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2007 KTM SX-F 250- 450 Kickstand Installation and Removal Manual Instructions

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Filed Under (KTM) by admin on 26-01-2012

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Remove the lower d bolt making sure you keep track of the order of the small parts for re-assembly. 2) Remove the lower in-frame bolt. 3) Install the supplied lower kickstand mounting bracket onto the frame at the lower chain roller boss. The counter bore should slide over and onto the frame boss. The chain roller should go back into place just how it came e supplied lower kickstand mounting bracket between it and the frame. Do not is bracket needs to pivot to align with the lower hole in the main . 4) Install the kickstand onto the bike using one of the provided M8x30mm flat head sub-frame to main-frame bolt location. Do not tighten yet. 5) Line up and install the other provided ad bolt thru the lower kickstand mounting hole into the supplied lower kickstand mounting bracket. 6) Now tighten all three bolts, two mounting bolts (front) and one lower kickstand mounting bracket 7) Periodically check the kickstand and all mounting bolts for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride! We recommend using a heavy-duty chain lube. If necessary, you can remove the back cover plate for additional cleaning. Never remove the kickstand leg pivot bolt!

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HARLEY DAVIDSON DYNA AND SPORTSTER Chrome Front Wheel Spacers INSTALLATION ISNTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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Harley davidson Sportster Custom Straightshot Exhaust System REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove the nut that mounts the front muffler to the engine, located below the rear brake master cylinder. 4. Remove the bolt that mounts the rear muffler to the mounting bar. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips . INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Vance and Hines recommends you replace your exhaust gaskets with Sceamin’ Eagle gaskets part number 17048-98. 2. Install the circlips and flanges from the stock system on to both of the new head pipes. 3. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of both heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the front head pipe using the stock nuts, do not tighten at this time. 5. Install the rear head pipe using the stock nuts, do not tighten at this time. 6. Install one muffler clamp (supplied) over the inlet (notched end) of each muffler. 7. Identify the front and rear muffler mounting brackets. The front bracket is stamped with the number 305 and the rear muffler bracket is stamped 213 . 8. Install the front muffler mounting bracket to the stud on the engine (where the stock muffler mounted) and fasten using the stock nut (leave loose at this time). The bracket will bend inward towards the center of the motorcycle when installed correctly. Note: You may need to move the wires and hoses on the lower frame rail to decrease the possibility of them chaffing on the bracket bolts. 9. Slip one of the mufflers onto the front head pipe. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the muffler to the mounting bracket using the 5/16″ flange head bolts (supplied) leave them loose at this time. 10. Attach the rear mounting bracket to the rear muffler. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the bracket to the muffler using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note: The single hole in the bracket will point downward and slightly forward when installed correctly

Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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HARLEY DAVIDSON SPORTSTER LOW REAR SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION NOTE Internal shock absorber components are not repairable beyond the Service Parts listed on this instruction sheet. Consult your Harley-Davidson dealer if further service is required. The installation procedures for this kit are the same as the original equipment (OE) installation procedures in the Service Manual. Refer to the appropriate Service Manual for the rear suspension system removal and installation procedures. The OE hardware will be re-used in the kit installation. Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) SHOCK PRELOAD (SPRING) ADJUSTMENT Refer to the appropriate Service Manual for spring adjustment. Spanner wrench (94700-52L) is required for spring adjustment. SERVICE PARTS 1 is04854 Figure 1. Service Parts: Sportster Low Rear Suspension Kit Table 1. Service Parts: Sportster Low Rear Suspension Kit Part Number Description (Quantity) Item 54734-04 Rear shock (2)

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Harley Davidson Sportster Straightshots HS Slip-on Exhaust system

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Filed Under (Harley Davidson) by admin on 19-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Loosen, but do not remove, the two head pipe mounting nuts from each flange located at the cylinder head. 3. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 4. Loosen the clamp holding the mufflers onto the head pipes. Page 1 of 4 D480IN Rev. 1.0 Sportster Straightshots HS Slip-on Exhaust system Part #16819 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: 1/2″ combination wrench 3/8″ drive ratchet and 9″ extension 9/16″ and 1/2″ sockets 5/16″ Nutdriver/flat blade screwdriver 5. Remove the two bolts from each muffler which attach the mufflers to the mounting bar. 6. Remove the mufflers by sliding them off the head pipes. 7. Remove the clamp from the nose of each muffler (these will be re-used when installing the new mufflers). 8. Remove the gaskets from the crossover ports on the stock mufflers. Inspect the gaskets and replace if damaged or worn (H-D part #65927-00). 9. Install crossover gaskets onto mounting bar on motorcycle. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Remove mufflers and heat shields from protective packaging. 2. Slide the nut plate inside the bracket that is welded to the backside of each muffler body and attach the muffler bodies to the mounting brackets (stamped 379-P) using four 5/16″ x 5/8″ flange head bolts (supplied). Leave them loose at this time (Figure 1). 3. Slide stock exhaust clamp onto nose of each muffler. 4. Slide mufflers onto head pipes and align crossover port with gasket on mounting bar (Figure 2). Press into place on gasket. 5. Attach the muffler brackets to the stock mounting bar using four 5/16″ x 3/4″ hex head bolts, washers, and nuts (supplied). Leave them loose at this time (Figure 3). 6. Tighten cylinder port exhaust flange nuts on front and rear cylinders. 7. Install and tighten the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 8. Align muffler and bracket so they sit level. Tighten the muffler mounting bolts and the bracket mounting bolts. 9. Tighten the clamp holding the muffler onto the head pipe.

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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HARLEY DAVIDSON HARDWARE/ TURN SIGNAL RELOCATION KIT FOR SPORTSTER LEATHER SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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Installation Instructions for 79052-04 and 79073-04 Do not exceed 7 lbs (3.17 kg) maximum load in each saddlebag. Additional weight can affect a motorcycle’s stability, handling characteristics, and safe operating speed which may lead to an accident resulting in death or serious injury. NOTE A pick tool (Snap-on TT600-3) will be required for 1996 and later models for removing and reinstalling a multi-lock amp con- nector. NOTE A Service Manual for your vehicle is available from your Harley- Davidson Dealer. Installation – Hugger Models Only (1994-1997) To perform the following steps for Hugger Models only, fender and frame must be sufficiently supported, as both shocks will need to be removed at the same time. An improperly supported vehicle could result in death or serious injury. A Service Manual is needed to install this kit. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation of this kit could result in death or serious injury. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Remove seat, sissy bar and sideplate, if applicable. Retain hardware for reinstallation. Disconnect battery, negative cable first. 2. Properly support motorcycle under frame to prepare for removal of right and left shocks. 3. Remove rear buttonhead screw on each side of fender. 4. See Figure 1. With rear fender and frame securely supported, remove left and right shocks by removing upper nut (2), washer(s) (3) and shock cover (4). Remove bolt (6), washer (7) and locknut (8) at lower shock mount. Remove shock

HArley Davidson Sportster Sideshots Exhaust system Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Remove the two head pipe mounting nuts from each flange, located at the cylinder head. 3. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 4. Remove the two bolts from each muffler body which Page 1 of 4 D465IN Rev. 1.0 Sportster Sideshots Exhaust system Part #26011 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: Wrenches – 9/16″ and 1/2″ Ratchet, 3/8″ drive and 9″ extension Torx sockets – T30 Sockets – 9/16″ and 1/2″ 3/16″ & 5/16″ Allen wrench 5/16″Nutdriver/flat blade screwdriver Snapring pliers attach the muffler bodies to the mounting bar and carefully remove both exhaust pipes from the motorcycle. 5. Remove the drive belt cover and take the bracket off the rear cover bolt, it will not be re-used. 6. Loosen the brake rod at the rear eyelet using a T30 Torx driver. 7. Remove the exhaust mounting bar, saving the three mount bolts and washers for re-use. 8. Using snapring pliers, carefully remove the flanges and circlips from the stock exhaust system. Save for re-use. Note: If circlips look bent or twisted replace them with new circlips.

Harley-Davidson Sportster 883/ 1200 Straightshot HS Exhaust system REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Remove the two head pipe mounting nuts from each flange, located at the cylinder head. 3. Remove the two bolts from each muffler body which attach the muffler bodies to the mounting bar. 4. Remove the clamp bolt which mounts the rear head Page 1 of 4 D445N Rev. 1.0 Sportster 883/1200 Straightshot HS Exhaust system Part #17815 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: 3/16″ & 5/16″ Allen wrenches 3/16″ & 5/16″ Allen & 1/2″ sockets 3/8″ Ratchet & Extensions T30 Torx driver 1/2″ Wrench 5/16″ nutdriver/flat blade screwdriver Ft/lb. & In/lb. Torque wrenches Snapring pliers pipe to the belt drive cover bracket and carefully remove both exhaust pipes from the motorcycle. 5. Remove the drive belt cover and take the bracket off the rear cover bolt, it will not be re-used. 6. Loosen the brake rod at the rear eyelet using a T30 Torx driver. 7. Remove the exhaust mounting bar, saving the three mount bolts and washers for re-use. 8. Using snapring pliers, carefully remove the flanges and circlips from the stock exhaust system. Save for re-use. NOTE: If circlips look bent or twisted replace them with new circlips. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. Vance & Hines recommends you replace your gaskets with Screamin’ Eagle gaskets part number 17048-98. 2. Install and tighten supplied mounting bracket (stamped 356-P) using stock bolts and washers (Figure 1). Torque to 30-33 Ft/Lbs. NOTE: Support the rear of the bracket during tightening to insure it is aligned with the bottom edge of the frame. 3. Re-install drive belt cover. Torque to 1 x 3/8″ bolt 30-33 Ft/Lbs. 2 x 1/4″ bolts 80-120 In/Lbs. 4. Re-install brake rod eyelet using blue thread locking compound (Loctite® 243). There is a 1/2″ clearance hole in the bracket to allow access for tightening brake rod eyelet. Torque to 120/180 In/Lbs. (Figure 1). 5. Remove header pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips where hose clamps will loop through (Figure 2). 6. Install circlips and flanges from the stock system onto both new head pipes.

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