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HARLEY DAVIDSON "LIVE TO RIDE" HANDLEBAR GRIPS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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installation Do not lubricate the left grip of handlebar in any way before installation. This could allow grip to come off while riding which could result in loss of control of vehicle and death or serious injury. 1. Remove existing left handlebar grip by carefully cutting it away from the handlebar using a sharp blade or knife. Remove right grip/throttle sleeve assembly following instructions in appropriate Service Manual. After removal, make sure that left and right handlebar ends are clean and smooth. 2. Check that end caps are securely fastened to grips. Tighten screw inside grip to secure end caps. 3. Assemble new throttle sleeve to handlebar. Refer to appropriate Service Manual for detailed procedure. NOTE Surfaces to be glued must be clean, dry, and free from oil. If surfaces are not clean, dry, and free from oil, then the new application may not adhere as desired. Please observe the following WARNINGS when using the adhesive contained in this kit. FLAMMABLE, INJURIOUS TO EYES, HARMFUL IF SWALLOWED, VAPOR HARMFUL. FLAMMABLE: CONTAINS METHYL ETHYL KETONE. Use only in well ventilated areas. Avoid contact with eyes, mucous membranes, and prolonged skin contact. KEEP OUT OF REACH OF CHILDREN. If swallowed, do not induce vomiting. Call a physician immediately. This product contains a chemical(s) known to the State of California to cause cancer, birth defects or other reproductive harm. 4. Liberally apply a coating of Harley-Davidson Adhesive (Part No. 99839-95) to the inside of left handlebar grip using the cotton swab. Make sure adhesive fully covers all inside surface area of the grip. Also, apply a coat of adhesive to the handlebar end. 5. Check how the rectangular pattern is oriented on the throttle (right) grip. Align pattern on left grip to match right grip and immediately push the new grip completely onto handlebar end. 6. Rotate the end caps so the “Live to Ride”text is positioned at the top of both grips. NOTE Do not hesitate when installing left grip or adhesive will dry before installation is complete. Allow 6-8 hours at 70°F to achieve full cure of the adhesive. Prior to starting engine, verify that the throttle control will snap back to the idle position when released. A throttle control that prevents the engine from automatically returning to idle can lead to a loss of control of vehicle which could result in death or serious injury. Cleaning

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2010 APRILIA RS125 TECHNICAL SPECIFICATIONS

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

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1. MACHINES Aprilia RS 125 production models, as produced from 01-11-05 and available in the UK via IN Competition from 01-01-06. (any parts exclusive to the older models including the pre-1999 SP model are not permitted to be used on machines in this series). The only eligible models are designated as Euro 2 & Euro 3 New Euro 2 machines are supplied with race kits included through The machines used are allowed only limited modifications. Most modifications are allowed only on safety and cost control grounds. All motorcycles must comply in every respect with all requirements for Road Racing as specified in the ACU regulations. The appearance from both front, rear and profile of machines must (except when otherwise stated) conform to the homologated shape. The appearance of the exhaust system is excluded from this rule. 2. DISPLACEMENT CAPACITY The displacement must remain at 124.9cc and the bore and stroke (54 x 54.5) must remain as originally produced. 3. MINIMUM WEIGHT The minimum weight at post race control must not be less than 102kg , this includes oil and water but excludes fuel. At any time during the event, the weight of the whole machine (including the tank) must not be less than the minimum weight, with a tolerance of 1kg. 4. NUMBER PLATE COLOURS The background colours and figures for Aprilia Superteens are: FRONT RED background with WHITE numbers – Nitro Newcomers Class BLACK background with WHITE numbers – Aprilia Championship Class REAR BLACK background with WHITE numbers – Both Classes Placed in accordance with the ACU regulations. 5. CARBURATION INSTRUMENTS Carburation instruments must remain as homologated. Carburettor jets and needles may be replaced. No modification, polishing or cutting is allowed. Only the 28mm bodied standard carburettor is permitted. Electronic or mechanical enriching devices must remain installed and active (If the carburettor is changed from one model to another, the appropriate wiring loom must also be installed and be operative). Bell mouths must be as originally produced by the manufacturer for the homologated machine. Throttle must be standard, quick action throttles are not permitted. 6. FUEL All machines must function on normal unleaded fuel with a maximum lead content of 0.005 g/l (unleaded) and a maximum MON of 90 (RON 102 max) and be readily available from roadside service stations nationwide. E85 Bio Fuel is also permitted when purchased from normal roadside outlets.

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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

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

2009 APRILIA RS125 TECHNICAL SPECIFICATIONS

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

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1. MACHINES Aprilia RS 125 production models, as produced from 01-11-05 and available in the UK via IN Competition from 01-01-06. (any parts exclusive to the older models including the pre-1999 SP model are not permitted to be used on machines in this series). The only eligible models are designated as Euro 2 & Euro 3 New machines are supplied with race kits included through: IN Competition Unit 1 New Lane Burscough Lancs 2. DISPLACEMENT CAPACITY The displacement must remain at 124.9cc and the bore and stroke (54 x 54.5) must remain as originally produced. 3. MINIMUM WEIGHT The minimum weight at post race control must not be less than 102kg , this includes oil and water but excludes fuel. At any time during the event, the weight of the whole machine (including the tank) must not be less than the minimum weight, with a tolerance of 1kg. 4. NUMBER PLATE COLOURS The background colours and figures for Aprilia Superteens are: FRONT RED background with WHITE numbers – Nitro Newcomers Class BLACK background with WHITE numbers – Aprilia Championship Class REAR BLACK background with WHITE numbers – Both Classes Placed in accordance with the ACU regulations. 5. CARBURATION INSTRUMENTS Carburation instruments must remain as homologated. Carburettor jets and needles may be replaced. No modification, polishing or cutting is allowed. Only the 28mm bodied standard carburettor is permitted. Electronic or mechanical enriching devices must remain installed and active (If the carburettor is changed from one model to another, the appropriate wiring loom must also be installed and be operative). Bell mouths must be as originally produced by the manufacturer for the homologated machine. Throttle must be standard, quick action throttles are not permitted.
6. FUEL All machines must function on normal unleaded fuel with a maximum lead content of 0.005 g/l (unleaded) and a maximum MON of 90 (RON 102 max) and be readily available from roadside service stations nationwide. E85 Bio Fuel is also permitted when purchased from normal roadside outlets. 7. FRAME BODY AND REAR SUBFRAME Frame must remain as originally produced by the manufacturer and may not be painted. The sides of the frame body may be covered by a protective part made of composite material of the original frame colour. Nothing can be added by welding or removed by machining from the frame body. Engine mounting brackets or plates must remain as originally produced by the manufacturer. Bolt on accessories to the rear sub-frame may be removed. 8. FRONT FORKS Forks structure (spindle, stanchions, bridges, stem etc) must remain as originally produced by the manufacturer. Standard original internal parts of the forks may be modified. After market damper kits or valves may be installed. The fork caps can be modified or changed to add spring preload/compression and damping adjusters. Dust seals can be modified, changed or removed providing the fork remains totally oil sealed. Any quantity or quality of oil can be used in the front forks. The height and position of the front fork in relation to the fork crowns is free. A steering damper may be added but may not act as a steering lock device. 9. REAR FORK (Swing Arm)

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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HONDA TRX 450R Nerf Bar INSTALLATION AND REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 23-12-2011

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Parts List: Quantity Part 1 Nerf Bar Left 1 Nerf Bar Right 2 Hex Head Bolt, M10 x 70mm 2 Flat Washer, M10 2 Hex Head Bolt, M6 x 16mm 2 Flat Washer, M6 4 Net Clips 1 Net Set 2 Footpeg Washer 2. Preparation: a) Set/Lock rear parking brake on bike, turn gas petcock to ‘Off’ position and stand bike upright so that it is sitting on the rear grab bar. Make sure vehicle is secure and will not fall over while installing your new Nerf Bars. 3. Installation: a) Install Hardware & Web Strap per photo’s: NOTE: Loosely install all hardware and tighten when complete. Torque M10 Bolts @ 30 ft. lbs. Torque M6 Bolts @ 8 ft. lbs. REMOVE & REUSE OEM BOLTS TO ATTACH FOOT PEG. ATTACH FOOT PEG TO NERF SUPPORT USING M6 X 16MM HEAD BOLT AND WASHER. ATTACH NET CLIPS NOTE: FIRST SLIDE LEFT NERF WELDED TUBE INTO RIGHT NERF TUBE THEN, LOOSELY ATTACH FRONT NERF BARS TO THE A-ARMS USING OEM NUTS AND SUPPLIED M10 X 70MM BOLTS AND WASHERS

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Aermacchi IHRO1 Machine Specifications

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Filed Under (Aermacchi) by admin on 13-11-2010

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1. IHRO 1 caters for single cylinder thoroughbred Grand Prix racing motorcycles constructed during the period 1945-1972 inclusive, for the specific purpose of participation in Grand Prix competition during that era. Maximum capacity for any machine is 500cc, and wherever possible it is intended to run three classes, for machines up to 250cc, 350cc and 500cc. 2. Motorcycles must be presented in original, period condition, with no external updating. Period appearance seats, fuel tanks and fairings (if fitted) must be used. No external changes may be made to the appearance of any machine unless it can be proved that such a change was made in the period. Modern safety fixtures required by some federations and modifications mentioned in this document are not covered by this ruling. 3. No disc brakes are allowed. Drum brakes only may be used. 4. No alloy/magnesium wheels are allowed. Wire wheels only may be used. 5. All machines must have twin shock rear suspension: No monoshocks except Vincent Grey Flash. Suspension units must resemble period components, i.e. no external gas reservoirs etc. 6. All frames and swinging arms must conform exactly to period appearance; no box section swinging arms allowed unless fitted by the manufacturer to that machine in the period. 7. The maximum permitted rim width on either wheel is WM3. 8. No slick tyres, hand cut slicks or modern racing tyres designated by the manufacturer as being exclusively for wet weather use are permitted. Only the following rear tyres may be fitted. Any 19″ tyre. The following 18″ tyres, Dunlop 3.50×18, 3.50/3.25×18 KR124 and KR124A, Avon AM22 110/80×18 Rear Fitment and Avon AM18 120×18 9. Choice of carburettor is free, provided that this is of a period type cylindrical slide model, albeit of a later manufacture. Flat slide instruments are not permitted with the exception of Gardner carburettors. Fuel injection is not permitted except if it can be proved that particular motorcycle ran between 1945-72 with the same type of injection system fitted. A Wal Philips injector is classified under this heading. 10. The type of fuel used must conform to the ACU and FIM’s current fuel regulations for 100LL Avgas at 102 MON. See full specifications below. All machines must finish a race with a minimum of 2 litres of fuel in the tank to allow a sample to be taken for analysis. 11. The use of belt primary drives is encouraged.

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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.

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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