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Indian Rocker Arm End Play Rear Cylinder/ Front Cylinder Installation

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Filed Under (Indian) by admin on 12-11-2010

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Rear Cylinder 1Rotate the engine so that the rear piston is at Top Dead Center (TDC), compression stroke, so no load is on the valves. 2Using a 3/16″ allen wrench, remove the four screws securing the rear cylinder rocker cover. 3Remove the cover and inspect both O-ring seals. Discard if damaged or worn. 4Push both rocker arms towards the valve end support bracket (A) and using a feeler gauge check the gap between the rocker arms and the pushrod end support bracket (B). NOTE: The Rocker arm end play specification should be between 0.003″ to 0.012″. 5 Compare the measurement to the specification an determine whether adjustment is necessary. If the end play is within specification, adjustment will not be required. Refit the rocker cover (instructions 14 to 15) and carry out the same inspection on the front cylinder . If the measurement is outside the specification, adjustment will be required and shimming will be necessary (follow the remainder of these instructions). Adjustment 6Using a 1/4″ allen wrench remove the 4 screws securing the rocker shaft assembly.Refit the LH support bracket and reposition the complete assembly on the rocker base. Make sure that the three dowels are in place and the slots in the rocker shafts are properly aligned with the mounting screw holes in the RH support bracket. 11Clean the threads of the 4 support bracket screws and apply Blue Loctite to the first 4 threads. 12Fit the 1-3/4″ screws into the LH support bracket (A) and the 2″ screws to the RH bracket (B). Torque all screws in cross pattern to 16-20 foot-pounds. CAUTION: The rear piston must be at TDC, compression stroke, when tightening the support bracket screws. 13Re-check the rocker end play to ensure it is within specifica- tion. 13Lubricate the two O-rings with clean engine oil and refit them in the grooves in the rocker base. 14Refit the rocker cover.

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Harley-Davidson Style Rocker Cover Assemblies installation Instructions

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Filed Under (Harley Davidson) by admin on 27-10-2010

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Installation 1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of OEM rocker housings. Refer to authorized Harley-Davidson Service Manual as necessary. WARNING – Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. WARNING – Gasoline is toxic when fumes inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head.
3 Picture 3 Picture 4 Right Left Rocker shaft reliefs must align with these holes. NOTE – Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. CAUTION – Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

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Harley-Davidson Evolution Engines S&S Billet Rocker Cover Assemblies Installation Instructions

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Filed Under (Harley Davidson) by admin on 30-10-2010

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1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of rocker housings. Refer to authorized Harley-Davidson®Service Manual as necessary. Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. Gasoline is toxic if fumes are inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson®Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head. NOTE: Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 3 CAUTION WARNING WARNING CAUTION 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

Harley-Davidson Twin Cam 88 S&S Billet Rocker Covers Installation Instructions

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Filed Under (Harley Davidson) by admin on 30-10-2010

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Failure to confirm pushrod/lifter placement before proceeding with installation can result in damage to rocker arm support plates and other parts. With pushrods at lowest point, front piston will be at TDC on Compression stroke. 4. Remove breather cover and baffle assembly. See Picture 2. 5. Remove rocker arm/rocker support plate. See Picture 3. NOTE – Gradually loosen rocker arm support bolts in following sequence (See Figure 1): 1. Left (driveside) rear 2. Right (camside) front 3. Right (camside) rear 4. Left (driveside) front Loosen bolts in sequence and in 1⁄ 4 -turnincrements for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 6. Remove lower rocker housing bolts. NOTE – Gradually loosen lower rocker housing bolts in following sequence (See Figure 2): 1. Right (camside) front 2. Left (driveside) rear 3. Left (driveside) front 4. Right (camside) rear 5. Center front 6. Center rear Loosen bolts in sequence and in 1⁄ 4 -turn increments for first 3⁄ 4 turn. Bolts can then be removed according to normal procedure. 7. Remove lower rocker housing and gasket from head. Remove oil and any remaining gasket material from cylinder head gasket surface and clean gasket surface with lacquer thinner

Harley-Davidson Twin Cam Engines Performer RPM Gear Drive Camshaft Kit INSTALLATION PROCEDURE

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

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1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 INSTALLATION PROCEDURE 1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 . 7. On pre-2000 models with a cam position sensor, you may want to remove the inspection cover, unplug the wires, and remove the sensor at this time to ease installation later on. 8. Remove the cam housing cover keeping the bolts in a separate cup. ( Note: Oil will run out of the cam housing.) 9. Using the Chain Tensioner Unloader Tool, unload pressure on the outside chain tensioner, and pin it in place with the retaining pin (See Figure 2) .

HARLEY DAVIDSON SOFTAIL SPRINGER Dual Slip-On Exhaust System Installation Manual

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

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REMOVING THE STOCK MUFFLERS 1. Loosen the bolt on the pinch clamp at the front end of each muffler. 2. Remove the two bolts that mount the muffler to the mounting bar. Repeat this step on the opposite muffler. 3. Remove the stock mufflers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the mufflers from the head pipes. INSTALLING YOUR NEW VANCE & HINES SLIP-ON EXHAUST SYSTEM 1. Remove the two 5/16″ flanged head bolts from the bracket that is welded to the backside of each muffler. Attach one of the mounting brackets (supplied) to each muffler, using two of the 5/16″ flanged head bolts (removed earlier), leaving them loose at this time. When the bracket is mounted correctly on the muffler, the single hole end should point down when the muffler is mounted to the bike. 2. Be sure there is a muffler clamp (supplied) over the front (notched end) of each muffler. 3. Slip the muffler onto the stock head pipe, mount the muffler to the rear most hole of the stock mounting bar, using one of the stock bolts and tighten. Repeat this step on the opposite muffler. Note: When installed correctly, the Vance & Hines logo on the muffler should face outwards. 4. Tighten the two muffler clamps. 5. Tighten the two 5/16″ flange bolts on each muffler bracket. 6. Wipe any finger prints or oil off any chrome parts of the exhaust system before starting the motorcycle. 7. Be sure to tighten all hardware before starting your motorcycle. RE-JETTING INSTRUCTIONS Re-jetting the carburetor will result in realizing the “full” potential of this performance exhaust system. Vance & Hines offers jet kits for most applications

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HARLEY-DAVIDSON SPRINGER FORKS MOUNTING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-04-2012

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1. The shock mounts with the body up —shaft pointing down. The nitrogen fill valve can be positioned toward the rear of the motorcycle. 2. Make sure that both halves of the upper and lower bushings are in place. NOTE: Do not try to install the shock with only half of the bushings, as this will lead to poor performance and premature seal leakage. The amount of “float” in the bushing set is necessary to ensure smooth operation of the damper assembly. 3. It is easiest to install the shock when the forks are fully extended, however the shock can be installed with the bike on the kick stand. 4. Insert the body eye into the mounting channel on the fork crown. Rotate the shock down into the lower channel. NOTE: A thread locking compound such as Red Loctite 262 or other similar product should be used on the shock fasteners. 5. Install the upper mounting stud and nuts, finger tight. 6. Push the shaft up far enough to insert the lower mounting stud and nuts. This will take a little effort because of the gas pressure in the shock. 7. Torque the upper and lower shock mount nuts to 22 ft. lb.

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2008 HARLEY-DAVIDSON FXCW Softail Rocker Specifications

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Three-phase, 38-amp system ………………………………………. (439W @ 13V, 2000 rpm, 489W max power @ 13V) Starting……………….. 1.2 kW electric with solenoid shift starter motor engagement Lights (as per country regulation): Headlamp ……………….. Quartz Halogen, 55-watt low beam, 60-watt high beam Tail/Stop ghts……………………………………………………………….. Integrated LED Turn Signal Lights ……………………………………………………… 21W self-canceling Instruments …………………. Tank-mounted electronic speedometer with odometer; ………………………………………………… Time-of-day clock; Dual resettable tripmeter Indicator Lamps …………………… High beam, neutral, low oil pressure, turn signals, ………………………………………………………….. engine diagnostics, security system6, ……………………………………………………………………….. 6-speed, low fuel warnings Colour Options7 Vivid Black; Pacific Blue Pearl; Crimson Red Sunglo Model Features Silver powder-coated engine; Custom finned cast aluminium “horseshoe” oil tank with chrome external oil lines; Painted, stretch low profile tank console; Fire-truck inspired bullet headlamp; Bullet style LED turn signals; Adjustable, V-bar riser; Forward-mounted rider footpegs; Stainless steel, pull-back, internally-wired handlebars; Lowest seat height of all Harley-Davidson® motorcycles Warranty Warranty8 ……………………………………………………… 24 months (unlimited mileage) Service Interval9 ………………………………………………. First 1,000 miles (1,600 km), ………………………………………………………. every 5,000 miles (8,000 km) thereafter Dimensions

Harley-Davidson feuling Adjustable Pushrods Installation Instructions

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Filed Under (Harley Davidson) by admin on 22-04-2012

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1. Refer to the proper factory service manual for your model and year of engine, for removal of existing pushrods. 2. The Feuling pushrods are designed with a small adjustment parameter for rigidity creating maximum lift – These are not quick install pushrods and may require the removal of the lifter blocks and or loosing of the breathers/rocker arms supports. When loosening the rocker arm supports always remove the breather bolts first. 3. Clean and inspect each new Feuling pushrod including center oil hole 4. Feuling pushrods are marked Intake and Exhaust. The shorter pushrods are Intake and the longer pushrods Exhaust 5. Feuling recommends using new O-rings and gaskets where applicable to prevent oil leaks
6. Always pump up hydraulic lifters before installing them. Use an oil squirt can to fill the lifter with oil through the feed hole on the side of the lifter, push oil through the feed hole until the air bubbles are gone. If needed work the oil back and forth through the feed hole and pushrod seat with the squirt can. Light weight oil can be helpful. 7. Assemble and adjust one cylinder at a time, the servicing cylinder needs to be on TDC of compression stroke so the cam lobes are at their lowest point 8. Install pushrods into proper locations with the adjusting side of the pushrod down, towards the lifter. Slide the pushrods through the pushrod covers up into the rocker housing and set the pushrod on the seat of the lifter. We recommend filling the pushrods with oil then maneuver the pushrod up into the rocker arm seat. 9. Torque rocker arm housings and breathers to factory torque spec’s 10. See the instructions for your lifters for the proper adjustment. All Feuling hydraulic lifters run best at . 090″ – . 100″ of crush.

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Honda GL1100/ 1200 Saddlebag Bent Rails Installation Manual

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Filed Under (Honda) by admin on 28-02-2011

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Read instruction thoroughly before installing. DRILLING REQUIRED. 1. Place bike on center stand. 2. Place masking tape on feet of rail to prevent scratches on the saddlebags. Position saddlebag rails on saddlebag to mark for drilling. 3. When positioning the rail, carefully move the rail back and forth until proper alignment is achieved and there is no interference with the saddlebag latch. 4. Mark position for drilling holes on a piece of masking tape placed on the saddlebag under each leg. 5. Drill a 6mm hole. 6. Remove tape from rail and clean the saddlebag if necessary. 7. Attach the rail with the hardware included from the inside of the saddlebag lid. 8. Repeat on other side.

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