adjust brake line if necessary. 5. Install clamps from kit by wrapping clamp around braided brake line at each of the clamp mounting locations. Verify clamps are oriented the same as the stock clamps. Install clamp screws but do not tighten. 6. Check entire length of braided brake line: a. Be sure brake line is not twisted. b. Turn handlebars fully-left and right while checking to make sure brake line does not contact any vehicle components. c. Be sure brake line length between clamps is sufficient. 7. Adjust brake line if necessary. 8. Tighten caliper and master cylinder banjo bolts to 20-25 ft-lbs (27-34 Nm) .

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Kawasaki MULE 600 / 610 SNOW PLOW INSTALLATION INSTRUCTIONS

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

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1. PRELIMINARY: 1.1 Remove the six 6 mm. screws and plastic skid / splash shield from the bottom front of the vehicle frame. (These bolts and plastic skid / splash shield will not be reused snow plow mounting frame installed onto the vehicle.) 1.2 If the vehicle has the Kawasaki optional brush guard installed, it will have to be removed and then reinstalled after the snow plow mounting frame is installed. (The brush guard will fit with the snow plow mounting frame installed first.) 2. VEHICLE MOUNTING FRAME 2.1 Position the vehicle mounting frame (13) under the front of the vehicle so that the six holes (with pipe spacers) line up with the six 6 mm. threaded holes that the plastic skid / splash shield was attached with and the upper plate is through the large oval hole in the vehicle plastic fascia. Fasten loosely using 6mm. x 1.0mm. x 30mm. bolts (33) , 6mm. lock washers (35) and 6mm. flat washers (34). 2.2 Place a 5/16″-18 “U” bolt (36) around the front cross tube behind the plastic fascia and through each set of holes in the flange of the upper plate of the vehicle mounting frame (total of two “U” bolts). Fasten loosely using 5/16″flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.3 Install a 5/16″-18 “U” bolt (36) around the lower frame tubes and through each set of slotted holes in the lower plate of the vehicle mounting frame (total of four “U” bolts). Fasten loosely using 5/16″ flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.4 Tighten all the fasteners holding the vehicle mounting frame to the vehicle starting with the 6mm. bolts

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HARLEY DAVIDSON STREET SLAMMER HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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

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This kit does not fit models equipped with Hydraulic Clutch Kits, handlebar mounted gauges or the Road Tech® Radio or FLHRS models equipped with an accessory windshield. REMOVAL Preparation – All Models To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 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. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Save the seat hardware for installation. -J04406 When servicing the fuel system, do not smoke or allo w open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Softail and Dyna models: See the service manual and loosen the fuel tank. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled DOT 4 brake fluid. 3. See the service manual and drain the brake fluid from the front brake reservoir and brake lines. Handlebar Removal – Dyna and Softail NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 1. Note the front brake line routing and the orientation of the banjo fittings. See the service manual and disconnect and remove the brake line. Save the banjo bolts, but discard the brake line gaskets. 2. Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar, if equipped. 3. Remove the front brake master cylinder and clutch lever assemblies from the handlebar.

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APRILIA MOJITO 50-125-150 workshop manual

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Filed Under (Aprilia) by admin on 27-11-2010

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FUEL DANGER Fuel used to drive internal combustion engines is highly inflammable and may become explosive under certain conditions. It is best to refuel and carry out maintenance in well ventilated places with the engine switched off. Do not smoke during refuelling or near fuel fumes. Avoid all contact with naked flames, sparks, or any other source that may cause ignition or explosion. Also avoid allowing the fuel to spill out of the filler cap as it could catch fire on contact with the very hot surfaces on the engine. Should fuel be spilled accidentally check that the area is completely dry before starting up the vehicle. The fuel expands when subjected to heat or the sun’s rays. The fuel tank should therefore never be filled to the brim. Close the filler cap carefully on completing refuelling. Avoid the fuel coming into contact with your skin, inhaling vapours, ingestion and siphoning from one container to another using a hose. DO NOT DISPOSE OF THE FUEL INTO THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Only use super lead-free petrol, with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.). LUBRICANTS DANGER Adequate lubrication of the vehicle is essential to guarantee the safety of the vehicle. Failure to keep lubricants at sufficiently high levels or the use of inadequate, new and clean lubricants may cause the engine or gearbox to seize, resulting in accidents, serious injury or death. Gearbox oil may cause serious harm to your skin if handled for long periods of time and on a daily ba- sis. We recommend washing your hands carefully after having handled this oil. Do not dispose of the oil into the environment. Deliver this oil to the nearest collection company for spent oil or the supplier, or have them collect it. WARNING When putting oil into the vehicle be very careful not to spill any. Immediately clean off any spilt oil, otherwise it may damage the paintwork on the vehicle. In addition, any oil that ends up on the tyres will make them extremely slippery, creating a dangerous situation. If an oil leak should arise, do not use the vehicle. Check and identify the cause of the leak and repair the component involved. ENGINE OIL DANGER Engine oil may cause serious harm to your skin if handled for long periods of time and on a daily ba- sis. We recommend washing your hands carefully after having handled this oil. Do not dispose of the oil into the environment. Deliver this oil to the nearest collection company for spent oil or the supplier, or have them collect it. When carrying out maintenance we recommend wearing latex gloves. FORK OIL DANGER Adjusting the setting on the shock absorbers and/or the viscosity of the oil used in them may partially change the reaction of the suspension. Standard oil viscosity: SAE 20 W. The viscosity grade may be chosen in relation to the type of set-up you want on the vehicle (SAE 5W soft, 20W rigid). These two products may be used in varying percentages in order to obtain the required reaction

TOYOTA TACOMA 2005 SUPERCHARGER FIT KIT

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Filed Under (Toyota Manuals) by admin on 27-09-2011

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are must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- • Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). • The TIS Repair Manual can be referenced for additional details. Please see your Toyota dealer for a copy of this document. 1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 7

TOYOTA COROLLA 1984-2006 VEHICLE WIRING VEHICLE WIRING REMOVAL

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Filed Under (Toyota Manuals) by admin on 04-10-2011

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IRING INFORMATION: 1984 Toyota Corolla FWD WIRE WIRE COLOR WIRE LOCATION 12V CONSTANT WIRE WHITE OR WHITE/RED Ignition Harness STARTER WIRE BLACK/WHITE Ignition Harness IGNITION WIRE BLACK/YELLOW Ignition Harness SECOND IGNITION WIRE BLACK/ORANGE Ignition Harness ACCESSORY WIRE BLUE/RED Ignition Harness POWER DOOR LOCK (-) BLUE/WHITE Harness In Driver’s Kick Panel POWER DOOR UNLOCK (-) BLUE/RED Harness In Driver’s Kick Panel PARKING LIGHTS (+) DK. GREEN Harness In Driver’s Kick Panel PARKING LIGHTS (-) LT. GREEN Harness At Steering Column HEADLIGHTS (-) RED/WHITE Harness At Steering Column DOOR TRIGGER (-) RED/WHT OR BLK/WHT Harness At Fuse Box TRUNK TRIGGER COMMON WITH DOORS (Hatchback Only) TACHOMETER WIRE BLACK At Ignition Coil BRAKE WIRE (+) GREEN/WHITE Brake Pedal Switch HORN TRIGGER (-) GREEN/RED Steering Column LEFT FRONT WINDOW UP GREEN/BLACK At Driver Window Motor Inside Door LEFT FRONT WINDOW DOWN BLUE/RED At Driver Window Motor Inside Door RIGHT FRONT WINDOW UP GREEN Harness In Driver’s Kick From Driver Door RIGHT FRONT WINDOW DOWN BLUE/WHITE Harness In Driver’s Kick From Driver Door LEFT REAR WINDOW UP RED/BLACK Harness In Driver’s Kick From Driver Door LEFT REAR WINDOW DOWN RED/YELLOW Harness In Driver’s Kick From Driver Door RIGHT REAR WINDOW UP RED/BLUE Harness In Driver’s Kick From Driver Door RIGHT REAR WINDOW DOWN BLUE/BLACK Harness In Driver’s Kick From Driver Doo

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HARLEY DAVIDSON ROAD KING FAT HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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PREPARATION – ALL MODELS 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. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled D.O.T. 4 brake fluid. 2. See the service manual and drain the brake fluid from the front brake reservoir. ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 1. Using a T-40 TORX® drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the service manual. 3. Remove the old brake lines from the motorcycle. 4. Using a T27 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies (refer to CLUTCH CABLE in the service manual) from the stock handlebar.

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HARLEY DAVIDSON BRAIDED, DUAL DISC, FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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INSTALLATION 1 is03017 1. Bleed valve cover Figure 1. Brake Caliper Bleed Valve Rubber Cover 2 1 3 is03018 1. Plastic tube 2. Caliper bleeder valve 3. Container Figure 2. Draining Brake Fluid NOTE This instruction sheet covers motorcycle models that use either DOT 4 or DOT 5 Hydraulic Brake Fluid. The owner’s manual -J03109 1 of 2 will indicate which type of br ake fluid should be used on the motorcycle. Read and follow the owner’s manual carefully. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 1. See the service manual and disconnect negative (-) battery cable or remove the main fuse. Save the seat hardware for installation. 2. See Figure 2. Open bleeder nipple cap on front brake caliper. Install end of a length of plastic tubing over caliper bleeder valve (1), while placing free end in a suitable container. Open bleeder valve approximately 1/2 turn. Pump brake lever to drain brake fluid. Repeat step for the other caliper. 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Save bolt and discard washers.

HARLEY DAVIDSON SPORTSTER CHOPPED FENDER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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INSTALLATION Preparation 1. Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level. 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) 2. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. 3. Remove the battery from the vehicle per the instructions in the service manual. 4. Raise the rear of the vehicle to relieve the load on the shock absorbers. 5. Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle. Save the fasteners for later assembly. 6. Raise the rear of the vehicle further to allow access to the underside of the rear fender. 7. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. Rear Fender Removal NOTE Note the location and orientation of rear fender mounting hardware, and save for later assembly. 1. Refer to the service manual and follow the instructions given to remove the rear fender, with the following exceptions: a. Removal of the tail lamp from the fender is not necessary. Rear Lamp Wiring 1. Cut off and discard the socket housings and terminal ends from the turn signal wires. 2. See Figure 1. Unscrew and remove the turn signal stalk (15) from one of the turn signal lamps, and discard. Remove and retain the turn signal lamp and support (14) from the rear fender support cover. 3. Insert the blade of a small screwdriver into the slot at the bottom of the turn signal lamp lens (2), and twist to unsnap the lens from the housing (1)