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HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

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ROAD TECH ZUMO 660 GLOBAL POSITIONING SYSTEM (GPS) FAIRING MOUNTING KIT INSTALLATION

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Filed Under (Tips and Review) by admin on 27-10-2010

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1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. Remove the outer fairing and windshield. Refer to the service manual. is05900 Figure 1. Road Tech Zumo Drilling Template Placement 3. See Figure 1. Obtain the drilling template from the kit. 4. Position the template on the back side of the inner fairing, in the upper left corner above the fuel gauge, aligning the template to the top of the inner fairing and the plastic rib as shown. 5. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing per the template. 6. See Figure 4. Position the gasket (2) and GPS mount (1) onto the face of the inner fairing, aligning the upper hole in the mount with the hole drilled in the previous step. 7. Temporarily install one of the screws (4) through the upper hole to help align the GPS mount. 8. See Figure 2. Mark the location of the lower mounting hole on the face of the inner fairing, using the GPS mount and gasket as a template. Mark the location of the wire routing hole using the guide hole (3) in the gasket as a template. 9. Remove the screw, GPS mount and gasket from the inner fairing. 10. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing in the lower mounting location. Drill an 11/16 (17 mm) diameter hole through the inner fairing in the wire routing location. 1 2 3 is06149 1. Gasket 2. Wire routing guide hole and ribs 3. Guide hole Figure 2. Remove Gasket Ribs and Guide Hole 11. See Figure 2. Remove the wire routing guide hole and four ribs (2) from the gasket (1). 12. See Figure 4. Install the GPS mount and gasket to the inner fairing with screws (4) flat washers (5) and locknuts (6). Tighten to 50-60 in-lbs (5.6-6.8 Nm) 13. Obtain cradle with harness from GPS system kit. NOTE The fuse holder on the harness must be opened to fit through the hole. 14. Insert harness through the 11/16 inch (17 mm) diameter hole drilled earlier. 15. Insert the split grommet into the 11/16 inch (17 mm) diameter hole around the harness. Installing the Cradle 1. See Figure 4. Install four bushings (H) from the GPS system kit and insert them into the back of the cradle mounting holes. 2. Position the cradle to the GPS mount. Direct the harness out through the slot (G) of the mount. 3. Insert a button head screw (3) through one of the holes in the cradle and into the corresponding hole in the GPS mount, but do not fully tighten

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MC 1200 Motorcycle Trailer – 1200 lbs Assembly Instructions

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Filed Under (Tips and Review) by admin on 29-01-2011

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Tongue: Remove tongue assembly from the frame bundle. Insert into the tongue channel and slide into the front cross member of the frame. Secure with two (2) 3/8″ X 4″ carriage bolts and 3/8″ flange lock nuts. Tighten. Thread the tongue wire harness through the front top hole in the tongue and pull out the hole provided in the left side of the tongue towards the rear. Connect to the frame harness with the plugs provided. Install grommets. Safety Chains: Insert a 3/8″ X 1-1/4″ hex bolt into a 3/8″ flat washer, safety chain and then through the lower hole on the front of the tongue. Place on a 3/8″ flat washer on the inside of the tongue and secure with 3/8″ flange lock nuts. Repeat procedure on the opposite side of the tongue. Tighten. Coupler: Mount the coupler onto the tongue with a 1/2″ X 4″ hex bolt trough the rear mounting holes of the coupler. Using two (2) 1/2″ X 1″ hex bolt attach the coupler to the tongue using the front mounting holes. Secure with flange lock nuts. Tighten. Axle: Attach the spring busing in the rear spring shackles with 1/2″ X 3- 1/4″ hex bolts and 1/2″ flange lock nuts. Position the axle under the trailer with spring eye to the front of the trailer. Slip the flat end of the spring in the rear spring shackle above the bushing just installed. Secure the front spring eye to the front spring shackle with 98/16″ X 3-1/4″ hex bolts and 9/16″ hex lock nuts. Tighten. Mount the tire and rim assemblies to the axle assembly with 1/2″ lug nuts and tighten to 80-90 ft./lbs. of torque using the rotation pattern as shown in the Shore Land’r Owners Manual . Retorque the lug nuts after 50 miles of driving and then periodically thereafter. Ramps: Locate the loading ramp. Note that one end has two holes punched in the bottom of the channel. (See parts drawing) Insert a 3/8″ X 1-1/2″ full threaded carriage bolt into one of these holes. Secure in this position using a 3/8″ flange lock nut. Tighten Place a second 3/8″ flange lock nut onto the same bolt only until the threads of the bolt are exposed through the nut locking it in

2007 Kawasaki ZX6R Full System Installation

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Filed Under (Kawasaki) by admin on 05-11-2010

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1. Remove the faring lowers (save STD bolts for reuse) , side faring (save STD bolts for reuse) , seat faring (save front 2 STD bolts for reuse) and right silencer cover. 2. Detach the turn signal assy, (unplug the cable coupler of turn signal and brake light at the same time) 3. Remove the radiator under bracket and lightly unscrew the radiator mounting bolt. Move the radiator forward. This will make you to have enough room for detaching exhaust pipes and flange nuts. Then, take off the standard headpipes. Detach the cable of the exhaust device and l eave servomotor stayed in the motorbody. (save (3) STD bolt and nut and (8) flange nuts for reuse) 4. Assemble the enclosed head pipes 1,2,3 and 4 by matching the 4-2-1 joint. Do not install the exhaust springs at this time. Lightly attach the assembled head pipe sections to the exhaust ports. Make sure the ends of the head pipes fit snug in the ports. 5. Install the tail joint and tail pipe to the joints. Do not install the exhaust springs yet. Jiggle the whole assemble for better fitting. Lightly attach the tail pipe by standard bolt and nut saved in step 3, but do not tighten the bolt fully. (see Image 1) *Recommend to use new gasket to prevent from leaking the exhaust. *Lightly screw the (8) STD flange nuts saved in step 3. * Cylinder number is 1, 2, 3 and 4 from the left hand side with you on the motorbike. 6. Attach enclosed silencer stay A to the place where the standard silencer mounted by (2) STD bolts and nuts saved in step 3. Reinstall the seat faring and penetrate the (2) 5x45mm to the hole of a seat faring mounted. Fix the Silencer stay A by enclosed (2) M5 nuts and (2) aluminum collar using the thread of penetrated M5x45bolts. (see Image 2 and drawing 1) Image 2 7. Insert the TiForce silencer to the tail pipe. Put silencer band and band rubber to the assembled silencer stay A by enclosed (2) M8x20mm bolt and (2) M8 washer. (see drawing 1) 8. Attach the supplied springs to all the joints. Use a spring puller to prevent damage to the springs that could lead to future failure. Put the radiator back to the original position. 9. Attach the L and R license number stay to the silencer stay A. (see Image 3) (see drawing 1) 10. Reinstall the firings detached in step 1. Attach the right silencer cover to the frame by using enclosed faring stay and (1) M6x20mm. (see drawing 1) 11. Make sure the exhaust system is free and clear of the faring. If necessary, adjust for proper clearance.. Removed the fairings reinstalled in step 10. 12. Securely tighten all fasteners in this order (from exhaust pipe flange to silencer stay) Image 3 14. Attach the turn signal assy detached in step 2 to the license number stay. (Use (4) M6x15mm) (See Image 4) Plug the cable couplers.

GL1800 Goldwing Trike Conversion Kit Installation Instructions

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

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Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh

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HARLEY DAVIDSON FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION Removing Outer Fairing 1. Standing at the front of the vehicle, use a T-27 TORX® drive head to remove the three outer fairing screws (with flat washers) just below the windshield. 2. Moving to the inner fairing side, use a T-27 TORX drive head to remove the two fairing screws just above the wind deflectors on the left and right side. 3. Turn the handlebar to the right and remove the outer fairing screw (reach in below the fairing cap). Turn the handlebar to the left and remove the fairing screw on the opposite side. 4. Tilting the outer fairing toward the front, squeeze the two external tabs to remove the wire connector at the back of the headlamp assembly. 5. Lift the fairing (with headlamp assembly) off the motor- cycle. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 6. Remove the Windshield. Installing Mirrors 1. See Figure 1. Place template on inside of fairing as shown to locate mounting holes for mirror. 2. Begin by drilling a 1/8 inch pilot hole at each location marked on the template. For the center hole (2) where the 3/8 inch threaded stud passes through the fairing use a 13/32 inch diameter twist drill to drill the hole to its final size. For the alignment hole (1), use a 7/32 inch diameter twist drill to drill the hole to the final size. 2 1 is 02115 1.7/32 inch hole location 2.13/32 inch hole location Figure 1. Positioning Template 1 is06315 1. Auxiliary mirror Figure 2. Orientation of Auxiliary Mirror NOTE The flange nut is a self locking nut and must not be tightened more than 30 in-lbs (3.4 Nm). 3. See Figure 3. Place mirror (2) in position and install backing plate (4) with the raised post (B) (with the L and R marking) toward the nut surface. Install the flange nut (6) and tighten nut to 20-30 in-lbs (2.3-3.4 Nm). 4. See Figure 2. Position the mirror so the round auxiliary mirror is in the upper inside corner position. 5. Repeat for right side

HARLEY DAVIDSON XL SOLO CUSTOM SEAT KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. 1 2 4 1 3 is03341 1. Stock retention nut and washer 2. Plastic cap 3. Rearward fender hole 4. Center fender hole Figure 1. Retention Nut and Plastic Cap Location 2. For models that had a solo seat: Proceed to Step 3. For models that had a 2-up seat: The retention nut and washer must be moved from the rearward mounting hole to the center fender hole where the rear seat bracket will be attached. Use a cable strap to aid in this step as fol- lows: a. See Figure 1. Remove retention nut from rearward fender hole (3) and plastic cap (2) from center fender hole (4). b. Install plastic cap into the rearward fender hole. c. See Figure 2. Place the retention nut over the cable strap so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the center fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib of the retention nut seated into the notch in the fender hole, slide the retention washer into place from the rear. This will lock the retention nut in place. 3. Position the solo seat on the motorcycle frame with the mounting bracket at the rear. Bring the seat forward and engage the tab on the seat into the slot at the base of the fuel tank. 4. See Figure 3. Secure the seat to the fender using the knurled knob (3) and neoprene washer (4) from the kit. Install the washer on the knob and tighten the knob securely to the fender seat nut

Harley-Davidson HEAT DEMONS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-03-2012

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1. Remove the Right Handlebar Control, upper and lower switch housing screws, and Right Grip from the Handlebar according to the service-manual instructions and set aside or leave hanging. Remember to insert a spacer between the rear brake light switch and the lever to keep the switch from being broken. 2. Remove the Left Hand switch housing from the handlebar according to the service-manual instructions. 3. Using a T27 TORX drive head remove the half of the clamp that secures the clutch hand lever to the handlebar and discard. The Heat Demon controller will replace this clamp when finishing the installation. Separate the clutch hand lever assembly from the handlebar and move away from the bar. 4. Mark the location of the Left Grip and remove it by twisting, heating or with air pressure. Almost all grips can be removed without damage. If this does not work it may be necessary to cut the grip for removal. 5. A hole needs to be drilled in the bottom of the handlebar to route the power wires and wires from the Controller. The location of the hole should be in the groove or recess on the bottom of the handlebar under the Left Switch Housing at the end of the groove toward the grip. Start by punching a hole location with a center punch to pierce the chrome. Use safety glasses that completely cover the eyes to protect from steel chips while drilling! Start with a small drill like a 3/32″ size to make the initial hole. Then use progressively larger drills or a step drill to increase the hole size to 5/16″. After the hole is drilled use a round file or deburring tool to remove the sharp edges. 6. Uncoil the plastic snake from the kit and run it from the right end of the handlebar out the left end. Twisting the snake or inserting it vertically versus flat can help to push around the corners. 7. Attach the white and yellow wires from the Right Grip Heater (Item 3) to the hole in the plastic snake and pull them through the bar so they exit the left end. (See drawing below) 8. Push the right heater into the handlebar by squeezing it together and sliding it fully inside of the bar. The end of the heater with the orange cap should be pushed in first. Cut the white and yellow wire to extend 4 inches beyond the left end of handlebar. 9. Install the Right Throttle Control and Grip according to the service manua

HARLEY DAVIDSON ILLUMINATED CHROME COVER KIT FOR FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION Preparation Models with main fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. Models with main circuit breaker: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. Installation NOTE Cover the work surface with an H-D Service Cover or clean shop towels to prevent scratching the finish of the outer fairing. 1. Remove the outer fairing per the instructions in the service manual. Lay the fairing face down on a sturdy work sur- face. 2. See Figure 2. Remove the mirrors (2), flange nuts (3) and plastic backing plates (4) securing the mirrors to each side of the inner fairing (1), and retain all items 3. Measure one inch (25 mm) straight down (5) from the large mirror stud hole in the inner fairing, and make a mark. 4. Drill a 1/4 inch (6 mm) diameter hole (6) through the inner fairing at the mark. 5. See Figure 1. Obtain a chrome wire collar (3) from the kit, and press it into the new hole from the outside of the inner fairing. Gently tap into place with a soft-faced hammer. 6. Repeat Steps 3 through 5 on the opposite side of the inner fairing. NOTE Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the mirror cover to the mirror. 7. Clean the back surface of the mirrors with the alcohol pad (7) provided. Allow to dry thoroughly. 8. Obtain the primer tube (8) from the kit, and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back surface of one mirror. 3 6 2 1 4 5 is06091 1. Inner fairing 2. Fairing mount mirror 3. Flange nut (2) 4. Plastic backing plate (2) 5. Measure one inch (25 mm) down 6. Drill 1/4 inch (6 mm) hole (2) Figure 2. Fairing Drill for Illuminated Mirror NOTE The Illuminated Chrome Mirror Covers are side-specific. The covers install with the wire harness exiting from the bottom. 9. Obtain the correct mirror cover from the kit. Rub the liners on the three pads on the back surface of the mirror cover to activate the adhesive, then remove the liners. 10. Place the mirror cover over the back surface of the mirror and press into place for a minimum of 60 seconds. 11. Repeat Steps 8 through 10 for the remaining mirror and cover. NOTE The plastic backing plates (removed earlier) are identified with a letter “L” (left) or “R” (right) stamped on the post. The mirrors are marked with a letter “L” or “R” stamped on the swivel block. Use the correct backing plate for each mirror by matching the letters. 12. Position the mirror on the outer face of the inner fairing, with the rounded side of the mirror outboard and the Bar & Shield logo upright. a. Insert the mirror cover wiring harness through the chrome wire collar installed in Step 5. b. Insert the mirror post through the original mirror mounting hole. c. Place the correct plastic backing plate against the inner face of the inner fairing, engaging the two holes in the backing plate with the threaded stud and index pin on the mirror swivel block. d. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . e. Repeat for the remaining mirror on the other side of the fairing

HARLEY DAVIDSON DYNA PASSENGER PILLION SEAT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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REMOVE SEAT NOTE When performing the following installation procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove screw to detach rear seat mounting bracket from fender. 2. Remove two capscrews that attach seat mounting bracket to bottom of stock seat. 3. Remove the existing seat from the motorcycle. Save the seat bracket and mounting screws for installation of the new seat. 4. If motorcycle has a grabstrap installed, remove nut and washer that holds passenger strap in place and remove strap. 5. See Figure 1. Remove the plastic cap from rearmost fender hole (3). 6. Remove the seat retention nut and washer from the solo seat mounting hole. 7. See Figure 2. A cable strap may be used as an installation aid to remove and reinstall the retention nut and washer. Place the retention nut (1) over the cable strap (3) so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the rearmost fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. 8. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear. This will lock the retention nut in place. Remove the cable strap. 2 5 1 2 1 3 6 7 4 is00363 1. Retention nut and washer (2-up seat positon) 2. Retention nut and washer (solo seat position) 3. Rear-most fender hole 4. Middle fender hole 5. Grabstrap mounting hole 6. Flange screw 7. Plastic retention nut

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