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HARLEY DAVIDSON DASH PANEL EXTENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the seat. 2. See Figure 1. Loosen the two socket head screws on the instrument panel console. Raise the console enough to access the two pushnuts holding the upper end of the leather insert. Remove and discard the pushnuts using pliers or a blade-type screwdriver. 3. Remove and discard the phillips head screw (3) and washer (4) securing the lower portion of the leather insert to the fuel tank. Remove the leather insert and discard it. 4. Obtain the dash panel extension (1) and the dash panel extension trim (2) from kit. Place the dash panel extension on the dash panel extension trim making sure the panel is centered and fits cleanly into the lips on both sides of the trim. 5. Gently lift up on the rear of the instrument panel console and install the dash panel extension with the rubber dash panel extension trim underneath, butting the two together. Make sure the rubber dash panel extension trim is aligned with the dash panel extension. Finger tighten the two socket head screws to hold down the instrument panel temporarily in place. NOTE The console rubber trim from a stock vehicle may need to be trimmed slightly to assure proper fit. NOTE When performing the next step, note that proper alignment is achieved when space is eliminated between the instrument panel console and/or between the dash panel extension trim piece and the fuel tank. Due to variances in fuel tank and instrument panel console fitments, the foam pads are used on “as needed” basis to achieve proper alignment. It may be necessary to experiment a few times using various combinations of pads to achieve the desired alignment. In some cases, pads may not be necessary while in others, it may be necessary to use all with one stacked above another. 6. Observe the overall fitment of the panels over the tank and determine whether the foam pads will be necessary to achieve the desired alignment. 7. If necessary, remove the dash panel extension assembly. Peel the adhesive backing and install the needed foam pads (5) to the raised areas extending from the front of the dash panel extension as shown. Re-install the panel. 8. When the proper alignment between the new kit and the fuel tank is achieved, tighten the rear mounting screw (3) with the washer (4) to the speed nut located on the tab at the rear of the fuel tank. 9. Tighten to 18-24 in-lbs (2.0-2.7 Nm). 10. Tighten the instrument panel console?s two socket head screws to 18-24 in-lbs (2.0-2.7 Nm). 11. Install the seat

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HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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Harley-Davidson FLH Accent Panel Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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1 Install Accent Panels Note: See hardware list on Page 4 for usage and descriptions. 1.1 Elevate the rear of the vehicle and support with jack stands under the rear differential tubes. 1.2 Remove the rear wheels 1.3 Remove the passenger foot rests. 1.4 Remove front fairing (for wiring later in installation) . 1.5 Install cross brace and frame clamps to frame in the approximate position shown in Figure 1. 1.6 Note orientation of cross brace (Figure 2). Flat side of the brace against bottom of frame tubes. Outboard tabs up and to the rear of the vehicle. 1.7 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.8 Install front brackets to vehicle between the frame and crash bars as shown, using the supplied hardware (the left side bracket is longer than the right. Figure 3 1.9 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.10 Position the accent panel to vehicle. Figure 4 1.11 Install supplied hardware to front and cross brackets. Figure 5 &Figure 6 1.12 Leave the bolts loose to allow the accent panel’s position to be adjusted later in installation. 1.13 If not already preinstalled to your accent panel, install rubber bead edge molding between trike body (fender) and accent panel. Bead edge molding 1.14 Clamp the accent panel to the body (fender). Check position of accent panel and ensure proper positioning of bead edge molding. 1.15 Four holes will be drilled though body (fender) and accent panel in the approximate positions shown (both left and right accent panels). Figure 8 Note: Hole location dimension in Figure 8 are approximations. Your drill location may and can vary. Note: Hole position should be as high an possible on the accent panel, allowing space to install hardware 1.16 With accent panel and bead edge molding properly positioned and clamped to body (fender), Drill the two outboard holes in the approximate position shown from inside the fender well through mounting surface of accent panel. Note: Drill outboard hole first and install hardware to reduce risk of accidental movement. Figure 9 1.17 Drill remaining two inboard holes from the accent panel mounting surface through the body (fender). Figure 10 1.18 With both left and right accent panels installed, tighten all hardware at the left and right front mounting positions. 1.19 Trim off excess bead edge molding. 1.20 With left and right front mounting secure, check position and alignment of cross bar and accent panel mid mounts and tighten all hardware. 1.21 With fairing removed, crimp supplied xxx to the black, purple and blues wires of the vehicle’s turn signal wire loom. 1.22 Crimp one of the supplied male spade connectors to the end each wire from the accent panel. 1.23 Connect wiring as indicated in Table 1 below. Accent Panel Wire Color Vehicle Turn Signal Loom Wire Color Yellow Purple (Signal) Orange Blue (Running) Black Black (Ground) Table 1

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BMW R1200RT Sport/ Touring 1100X Kit Installation Manual

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Filed Under (BMW) by admin on 17-12-2010

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Step 1 — Locate ‘mold circle’ indentation on each side fairing panel (Pic 1). With panel mounted on bike, this indentation is center, at rear inside panel edge, and faces inside. Temporarily install bracket as shown in (Pic 2), align bottom bracket hole over indentation and mark for hole. Remove brackets at this time. Step 2 — Remove fairing body side panels. Four screws per side required for removal, see owners manual. Drill a 3/8″ hole at mark. If harness kit has not been installed, do not re-install left side panel until finished unless you remove tank to install harness. Removal of the tank is the best option to route harness from battery area to front of the bike. Step 3 — As required, re-install fairing body side panels. Do not re-install the top factory inner panel Torx Screw yet, as you will re-use this screw to secure the top light bracket mounting hole to the fairing panel. Step 4 — Using 10/32×1/2 screws and black shoulder washers from Hardware package, secure lights to PIAA Ezy-Mount® brackets (See Pics 3 & 4). Right side bracket is stamped ‘EZY-MOUNT’. See note below for Powersports lights. Due to close proximity of the light body to fairing side panel, access to the vertical adjustment screw on the panel side of the light will not be possible after installation. To prepare for this; before installing bracket/light assembly to panel, make sure this screw is tightened so that you can barely move the light body. After bracket is installed, final vertical adjustment can be secured with the inside screw. Torque on this screw is adequate to hold vertical adjustment, and the screw that faces the panel will not come loose. NOTE: WHEN INSTALLING POWERSPORTS LIGHTS, YOU MUST INSERT THE SHOULDER ADAPTER WASHER INTO THE LIGHT FOOT, BEFORE INSERTING SCREW TO SECURE LIGHT FOOT TO BRACKET. THIS ADAPTER CENTERS LIGHT FOOT OVER PEMNUT (TIGHTEN THIS SCREW SECURELY). Step 5 — Insert well nut into previously drilled 3/8″ hole. Place bracket assembly against fairing, aligning top hole with the top fairing mounting position; re-install the factory Torx screw at this location. Adjust as necessary and install the second supplied SS 10/32 x 5/8 Torx screw thru the lower bracket mounting hole to the well nut. With constant pressure on the screw, tighten securely. Constant pressure ensures that the rear expandable section of the well nut captures the back of the plastic inner panel as you tighten the screw. Future removal of fairing panels is now possible with light assembly installed (utilizing the bottom bracket mounting screw), thus re-alignment of lights is not required after normal maintenance.

Kawasaki Teryx 750 Roof / Windshield Kit Installation Manual

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

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2. Installation iii) Adhere high density foam gasket to top portion of hood using marker line as centerline guide to ensure windshield panel will sit squarely onto foam after installation. If desired, install small edge trim to side edges of windshield panel and cut to suit. (Steps not shown) iv) Re-install windshield panel onto vehicle. Fasten panel with (6) #10-32 x 3/4″ Lg. screws and nyloc nuts (Fig.4) ensuring windshield panel sits firmly onto foam strip. v) Install and position roof panel onto vehicle allowing for equal spacing on either side of widshield panel edges. Once centered, carefully transfer upper windshield panel holes onto roof panel using a ¼” drill bit. (Fig. 5) NOTE: To prevent excessive rattling noise during operation, install foam strips between roof and rollcage contact points at this time. vi) Fasten roof panel to windshield panel using (6) ¼-20 x 5/8″ screws, washers and nyloc nuts (Fig.6).

HONDA 2005 CRF 50 F AKRAPOVIC RACING EXHAUST SYSTEM INSTALLATION

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Filed Under (Honda) by admin on 03-12-2011

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put the motorcycle on a side standn 2. unscrew and remove the bolts from the rear and front part of the motorcycle cowling (Figure 1, 2, 3, 4) m3. remove complete cowling together with the seat (Figure 5) 4. unscrew the bolt from the metal bracket for the muffler (Figure 6) 5. unscrew and remove the bolts on the flange of the header tube (Figure 7) 6. remove the stock exhaust system (Figure 8) 7. remove the stock heat shield (Figure 9) INSTALLATION OF THE AKRAPOVIC RACING EXHAUST SYSTEM installing the header tube: 1. attach the stock heat shield onto the Akrapovic header tube (Figure 10, 11) 2. set up the Akrapovic header tube and hand tighten the flange; use stock gasket; (Figure 12, 13) 3. make sure the header tube is not touching the engine or frame installing the muffler:
1. correctly position the muffler and slide it onto the header tube (Figure 14) 2. attach the spring at the muffler – header tube joint igure 15) 3. attach the muffler to the chassis hanging bracket – use the bolt, washer and spacers supplied in the Akrapovic kit. Do not
fully tighten. Make sure the additional parts from the Akrapovic kit are correctly installed. (Figure 16, 17) 4. make sure the header tube is not touching the engine or frame final installation: 1. tighten fully the bolts of the muffler metal bracket and header tube flange (Figure 18, 19) 2. reattach the complete cowling (Figure 20, 21, 22, 23, 24) 3. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. stainless steel header tube: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 4. position of the correctly installed Akrapovic RACING system (Figure 25)
5. Check the operation of the brakes and suspension. Make sure all the bolts are sufficiently tightened. In case the exhaust system touches the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer

Honda ST1300 Front Panel Kit installation

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Filed Under (Honda) by admin on 17-11-2011

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STEP #1 – Expose the battery by removing the seat & side panels on the rightnside of the bike. See the Honda service manual. If you are not familiar with this procedure, have a trained technician install the kit. STEP #2 – Drill a 18mm hole into the panel shown [A] (11/16” hole saw recommended and is available on our site). This hole must be drilled in
the correct spot on the panel, make sure it is not too far to the left. If the hole is small for the socket open it with emery cloth or file. There is a coil to the left. Do not install the socket yet. There is a raised lip on the back of the panel. Trim this off so the jam nut will contact the back of the panel evenly. STEP #3 – Attach the socket to the panel; use a dab of Silicone on the socket and jam nut. Important: Do NOT use Loctite or over-tighten; the plastic can crack. STEP #4 – Stretch out the wiring harness. Attach the fuse holder to the support bracket located above the battery [E]. Next remove the negative battery connection, followed by the positive battery connection. Slip the red wire under the red battery boot [C]. You may need to trim the red boot to accommodate the added wire. Connect the red wire to the battery posts as follow

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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APRILIA FUTURA LEFT FRONT PANEL Installation Instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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STEP #1 Remove the left side panel & seat. STEP #2 Mount the socket. STEP #3 Route wires starting at the battery and finishing at the bracket. STEP #4 Attach the wires to the socket and test. STEP #5 Look over your work. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the seat & the left side fairing. See the Aprilia service manual. STEP #2 – Drill a 18mm hole into the panel (11/16″ hole saw recommended and is available on our site) where shown [A]. There is plenty of room for the knee of a tall rider. An alternate position is show at [E]. There is no need to completely remove the front fairing, just unscrew the bolt under the left handgrip; the panel will flex enough to work behind it. Watch the clearance behind the panel; make sure the socket has room. Attach the socket to the panel; use a dab of Silicone on the socket and jam nut after assembly. Important: Do NOT use Loctite or over-tighten. STEP #3 – Disconnect the battery ground & positive connections. Install the fuse in the fuse-holder. Mount the fuse-holder to the round cross tube [B]. Route the harness up on the inside of the frame piggyback with the seat release cable. The harness can be inserted in the same clip that the seat- release cable uses [F]. Use wire ties to secure it from touching the engine. Connect the red wire to the positive battery posts [C]. The red rubber boot may need to be notched to allow the wire to exit. Connect the ground connection under bolt [D]. Run the black wire along the inside of the frame rail, then pass under the frame rail near the attachment point. STEP #4 -The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to terminals. Connect the red wire to the POSITIVE terminal and the black wire to the NEGATIVE terminal. Use a voltmeter to check if the polarity is correct

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