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Harley Davidson BoonDocker Nitrous System Installation MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2012

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BoonDocker Liquid Nitrous – 1589 Hollipark Dr. Idaho Falls, ID 83401 – (208) 542-4411 web site: www. boon dockers. com – email: info@boon dockers. com Revised 02-27-04 Page 2 of 10 This manifold is also designed to vary the float bowl pressure in relation to nitrous pressure, thus keeping the nitrous and fuel delivery in sync. Fluctuations in bottle temperature greatly affect nitrous pressure, which affects nitrous delivery. By automatically adjusting the fuel delivery as nitrous pressure varies, this manifold makes nitrous safe, reliable, and easy to use. Be sure to understand and follow the tuning instructions at the end of these instructions. Proper tuning is an important part of any performance-enhancing product. Part I – Bottle Installation A. Bottle Valve Fittings Insert the 4AN x 1/8″ NPT fitting and the 1/8″ NPT Plug into the bottle valve (these are attached to the lid of the box for the bottle) . Use Teflon tape to seal the threads – be sure not to get tape inside the threads! B. Bottle Mounting Position With nitrous in the bottle, both nitrous liquid and nitrous gas are present under high pressure (760 psi at 70 deg F) . Due to gravity and acceleration forces, the liquid portion of the nitrous will be at the bottom and rearward parts of the bottle. For this nitrous system to work properly, it is important that nitrous liquid be drawn from the bottle. Nitrous vapor will cause a significant decrease in performance. For best results, the bottle should be mounted so the valve is pointed down and towards the back of the vehicle as shown below. ************** *************** ******** ********* *************** (can be installed on top or bottom of air boot) ********** ********* push-button switch (mounts on handlebar) +12 V *********** ************ **** ****** *! “**#$******%* *! “**#$*#*%* 20 deg to 90 Front of motorcycle Rear of motorcycle BoonDocker Liquid Nitrous – 1589 Hollipark Dr. Idaho Falls, ID 83401 – (208) 542-4411 web site: www. boon dockers. com – email: info@boon dockers. com Revised 02-27-04 Page 3 of 10 Bottle mounted inside airbox: For some applications, a small bottle can be mounted inside the airbox as shown. Note: because of the restricted space, it was necessary to mount this bottle at a non-optimal angle (the valve is pointed towards the front instead of the rear)

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KTM ATV 525 XC specification

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

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

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Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

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Kawasaki VN1600 Highway Bar INSTALLATION AND OWNER'S MANUAL

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

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PREPARATION 1. Insure that the motorcycle is on flat level ground. 2. It is recommended that the motorcycle sit for at least one hour prior to installation to allow the engine to cool. During installation tight all fasteners to hold. Wait until you check all clearances and operation of the brake and shift lever to firmly tighten and torque all fasteners. INSTALLATION Right Side Highway Bar 1. Remove the front floor board bolt (M10). (14mm Socket) Figure 1. Right and Left side of Motorcycle is determined while sitting on the bike.
MAINTENANCE / CAUTION The high quality chrome finish of your National Cycle Chrome Highway Bar can be maintained with any quality chrome cleaner and / or polish applied with a soft cloth. Check hardware for tightness regularly. Never ride with loose mounting hardware. Check to be sure your Highway Bar does not contact any part of the motorcycle at a full turn left and right. Correct any problem before using the motorcycle. ©2005 National Cycle, Inc. PO Box 158, Maywood, IL60153-0158 USA 708-343-0400 / Fax: 708-343-0625 / www.nationalcycle.com / e mail: info@nationalcycle.com Page 2 of 2 10-114857-000 09/05 Install Upper “U” Bolt 2. Place “U” Bolt between the radiator and the down tube at the location shown in Figure 2. Threaded ends of “U” will face out- ward. 3. Select the right side Highway Bar. 4. Loosely install the Highway Bar at the lower mount point using the stock screw. (14mm Socket) Figure 3. While installing the Whizlock Nuts in the following Step #5 , be certain to tighten the nuts evenly, alternating left and right as you tighten. When complete you want the same amount of threads exposed on the ends of the “U” to insure the bolt does not rotate. 5. Install the upper Highway Bar with Whizlock Nuts. (1/2″ Socket) Figure 4. Orient assembly so Whizlock Nuts face outside. Firmly tighten after all clearances are checked. LEFT SIDE INSTALLATION 6. Repeat Steps 1 and 2. On the Left Side due to tight clearances between the radiator and the down tube you must locate the point where the radiator is “notched out” slightly. Figure 5. 7. Select the left side Highway Bar. 8. Repeat Steps 4 and 5.

Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

APRILIA SMV 750 DORSODURO Technical Specifications

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Filed Under (Aprilia) by admin on 07-11-2010

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Engine Aprilia V90 four stroke longitudinal 90° V twin. Liquid cooling. Double overhead camshaft with mixed gear/chain drive; four valves per cylinder. Fuel Unleaded petrol. Bore x stroke 92 x 56.4 mm. Total displacement 749.9 cc. Compression ratio 11 : 1. Maximum power at the crank 67.3 kW (92 HP) at 8750 rpm. Maximum torque at the crank 8.4 kgm (82 Nm) at 4500 rpm. Fuel system Integrated engine management system. Electronic fuel injection with ride-by-wire electronic throttle control. Ignition Digital electronic, integrated in the fuel injection system. Starting Electric. Exhaust Two in one system in 100% stainless steel with three-way catalytic converter and Lambda probe. Alternator 450 W at 6000 rpm. Lubrication Wet sump. Gearbox Six speed. Transmission ratios: 1 st 14/36 (2.57) 2 nd 17/32 (1.88) 3 rd 20/30 (1.5) 4 th 22/28 (1.27) 5 th 23/26 (1.13) 6 th 24/25 (1.04) Clutch Hydraulically operated multi-plate wet clutch. Primary drive Spur gears. Transmission ratio 38/71 (1.87). Final drive Chain. Transmission ratio 16/46. Frame Modular steel trellis secured to aluminium side plates by high strength bolts. Detachable rear frame. Front suspension 43 mm upside-down fork. 160 mm wheel travel. Rear suspension Aluminium alloy swingarm. Hydraulic shock absorber adjustable in spring preload and rebound damping. Wheel travel: 160 mm. Brakes Front: Double stainless steel floating disc (Ø 320 mm) . Four- piston radial calipers. Metal braided brake line. Rear: Stainless steel disc (∅ 240 mm) with single piston caliper. Metal braided brake line. Wheels Aluminium alloy. Front: 3.50 x 17″. Rear: 6.00 x 17″. Tyres Radial tubeless. Front: 120/70 ZR 17. Rear: 180/55 ZR 17. Dimensions Overall length: 2216 mm Overall width: 905 mm (at handlebars) Overall height: 1185 mm (at instruments) Seat height: 870 mm Wheelbase: 1505 mm Trail: 108 mm Rake angle: 26° Weight: 186 kg Tank capacity 12 litres (autonomy > 200 km)

APRILIA DORSODURO FACTORY 750 Technical Specifications

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Filed Under (Aprilia) by admin on 06-11-2010

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Engine type Aprilia V90 four-stroke longitudinal 90° V-twin engine, liquid cooled, double overhead camshafts with mixed gear/chain timing system, four valves per cylinder. Fuel Unleaded petrol Bore and stroke 92 x 56.4 mm Total engine capacity 749.9 cc Compression ratio 11: 1 Maximum power at crankshaft 67.3 kW (92 cv) at 8,750 rpm Maximum torque at crankshaft 8.4 kgm (82 Nm) at 4,500 rpm Fuel system Integrated engine management system. Injection with Ride by Wire throttle opening management and triple mapping Ignition Digital electronic ignition integrated with injection system. Starting Electric Exhaust system 2 into 1 exhaust system in 100% stainless steel with three-way catalytic converter and lambda probe Alternator 450 W at 6,000 rpm Lubrication Wet sump Gearbox 6 speeds, drive ratio: 1st 14/36 (2.57) 2nd 17/32 (1.88) 3rd 20/30 (1.5) 4th 22/28 (1.27) 5th 23/26 (1.13) 6th 24/25 (1.04) Clutch Multiple discs in oil bath, hydraulically operated Primary drive Straight cut gears, drive ratio: 38/71 (1.87) Secondary drive Chain. Drive ratio: 16/46 Chassis Modular tubular steel frame fastened to aluminium side plates with by high strength bolts. Removable rear subframe. Front suspension Multi-adjustable Sachs upside-down fork with Ø 43 mm diam. stanchions. Wheel travel 160 mm. Rear suspension Aluminium alloy swingarm Gas-operated shock absorber with piggy back with adjustable spring preload and compression and rebound damping. Wheel travel 160 mm. Brakes Front: Dual Ø 320 mm diam. stainless steel floating discs. Radial callipers with four pistons. Metal braided brake pipe. Rear: Stainless steel disc Ø 240mm. Single piston calliper. Metal braided brake pipe. Wheel rims Aluminium alloy Front: 3.50 X 17″ Rear: 6.00 x 17″ Tyres Radial tubeless tyres; front: 120/70 ZR 17 rear: 180/55 ZR 17 Dimensions Max. length 2,216 mm Max. width 905 mm (at handlebar) Max. height 1,185 mm (at instrument panel) Saddle height 870 mm Wheelbase 1,505 mm Trail 108 mm Steering angle 26° Tank 12 lt (range > 200 km)

APRILIA SL 750 SHIVER Technical Specifications

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Filed Under (Aprilia) by admin on 06-11-2010

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Engine Aprilia V90 Four stroke longitudinal 90° V twin. Liquid cooling. Double overhead camshaft with mixed gear/chain drive; four valves per cylinder. Fuel Unleaded petrol. Bore x stroke 92 x 56.4 mm Total displacement 749.9 cc Compression ratio 11 : 1 Maximum power at the crank 95 HP at 9000 rpm. Maximum torque at the crank 8.25 kgm at 7000 rpm. Fuel system Integrated engine management system. Injection with Ride by Wire technology control of the throttle bodies Ignition Digital electronic, integrated with the injection, two spark plugs per cylinder Starting Electric Exhaust Two in one system in 100% stainless steel with three-way catalytic converter and Lambda probe Generator 450 W at 6000 rpm. Lubrication Wet sump Gearbox six speed, transmission ratio: 1° 36/14 (2.57) 2° 32/17 (1.88) 3° 30/20 (1.5) 4° 28/22 (1.27) 5° 23/26 (0.88) 6° 24/25 (0.96) Clutch Multi-plate in oil bath, cable operated. Primary drive Spur gears, transmission ratio: 60/31 (1.75) Final drive Chain Transmission ratio: 16/44 Frame Dismountable steel trellis connected with high strength bolts to aluminium side plates. Dismountable rear frame. Front suspension 43 mm upside-down fork. 120 mm wheel travel Rear suspension Aluminium alloy swingarm with reinforcement truss. Hydraulic shock absorber adjustable in spring preload and rebound damping. Wheel travel: 130 mm. Brakes Front: Double stainless steel floating disc (Ø 320 mm ). Four piston radial calipers. Metal braided brake line. Rear: Steel disk (∅ 245 mm) with twin piston caliper. Metal braided brake line. Wheels In aluminium alloy Front: 3.50 X 17″ Rear: 6.00 X 17″ Tyres Radial tubeless; front: 120/70 ZR 17 rear: 180/55 ZR 17 Dimensions Overall length 2066 mm Overall width: 815 mm (at handlebars) Overall height: 1132 mm Seat height: 810 mm Wheelbase: 1449 mm Trail: 109 mm Rake angle: 25.7° Dry weight 189 kg Tank capacity 15 lt

Aprilia Shiver 750 Sport Technical Specifications

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Filed Under (Aprilia) by admin on 06-11-2010

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Engine Type Aprilia V90 four-stroke longitudinal 90° V-twin engine, liquid cooled, double overhead camshaft with mixed gear/chain timing system, four valves per cylinder. Capacity 749.9 cc Bore and stroke 92 x 56.4 mm Compression ratio 11 : 1 Maximum power at crank 95 HP at 9000 rpm. Max Torque at crank 8.25 kgm at 7000 rpm. Fuel supply Ignition Integrated engine management system. Injection with Ride by Wire technology control of the throttle bodies. Digital electronic, integrated with the injection. Exhaust system Two in one system in 100% stainless steel with three-way catalytic converter and Lambda probe. Clutch Multi-plate in oil bath. Hydraulically operated. Lubrication Wet sump Frame Modular tubular steel frame fastened to aluminium side plates by high strength bolts. Removable rear subframe. Front suspension 43 mm upside-down fork. 120 mm wheel travel. Rear suspension Aluminium alloy swingarm with swingarm stiffener brace. Hydraulic shock absorber adjustable in spring preload and rebound damping. Wheel travel: 130 mm. Front brakes Wave stainless steel floating disc (Ø 320 mm). Four piston radial callipers. Metal braided brake line. Rear brake Wave Stainless steel disc (∅ 240 mm) with single piston calliper. Metal braided brake line. Wheels Aluminium alloy Front : 3.50 X 17″ Rear : 5.50 X 17″ Length 2265 mm Width 800 mm (at handlebars) Height Tank Capacity 1135 mm (at instruments) 15 Litres

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