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Yamaha XVS 13AW Owner's Manual REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 06-01-2012

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GASOLINE IS HIGHLY FLAMMA- BLE: Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes

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HARLEY DAVIDSON ADVANCED AUDIO COMMUNICATION SWITCH KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 2. Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. 3. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. 4. On the fairing cap, remove the inner left side hole plug. See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch. If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. b. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. c. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B] 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. 6. Install the new left-hand control switch assembly (3) from the kit. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 7. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) • Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops. 8. Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. 9. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse

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YAMAHA V-Star 1100 Motorcycle Enhancements Remote Oil Filter Installation Manual

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Filed Under (Yamaha) by admin on 10-11-2010

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Removing Your Old Filter and Beauty Cover In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p. The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter. Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover. “O” ring for bottom bolt. When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover.

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Yamaha V-Star 650 Rear Lowering Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 18-10-2010

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INSTALLATION PROCEDURE 1. Secure motorcycle to a bike lift and raise the motorcycle. 2. Remove stock rear shock from the motorcycle per standard Yamaha shop manual instructions. 3. Place the shaft of the shock in V” blocks and secure this in a vice or press, applying firm pressure to the V” blocks to trap the shaft so it will not turn. Unscrew the upper shock mount eyelet from the shaft. NOTE: The upper mount is a standard thread so you will rotate the mount counter-clockwise to unscrew it. 4. Next, screw the New LA Choppers Shock Mount onto shock shaft using Loctite. 5. Re-install shock spring, making sure it is locked in place with the retaining ring prior to slowly releasing the spring compressor. Allow shock spring to expand against the retaining ring and machined washer. 6. Reinstall shock onto the motorcycle per standard Yamaha shop manual instructions. WARNING: Installing a lowering kit will decrease initial ground clearance. The motorcycle will be lower to the ground and care should be taken to avoid bottoming, especially over bumps or in turns. To maintain proper balanced geometry, the front and rear of the motorcycle should be lowered equally. Failure to properly install the lowering kit and operate the motorcycle after installation may result in serious injury or death to the rider. LIMITED GUARANTY: Because we cannot control the application of our products, buyer assumes risks for any and all damage caused to him or herself or any third party by virtue of any failure of these parts. Guaranty for such parts is limited to our replacement costs thereof. This guaranty is in lieu of all other guaranties or warranties express or implied, and all other such guaranties or warranties are hereby expressly disclaimed. By installation of these parts, buyer irrevocably agrees to the foregoing

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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SUZUKI GSX-R1000 SERVICE MANUAL

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

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Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. 5. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft) ! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. ! Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

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HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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KTM 250-525 SX, MXC, EXC RACING ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 07-02-2012

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TM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents. Remove page (s) Replace by page (s) Insert page (s) after page 2-1 / 2-7 2-1C 2-7C to 2-9C 3-1 3-1C 4-1 to 4-14 4-1C to 4-13C 5-1 / 5-3 5-1C / 5-3C 5-6 to 5-8 5-6C to 5-8C 5-12 to 5-26 5-12C to 5-27C 6-1 / 6-4 6-1C / 6-4C 6-7 to 6-16 6-7C to 6-17C 7-1 to 7-2 7-1C to 7-2C 7-7 to 7-11 7-7C to 7-11C 8-1 to 8-13 8-1C to 8-21C 9-1 9-1C 9-10 to 9-13 9-10C to 9-16C 10-1 10-1C 10-8C to 10-11C 11-1 11-1C 11-11C to 11-13C
Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E EXPLANATION – UPDATING Edition 01/2003 3.205.85-ERepair Manual 400/520 SX, MXC, EXC RACING Basic version Model year 2000 (Engine number with first digit “0″) 2/2000 3.210.01-EUpdating of Rep.Manual 3.205.85-E Model year 2001 (Engine number with first digit “1″) 1/2001 3.210.44-EUpdating of Rep.Manual 3.205.85-E Model year 2002 (Engine number with first digit “2″)

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1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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Yamaha YZF-R1 Undertail Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 11-01-2012

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Carefully remove the tail section body work. Save all bolts, washers and plastic rivets for re-installation of tail. Disconnect and remove the brake light (with all mounting grommets and washers), license plate and turn signals, key lock (with clip) and move all wiring out of the cutting areas. Remove the two bolts at the rear end of the stock fender (inside glove box) to allow the end to hang down for cutting. 2) Using a “Dremel” tool or cutting disc (this can also be done using a sharp edged knife, but is not recommended), remove the plastic shown in the photos above and below. Be sure to take your time cutting, so that you don’t cut away any more plastic than necessary. 3) Now relocate the rear mounting holes for the glove box 1.25″ lower in the tray to raise it up in the subframe as shown. Yamaha YZF-R1 Undertail Kit (2000-01, Available in: Yamaha Red, Yamaha Blue) Need Help? If you need additional help with the installation of the undertail, go to www.hotbodiesracing.com and look for the “FAQs” link at the bottom of the home page. Most of your general questions can be answered on those pages. This installation does require a basic mechanical aptitude, if in doubt, contact your local motorcycle shop and have a professional mechanic perform the installation, 3 hours is the average installation time. * After this modification your undertail is not returnable. Paint is not war- rantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray. 5) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail, carefully mark and drill holes, install using the two (2) sets of allen bolts and lock nuts

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