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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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SUZUKI M109 1800 cc FRONT/REAR EXHAUST / HEATSHIELD INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set collar and grommet aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve actuator solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System

SUZUKI M109 PASSENGER FLOORBOARDS RELOCATION ARMS

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Filed Under (Suzuki) by admin on 23-12-2010

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1. If you are installing the relocation arms at the same time as the floorboards follow their instructions first and then refer to this sheet. 2. Fold the floorboards up, remove the allen screws that attach them to the round spacers, remove the floorboards and set aside. 3. Install the left and right relocation arms (marked with an L and R on the back side) onto the pins of the round spacers in the upper or lower position as desired. Using the allen screws and washers supplied bolt the arms to the round spacers and tighten securely. 4. Re-install the floorboards onto the relocation arms placing the supplied dowel pins into the set of holes on the relocation arms that allow the floorboards to be level or parallel with the ground. Install and tighten the allen screws removed earlier

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SUZUKI M109 TURN SIGNAL RELOCATION BAR

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Filed Under (Suzuki) by admin on 21-12-2010

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1. Remove the windscreen/headlamp assembly by removing the two (2) 4mm allen screws located on the sides of the windscreen and the two plastic rivets at the top rear (push the center pin inward º” and then pull the rivet out). Pull the windscreen/headlamp forward to gain access to the rear, unplug the headlamp and set aside. 2. Locate the turn signal wire connections and unplug them from the wire harness. On the black connectors lift the tab up to unlock the connector and on the white ones use a small screwdriver inserted into one of the two longer slots and lift the center portion up while pulling the connector apart. Remove the screws which attach the turn signals to the chrome signal mounts located on the bottom of the mounts. Pull the turn signals out from the mounts and set aside. Looking thru the hole in the mount that the turn signals were in you will see a 4mm allen screw on each side, remove these. Remove remaining two (2) 6mm allen screws located on the bottom of the steering head that attach the mounts, remove and set aside. 3. Lay out the new turn signal mounting bar (see photo). Install the signals onto the bar as shown routing the wires thru the bar and out thru the slot in the center. Install the two (2) 6 x 8mm screws supplied and tighten securely. 4. Install the bar/signal assembly onto the steering head using the two (2) 6mm allen screws removed earlier (the brake hose clip should be on the bottom below the signal mount) and tighten securely. 5. Reconnect the turn signal wires (the pale blue/green wire goes to the right signal). Turn the ignition on and test the functions of the signals and running lights. Re-install the windscreen/headlamp assembly being sure to first plug in the headlamp

SUZUKI M109 ADJUSTABLE HIGHWAY PEG MOUNTS Installation Instructions

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Filed Under (Suzuki) by admin on 29-12-2010

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1. Starting on the left side of the motorcycle remove the two 14mm bolts that attach the left foot peg and shifter mounting bracket to the frame. Locate the longer two of the (4) supplied mounting bolts supplied, place a lock washer first and then a washer on each. Locate the left curved main mount (it will have its polished chrome side and the circle of dowel pin holes facing outward when installed on the left side). Place the bolts thru the bolts thru the holes in the mount the slide a spacer (supplied) over each bolt. Place the mount with the bolts and spacers thru the holes of the foot peg and shifter mounting bracket removed earlier and thread the bots into the frame then tighten securely 2. Repeat this procedure on the right side using the remaining shorter bolts, lock washers, washers, mount and spacers and again tighten securely. 3. Again starting on the left side install one of the dowel pins supplied into any of the holes in the mount, place one of the remaining mounting arms (they are the same left and right) onto the dowel pin that is closest to the position you want the arm to be in. Place one of the washers onto the large allen screws then thru the finished side of the arm and thread it into the center hole of the mount. 4. Repeat this procedure on the right side. Loosely install the foot peg set you have selected onto the arms. Sit on the motorcycle to see if you are comfortable with the position you have chosen. You can adjust the position of the arms in Ω” increments forward or back as follows. Remove the arm while leaving the pin in its hole, now move the pin to the next hole forward to rotate the arm back towards the rider Ω” or into the next hole back to rotate the arm forward Ω” and re-install the arm into the corresponding hole that is in the direction you want the arm to go. 5. Adjust the angle of the foot pegs so that they are both comfortable to your feet and will fold up and to the rear when not in use. Set the peg pivot bolts tight enough to hold the in the folded position but loose enough so that you can fold them down with your foot when you need them. Recheck all fasteners for tightness.

SUZUKI M109 BRAKE PEDAL INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 29-01-2011

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1. Remove the pinch bolt from the bottom of the stock brake pedal. Notice that the slot in the pedal aligns with a punch mark on the end of the shaft. Using a needle- nose pliers disconnect the return spring from the pedal. Remove the pedal by sliding it outward until it touches the foot peg mount and then pushing the shaft inward. 2. Remove the pinch bolt from the new brake pedal and install it so that the slot is aligned with the punch mark on the end of the shaft. Install the pinch bolt and tighten it securely. Reconnect the pedal return spring

BMW 3 SERIES INSTALLATION MANUAL

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Filed Under (BMW) by admin on 17-11-2010

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1. Turn off the ignition and disconnect the negative battery cable. NOTE: Disconnecting the negative battery cable erases pre-programmed electronic memories. Write down all memory settings before disconnecting the negative battery cable. Some radios will require an anti-theft code to be entered after the battery is reconnected. The anti-theft code is typically supplied with your owner’s manual. In the event your vehicles’ anti-theft code cannot be recovered, contact an authorized dealership to obtain your vehicles anti-theft code. TO START: 2. Depress the wire-locking clip and disconnect the mass air sensor electrical. BMW 3 SERIES (E46) 1999-00 323i, ci 1999 323iC 2001-05* 325i, ci L6-2.5L 1999-00 328i 2000 328ci 2002-05 325xi L6-2.8L NOTE: * Excluding 2003 & 2005 PZEV model with engine family 3BMXV02.5M56 & 5BMXV02.5M56 Flat Blade Screwdriver Ratchet Extension 10mm Socket 10mm Wrench 4mm Allen A intake tube (EL) 1 087139 B hose ; 4mm id x 2″ l 1 08062 C npt fi tting; 1/4″ x 5/16″ barb 1 08908 D hose clamp #48 3 08601 E silicone hose 3.25″id x 2″l 1 08690 F nut; 6mm nylock 7 07553 G washer; 1/4″id x 5/8″od fl at 7 08275 H washer; 1/4″ split lock 1 08198 I bolt; 6mm-1.00 x 16mm, b/h/a 2 07730 J bolt; 6mm-1.00 x 12mm, b/h/a 4 07794 K washer; 1/4″id x 1″od fender 2 08160 L bracket 1 010087 M heat shield “A” 1 07492 N heat shield “C” 1 07497 O heat shield “B” 1 07494 P edge trim 46″L 1 102487 Q air fi lter 1 RU-4730 3. Pull up on the four fresh air duct-retaining pins to release them from the radiator core support. 4. Lift up and remove the fresh air duct from the vehicle as shown. NOTE: Disconnect the fresh air tube from the fresh air duct. 5. Loosen the hose clamp which secures the intake tube to the mass air sensor, and then disconnect the intake tube from the mass air sensor as shown. 6. Remove the two-factory air box mounting bolts shown.

FLEXIBLE GAS PIPING DESIGN GUIDE and INSTALLATION INSTRUCTIONS

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Filed Under (S&S) by admin on 29-10-2010

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Definitions: Grounding : The process of making an electrical connection to the general mass of the earth. This is most often accomplished with ground rods, ground mats or some other grounding system. Low resistance grounding is critical to the operation of lightning protection techniques. Bonding : The process of making an electrical connection between the grounding electrode and any equipment, appliance, or metal conductor: pipes, plumbing, flues, etc. Equipment bonding serves to protect people and equipment in the event of an electrical fault. Equipotential Bonding : The process of making an electrical connection between the grounding electrode and any metal conductor: pipes, plumbing, flues, etc., which may be exposed to a lightning strike and can be a conductive path for lightning energy towards or away from the grounding electrode. 2. The National Fuel Gas Code NFPA 54/ANSI Z223 states, “Each above ground portion of a gas piping system upstream from the equipment shutoff valve shall be electrically continuous and bonded to any grounding electrode, as defined by NFPA 70, National Electrical Code ( ANSI/NFPA 70 1999 Edition.) 3. The TracPipe® gas piping system shall be bonded in accordance with the National Fuel Gas Code, NFPA 54/ANSI Z223. The piping system is not to be used as a grounding conductor or electrode for an electrical system. 4. For bonding of the TracPipe® system, a bonding clamp must be attached to the brass AutoFlare®fitting adapter (adjacent to the pipe thread area – see Figure 4-21) or to a black pipe component (pipe or fitting) located in the same electrically continuous gas piping system as the AutoFlare®fitting. The corrugated stain- less steel portion of the gas piping system SHALL NOT be used as the bonding attachment point under any circumstances. Bonding electrode conductor sizing shall be in accordance with Article 250 (Table 250-66) of ANSI/NFPA 70. The bonding is a requirement of the National Electrical Code

TOYOTA/ LEXUS Transponder Bypass TYPE 1 & 2 INSTALLS

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Filed Under (Toyota Manuals) by admin on 16-09-2011

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The 1100X/F-TL interface module is used when installing remote start
products in Toyota/Lexus vehicles equipped with a factory immobilizer.
The 1100X/F-TL allows for easy interfacing between the remote start and
the factory immobilizer, while maintaining the integrity of the OEM sys-
tem. The factory transponder-based anti-theft system uses a small elec-
tronic chip hidden in the key to send a code to the vehicle’s transceiver
when the ignition is energized. The key must be placed in the ignition
and turned to the RUN position. This energizes a coil surrounding the
key, which in turn energizes the chip, which sends a code to the vehicle. If
the vehicle does not detect the code being sent, the vehicle will start and
then immediately shut off or will just crank, and the anti-theft light will
flash. The 1100X/F-TL provides a valid code to the vehicle whenever it is
remote started, but does not affect the immobilizer system during normal
vehicle operation; the immobilizer system remains fully functional

2005 SUZUKI SV1000 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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TIRE PRESSURE FUEL + OIL COLD INFLATION TIRE PRESSURE FRONT REAR SOLO RIDING ITEM Fuel type kPa 250 250 DUAL RIDING kPa 250 290 NOTE E-03, 28, 33 The others E-33 The others Fuel tank Engine oil type Engine oil capacity SPECIFICATfON Use only unleaded gasoline of at least 87 pump octane (R12 + M12) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% etha- nol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. 16 L (4.2/3.5 USnrnp gal) 17 L (4.513.7 USIlmp gal) * SAE 10W-40, API SFlSG or SHISJ with JASO MA kgf/cm2 2.50 2.50 Change Filter change Overhaul psi 36 36 kgflcrn2 2.50 2.90 2 700 rnl (2.912.4 USllmp qi) 2 900 ml (3.112-6 US/lmp qt) 3 300 ml (3.U2.9 USllrnp qt) psi 36 42 CRANKCASE-CRANKSHAFT BEARING SELECTION Select the specrffed bearings from the crankcase bore I. D. code. The crankcase bore I.D. code (A) “A, “6″ or “C”, is stamped on the inside of each crankcase half. Bearing selection table Bearing thickness I.D. code @9 A B C Bearing must be replaced as a set. I.P. specification 52.000 – 52.006 mrn (2.0472 – 2.0475 in) 52.006 – 52.01 2 mm (2.0475 – 2.0477 in) 52.01 2 – 52,018 mm (2.0477 – 2.0479 in) Color (Part No.) Green (1 2229-1 6GOO-OAO) Black (1 2229- tGG00-OBO) Brown (I 2229- 16GOO-OCO) Color code 9 Bearing Green Black Brown Thickness 1.999 – 2.002 mrn (0.0787 – 0.0788 in) 2.002 – 2.005 mm (0.6788 – 0.0789 in) 2.005 – 2.008 rnm (0.0789 – 0.0791 in) FI SYSTEM WIRING DIAGRAM I ECM TERMINAL (For KCModel) ‘& ECM TERMINAL (For K5-Model) FAIL-SAFE FUNCTION & FI system is provided with fail-safe function ta allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition

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