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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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HW Prowler Carburetor Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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1. Remove both seats and the plastic seat pans under the seats. 2. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. 4. Disconnect the engine breather hose from the bottom of the air box 5. Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape. 7. Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig. #1 9. Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. #2 10. Loosen the clamp on the rear of the carb holding the carb on 11. Pull the carb out of the intake boot 12. Set OE carb to the side. 13. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. 14. Route all the breather lines connected to the carb down under the carb. 15. Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. See Fig. #3 16. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. See Fig. #3 17. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. 18. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. 19. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. 20. Remove the plastic nut from the bottom of the choke handle on the choke cable. 21. Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this

42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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Mikuni HSR 42/ 45 Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at ½ to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle.

BILLET ALUMINUM DISTRIBUTOR WITH ELECTRONIC ADVANCE AND ADJUSTABLE REV LIMITER FOR 1936-69 HARLEY BIG TWIN MOTORCYCLES INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ELECTRICAL SYSTEM A 12 volt electrical system is required. Check that the charging system is working properly and not producing over 16 volts. DISTRIBUTOR CLAMP A 1966-69 style distributor clamp (original or aftermarket) is required. MODULE This distributor uses an Accel Single/Dual Fire Ignition module part number 35496. See the enclosed form “Instruction Sheet Single/Dual Fire” for instructions on wiring, adjusting the rev limiter and selecting an advance curve. COIL(S) A coil(s) with a total primary resistance of 2 to 4 ohms is recommended. INSTALLATION Step 1 Turn the ignition switch to the off position. Rotate the engine until it is on the compression stroke for the front cylinder. Continue to rotate the engine until the TDC mark is visible through the timing hole. (see repair manual if necessary). Step 2 Remove the existing distributor if still in the engine. Step 3 Remove the two button head screws from the top of the Mallory distributor. Pull the top cover off the distributor. Remove the two hex standoffs and pull the module and upper housing off the distributor base assembly. Adjust the switches on the module for the desired advance curve and rev limit. FORM 1627 07/08 Step 4 Install the distributor base assembly in the engine with the screw holes and shutter wheel positioned as shown in Figures 1 and 2. It may be necessary to pull the distributor out, turn the shaft and reinstall to get the shutter wheel at the approximate angle shown. The slots should be at about the11 o’clock and 7 o’clock positions. The screw holes should be at the 9 o’clock and 3 o’clock positions. Step 5 Install the distributor clamp and tighten the clamp bolt lightly so the distributor can still be rotated. Step 6 Set the upper housing on the base assembly as shown in figure 3. (The upper housing will only install one way because of the locating screw) Rotate the base assembly slightly if necessary so that the slot in the shutter wheel lines up with the slot in the upper housing. Tighten the distributor clamp

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CL-1000 CONDOR CYCLE LOADER USER INSTRUCTION MANUAL

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Filed Under (Tips and Review) by admin on 25-11-2010

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Confirm that the cradle is set in the optimized position setting (See RECOMMENDED CRADLE SETTINGS) for the entering tire and wheel. Adjustment of cradle is crucial for optimum retention. Optimum retention is achieved by trying different settings. ( REFER TO CAUTION PARAGRAPH BELOW ): If the optimum vertical support is achieved, the motorcycle will hold itself upright. If optimum retention is not achieved try different cradle settings. ( REFER TO CAUTION PARAGRAPH BELOW ). Once cradle is positioned, tighten the brakes using the eye bolts and place the Cycle Loader in front of the motorcycle. Push or drive the motorcycle, centered into unit, until the cradle of the Cycle Loader has fully engaged the wheel. Once the wheel is cradled, proceed to push further into the Cycle Loader until the wheel has engaged the front stop. If the optimum vertical support is achieved, the motorcycle will hold itself upright. As an extra precaution, an optional Velcro strap may be used to strap the cradled wheel to the front stop (Optional Velcro strap purchased separately). Always strap Velcro through the wheel and around the front stop below the upper front stop flange. Loosen the brakes and use two (2) tie-down straps to secure the motorcycle to the two front eyebolts of the Cycle Loader. Hook wench to Ω” ‘U’ hook in front of Cycle Loader. Use the wench to pull the Cycle Loader with motorcycle up the flat bed. Once the motorcycle is all the way on the flat bed, the bike should be secured to the flat bed itself. For more information on use, refer to www.condor- lift.com. RECOMMEDED CRADLE SETTINGS: The Condor® Cycle Loader is designed so that for every tire/wheel size within the ranges specified a minimum of 2 cradle settings is suitable. **The optimum cradle setting for a specific tire would be, the setting that allows the cradle to tilt flush with the unit/ or º” below the opening in the main unit where the cradle sits, without touching.** The 2nd optimum setting would be the setting forward from the optimum setting away from the entry direction. If less retention is desired at any time due to too much retention or sticking, the cradle may be moved away from the entry direction one notch. RACING APPLICATIONS: For bikes with GP or low durometer front tires compounds, use the 5th cradle setting from the entry directions. CAUTION: Always make sure that all fasteners are tight and all pins are in place prior to use. Understand the limitations of this product and do not exceed these limitations. Always make sure that the unit’s cradle settings are optimum for the tire size of the motorcycle before use. For bikes with very low fenders and or cowlings, a custom cradle may be purchased fitted to specific tire sizes, so as not to make contact. For standard sport bike front wheel combinations, the 1, 2, 3, front settings may be suitable. If instructions are not clear, additional information is available at www.condor-lift. com or call 1-800-461-1344. Technical Components Development & Design is not responsible for any damage incurred by exceeding this product’s limitations in structure and/or functionality.

Cobra Motorcycle and ATV Specifications CX65 CX50 Sr. (The King) CX50 Jr. ECX 70 ECX 50 ECX80AC

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Filed Under (Cobra) by admin on 14-11-2010

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Dry Weight 122 lbs 91 lbs 81 lbs 210 lbs 206 lbs 210 lbs Engine Cobra 65cc 2-stroke Cobra 50cc 2-stroke Cobra 50cc 2-stroke Cobra 70cc 2-stroke Cobra 50cc 2-stroke Cobra 80cc 2-stroke Bore x Stroke 44.5mm x 41.7mm 39mm x 41.7mm 39mm x 41.7mm 44.5mm x 44.7mm 39mm x 41.7mm 47.6 mm x 44.7mm Induction Case Reed V-Force® Reed Valve- 24mm Mikuni carb Case Reed Carbon Pedal 19mm carb Case Reed Carbon Pedal 14mm carb Case Reed V-Force® Reed Valve- 24mm Mikuni carb Case Reed Carbon Pedal 21mm carb Case Reed V-Force® Reed Valve- 24mm Mikuni carb Cooling Water cooled Cylinder and Case Water cooled Water cooled Water cooled Cylinder and Case Water cooled Water cooled Cylinder and Case Clutch Hydraulic ally actuated Cobra 3Gx 3-Shoe Cobra 3Gx 3-Shoe Hydraulic ally actuated – (auto option) Cobra 3Gx 3-Shoe Rekluse Z-ball auto-clutch Transmission Six-speed sequential Single-speed auto Single-speed auto Six-speed sequential Single-speed auto Six-speed sequential Exhaust Tuned pipe and silencer Tuned pipe and silencer Tuned pipe and silencer Tuned pipe and silencer Tuned pipe and silencer Tuned pipe and silencer Lubrication Mixture lubrication Mixture lubrication Mixture lubrication Mixture lubrication Mixture lubrication Mixture lubrication Fuel Capacity 1.06 Gallons .85 Gallons .70 Gallons 1.9 Gallons 1.9 Gallons 1.9 Gallons Frame Twin Spar Oval HSLA Double Cradle 4130 ChrMo Steel Double Cradle 4130 ChrMo Steel Arens design twin spar Arens design twin spar Arens design twin spar Wheelbase 1140mm 990 mm 908 mm 1067mm (track 915mm) 1067mm (track 915mm) 1067mm (track 915mm) Seat Height 762mm 680 mm 607 mm 762 mm 737 mm 762mm Ground Clearance 250mm 240 mm 216 mm 205 mm 205 mm 205mm Front Brakes Hydraulic Disk (205mm) Hydraulic Disk (160mm) Hydraulic Disk (160mm) Hydraulic Disk (160mm) Hydraulic Disk (160mm) Hydraulic Disk (160mm) Rear Brakes Hydraulic Disk (165mm) Hydraulic Disk (140mm) Adjustable Drum Hydraulic Disk (180mm) Hydraulic Disk (180mm) Hydraulic Disk (180mm) Front Suspension Marzocchi 35mm USD Adjustable 220mm travel Cobra 30mm USD 210mm travel Marzocchi 32mm 168mm travel Dual A-Arm with SVO™ patented steering design. 248mm travel Dual A-Arm with SVO™ patented steering design. 248mm travel Dual A-Arm with SVO™ patented steering design. 248mm travel Rear Suspension Öhlins Fully Adjustable 270mm travel Fox Piggyback Fully Adjustable 248mm travel Öhlins Piggyback 170mm travel Fox Piggyback 220mm travel Solid axle Fox Piggyback 220mm travel Lightweight tube axle Fox Piggyback 220mm travel Solid axle Wheel Front / Rear 14″ spoke / 12″ spoke (Al rims, Billet hubs, 9ga. spokes) Cobra 12″ Billet Cobra 10″ Billet Cobra 10″ Billet Cobra 10″ Billet ITP 10×5 (4 x1) Al Douglas 8×6.5 (4×2.5) Al ITP 10×5 (4 x1) Al Douglas 8×6.5 (4×2.5) Al ITP 10×5 (4 x1) Al Douglas 8×6.5 (4×2.5) Al Tires Front / Rear 60-100×14 Dunlop 80-100×12 Dunlop 2.5×12 / 2.75×10 2.5×10 / 2.75×10 ITP Holeshot 19/6 ITP 16/6.50-9 ITP Holeshot 19/6 ITP 16/6.50-9 ITP Holeshot 19/6 ITP 16/6.50-9

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THUNDERJET INSTALLATION FIXTURE for S&S CARBURETORS

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Filed Under (S&S) by admin on 31-10-2010

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FUEL DELIVERY TUBE 6 5 6 5 6 5 6 5 -A Ambe -A Ambe r rton Drive, Elkridg e, MD 21075 410-579-2828 e, MD 21075 410-579-2828 ton Drive, Elkridg Using the two ¼”- 20 cap screws provided, secure t carb body at air cleaner surface to fixture through h # 2 & 5 . NOTE: Holes # 2 & 6 may be used to angle th ThunderJe clearance is needed below the fuel tank. he oles e t farther forward if additional ADJUSTABLE AIR BLEED les # RIGINAL AIR Secure Carb to fixture using ho & 8. 1 O LEED B BLOCKING Secure C fixture using ho & 6. arb to les # 1 BOWL VENT RELOCATION Secure Carb to fixture using holes # 6 & 7 . FLOAT BOWL ee Reverse side for S&S ‘B’ & ‘D’ Secure float bowl to fixture using the 3/8″- 16 flange nut and threaded rod provided using the 20 degree slope. S instructions. S&S ‘B’ & ‘D’ CARBS EXTERNAL BOWL VENT 6 5 6 5 6 5 6 5 -A Amberton Drive, Elkridge, MD 21075 410-579-2828 -A Amberton Drive, Elkridge, MD 21075 410-579-2828  ADJUSTABLE AIR BLEED THUNDERJET FUEL TUBE :00 position, viewed facing air filter (9 surface) sing the two #10-24 cap screws provided, :00 position, viewed facing air filter U secure the Carb body at bowl surface to fixture through the two holes marked ‘B’ . (3 surface) Using the two #10-24 cap screws provided, FLOAT BOWL secure the Carb body at bowl surface to fixture through the two holes marked ‘D

HONDA TRX 400EX Removing Stock Carb and Cables INSTRUCTION

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Filed Under (Honda) by admin on 21-12-2011

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Remove seat/fender assembly and fuel tank. 2. Remove throttle cables paying close attention to routing. 3. Remove thumb throttle housing if you are installing a twist throttle. 4. Remove air box and air box intake tube. 5. Remove stock carburetor. 6. Stuff a clean rag into intake manifold to keep debris from entering engine. Preparing machine for carburetor installation 1 . Route the provided throttle cables per manufacturer’s recommended procedure, routing them the same as the stock cables. 2 . Remove the rubber alignment tabs from the manifold using a razor blade or cutters. Be very careful not to damage the intake manifold! 3. Remove air box intake tube from the air box and use a hacksaw to cut approx. 1½” off of the air box intake tube. Your tube should resemble the one shown in Figure 1. Re-assemble the air intake tube into air box and install back onto bike. Don’t forget to tighten clamp around intake tube and reinsert crank vent into the air boot. Figure 1. Thumb Throttle Attach cable into cable wheel with the cable end at the 8: 00 position of the cable wheel, then into bracket. Secure by replacing the cable bracket end and phillips screw. See Figure 2. Figure 2. Twist Throttle 1. Install the pull (see figure 4 for cable identification) , cable end into the 8: 00 position and the idle cable end into the 11: 00 position on the cable wheel. See Figure 3

YAMAHA V-STAR 1100 HYPERCHARGER AIRCLEANER INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 09-11-2010

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STEP 1 Remove the driver and passenger seats from the bike. Remove the negative battery cable from the battery and tuck it out of the way to reduce the possibility of sparks. STEP 2 Remove the two rear tank mounting bolts. Remove the plastic tank mounting snap stud. (Push in on the center of it to release). Slide the tank back to expose the top of the engine. Make sure the tank is solidly in place so it does not fall! You may remove the tank completely from the bike if you’re not certain the tank will stay in place while you are performing this installation. STEP 3 Remove the stock air cleaner cover, element, and backing plate. Twarrants that any Küryakyn product sold hereunder, if properly installed, maintained and operated under normal conditions, shall be free from any defects in materials and workmanship for a period of one (1) year from the date the Küryakyn products are sold to the customer. CONSEQUENTIAL DAMAGES: Küryakyn shall not be liable for any consequential or incidental damages. ABOUTOURCA TA LOG You’ll find all our innovations for H-D, GL and Metric Cruisers in our annual catalogs. Order online today-select the “CATALOGS” icon. Each Küryakyn™ product comes with a Proof-of-Purchase good for a complimentary catalog. Details in packaging. Be sure to ask your local dealer about other Küryakynproducts, the motorcycle parts and accessories designed for riders by riders. ©2003 Küryakyn USA™All Rights reserved. STEP 4 See PIC. 1and PIC.2. Remove the grommet from the bracket. STEP 5 Placing your long handled Phillips screwdriver as shown in PIC.3, loosen the clamp on the air duct and remove the duct. Remove the clamp from the duct— it will be reused. Now is a good time to proceed with rejetting of the carburetors. Consult your factory service manual for this procedure. We have supplied jets to cover most common applications. Jetting Recommendations: See FIG. 1for jet locations. With stock exhaust or Cobra Slip-On Mufflers • 1.2 Pilot Air Bleeds in both carbs • One .020 shim added to raise each needle • 122.5 Main Jet in the front cylinder’s carb • 120 Main Jet in the rear cylinder’s carb • Pilot Mixture Screw (PMS) 2 turns out from lightly bottomed With Vance & Hines, Samson, or open “Drag” pipes • 1.2 Pilot Air Bleeds in both carbs • One .020 shim added to raise each needle • 125 Main Jet in the front cylinder’s carb • 122.5 Main Jet in the rear cylinder’s carb • Pilot Mixture Screw (PMS) 2 turns out from lightly bottomed NOTES 1. The factory installed plug covering the PMS will have to be removed in order to access the screw. 2. Because the float bowl screws are easily damage during removal, we have included 8 replacement float bowl screws with socket heads, just in case they are needed. BE SURE TO VENT THE FLOAT BOWLS TO THE BACK OF THE HYPERCHARGER — THIS IS NECESSARY FOR BEST DRIVABILITY AND MAXIMUM PERFORMANCE!!!! (See Step 12.) STEP 6 See PIC.4. Insert both flanges of the rubber air duct through the opening in the mounting bracket. Place the Stock duct clamp on the new intake duct — the clamp screw should face forward.

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