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2000 Honda Rancher ATV Winch Mounting Kit REMOVAL AND INSTALLATION

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Filed Under (Honda) by admin on 13-01-2012

Begin by removing the front fascia and front skid plate on the vehicle as shown in figure 1. Save the fasteners as they will be used later to re-install the front fascia and skid plate. 2. Remove the 8mm bolts on both sides located inside the front tires and on the ends of two horizontal tubes on the front tube frame as shown in figure 2. 3. Place the mounting plate (A1) inside the front tube frame. The tabs with the slotted holes facing down. The slotted tabs should align where the
two 8mm bolts were removed in step 2. Reinstall these two bolts at this time thighten to just fingertight. Install the two 1/4-20 u-bolts (B3) and locking hex nuts (B1) and flat washers (B7) at thism time see figure 3, do not tighten down at this time. so the plate can be adjusted for position see figure 2. 4. Place the rear support bracket (A4) into position
and attach with the two 5/16-18 x 3/4 hex cap screws (B6), flat washer (B5) and locking nut (B4). Adjust the position of the support bracket so that it comes in contact with the frame tubes and tighten the fasteners see figures 3 and 4.
Make sure the support bracket maintains contact with the rear frame tubes and tighten down the two front 8mm mounting bolts. Tighten the bolts to a recommended torque of 12 ft-lb (17 N-m). 5. Attach the fairlead bracket support (A2) to the front frame tubes see figure 5. The support bracket attaches behind the front tubes. Space the bracket away from the tubes using the spacer brackets (A3). Attach the brackets using the 1/4- 20 u-bolts (B2), lock nuts (B1) and flat washers (B7). Before tightening the u-bolts make sure the bracket is in the correct position by fitting the front
fasica into postion and checking location. Tighten the nuts to a recommended torque of 7 ft-lb (10 N-m). NOTE: If this kit is being installed on a 00 to 03 Honda the wider fairlead bracket (A2) will need to be used. This will require the use of the
wider u-bolts (B3). The spacer brkts (A3) will not be required when installing the wider fairlead brkt

Honda Foreman 500 And Honda Rubicon WINCH MOUNTING KIT INSTALLATION

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Filed Under (Honda) by admin on 13-12-2011

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Begin by removing the front skid plate located on the front of the ATV. Remove the four side 8mm bolts and four bottom 6mm bolts securing the front skid plate, figure 1. Save the fasteners as they will be used later to reinstall the front skid plate. 2. Remove the four plastic rivets on each side of the front plastic fascia, figure 2. Use a large screw driver to carefully remove the center rivet. After removing the center rivet, remove the rivet housing. Save the fasteners as they will be used to reinstall the front plastic fascia. 3. Remove the two 6mm bolts that attach the front plastic fascia to the bumper, figure 3. Remove the front plastic fascia at this time . Remove the two 6mm bolts that attach the front bumper to the plastic headlight assembly, figure 4. Save the fasteners as they will be used to reinstall the front bumper. 5. Remove the two top 8mm bumper bolts that attach the front bumper to the front rack, figure 5. Save the fasteners as they will be used to reinstall the front bumper. Figure 5 Remove Top Bumper Bolts Remove (both sides) 6. Remove the two ottom bumper bolts that attach the bumper to the bottom of the vehicle frame, figure 6. Save the fasteners as they will be used to reinstall the front bumper

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HONDA 420 RANCHER 2×4/4×4 2007-2009 CLUTCH KIT INSTRUCTIONS

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Filed Under (Honda) by admin on 22-12-2011

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Remove key from the ignition switch. Remove the side panels from both sides. Remove both foot wells. 2. Drain coolant. Remove the oil drain plug from the motor; if you carefully drain it into a clean container you should be able to reuse it. 3. Disconnect shift motor (on electric shift models only). Remove coolant hoses. 4. Remove the bolts that mount the front differential to the frame, no other parts need to be removed. Carefully slide the front differential towards the front of the machine; you might need to lift up slightly to get the differential to move. Remove the drive shaft. Remove o-ring on output shaft (on motor). 5. Remove the fuel pump. 6. Loosen the front crankcase cover bolts, keep track of each bolt length and location. Slowly remove the crankcase cover. Carefully watch for o-ring shims and dowel pins that may fall out. 7. Unstake the nut holding the clutch on and remove nut. Using Honda tool #07933-HB3000A thread the large part of the tool into the center of the clutch. Tighten the center bolt on the tool while holding the large part of the tool with a wrench. This will pull the clutch off the machine. Place the clutch on a clean work surface. EPI performance.com
8. Using the c-clamps push down slightly on the outside cover and remove the four e-clips. Keeping track of which way they come off, remove the round metal plates one at a time. This will allow you to see the complete spring. Remove one end of each spring using a spring tool or needle nose pliers and then remove springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the hole. Install the metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up. Slide the clutch into the machine. The Sprague clutch is marked “outside” when installing make sure this is facing out. Torque clutch nut to 87 ft/lbs. 9. Clean the gasket surface on the motor and on the cover. Put a thin layer of Honda Bond or Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase cover. Carefully install crankcase cover, do not force cover on. Torque bolts to 9 ft/lbs. 10. Install the fuel pump. 11. Install the o-ring on the output shaft (on motor) and install the drive shaft. Carefully slide the front differential back into place and mount to the frame. Install the coolant hoses. Refill your engine coolant to the proper level according to your owner’s manual. 12. Install the oil drain plug. Refill your engine to the proper level according to your owner’s manual. You can reuse your oil if it is clean and was drained into a clean container. Only use manufactures recommended oil. 13. Be sure to double check coolant and oil levels and to look for any leaks after the machine has run for a few minutes. 14. Go out and ride your machine. If your performance doesn’t seem right double check to make sure everything has been done properly. 15. EPI is constantly testing our products. Sometimes there is a need to contact the user with new technical information. To ensure that you are receiving this information visit our web site EPIperformance.com to register your clutch kit.

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1500cc Honda Goldwing Installation Manual

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Filed Under (Honda) by admin on 02-12-2010

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Review entire installation manual Loosen saddle bags and remove rear fender cover Modify rear fender cover Install receiver hitch and double check all bolts Remount rear fender and tighten saddle bags Assemble InstaTrike hitch cart Attach InstaTrike to motorcycle via receiver hitch Attach leanstop brace bolts to receiver hitch Align InstaTrike wheels Double check all bolts for tightness Test ride InstaTrike slowly in an open area to familiarize yourself with handling characteristics Receiver Hitch Installation NOTICE: Install all bolts and brackets loosely until all bolts and brackets are in place 1) Place motorcycle on center stand. NOTE: Some Goldwings are not level when on center stand. Shim underneath center stand to level motorcycle. 2) Remove side covers 3) Loosen saddle bags and remove rear fender cover. 4) Modify rear fender cover. See diagram 5) Remove muffler bolts. Replace with enclosed muffler bolts. (hex bolt head toward inside with washers on bolt head side) This allows clearance between the hitch and muffler bolt. 6) Replace existing motorcycle rear crashbar bolts with those provided (2 each side). Ensure new crashbar bolts are securely tightened before attaching brackets A and B. 7) With brackets A (left) and B (right) attached to bottom of forward arms of hitch, slide hitch under bike and loosely attach A and B to bottom of rear crash bar with provided U-bolts. Use caution not to crush crash bar with U-bolt

1100cc Honda Goldwing Installation Manual

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Filed Under (Honda) by admin on 29-04-2011

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Receiver Hitch Installation Install all bolts loosely until all brackets are in place 1) Place motorcycle on center stand and be certain it is level. 2) Remove saddlebags if necessary for easier installation. 3) Mount bracket A to the lower front crash bar bolt Left side (new bolts provided) and top of left hitch arm. 4) Mount bracket B to the lower front crash bar bolt Right side (new bolts provided) and top of right hitch arm. 5) Bracket C mounts to rear of hitch and sub frame bolt located behind tail light (new bolt provided) This bracket mounts inside the rear fender. 6) Attach brackets D and E to rear of hitch. 7) Bracket F attaches to bottom of bracket D and trunk sub frame with U-bolts. Insert bottom U-bolts at step 9 8) Bracket G attaches to bottom of bracket E and trunk sub frame with U-bolts. Insert bottom U-bolts at step 9 9) Brackets D and E (with brackets F and G) attach to bottom rear saddlebag sub frame with U-bolts. 10) Tighten all bolts. INSTALLATION OF THE TOW-PAC HITCH CART. 1. Place your motorcycle on a smooth flat surface, like a garage floor, and rest it on its center stand. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bolt. 5. Push the motorcycle off of the center stand and risers if used. 6. Bolt leanstop braces to hitch. (Bolt inserts from the bottom) Be certain to replace washers/spacers in the same configuration as when you removed them. see diagram next page 7. Check all bolts for tightness. 8. You are now ready for the test ride. A. Keep your feet up! B. Ride slowly in first gear until you are comfortable with the Tow-Pac system.

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How to Replacing Rear Main Seal 1

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Filed Under (Tips and Review) by admin on 24-11-2010

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The next day I woke up early and drank lots of coffee before going out to the garage. I knew I had two distinct problems confronting me. First, I would have to purchase an impact tool in order to loosen the six bolts holding the clutch together. Also, I would have to purchase at least three 8mm by 50mm bolts and nuts in order to prevent the clutch from exploding when the six bolts were unscrewed. For the third time in two days, I went to Sears and asked the salesman, (who I now I knew as Art,) where I could find an impact tool. He did not know what it was I was looking for, but he asked another employee and soon I had the tool as well as a 6mm Allen socket. Unfortunately, the Allen socket only came in 3/8″ drive, and the impact tool only came in 1/2″ drive. Thinking quickly, I purchased a 1/2″ to 3/8″ adapter, as well as a 3lb. dead- blow hammer. On the way home, I stopped at a Chief Auto Parts to buy the bolts I would need. The closest size they had were 8mm by 40mm, which was nearly 10mm too short. I was unsure whether the clutch cover bolts were coarse thread or fine thread, so I bought three of each, along with corresponding nuts. Finally, around 11 o’clock in the morning, I was back at the garage ready to work. I prepared the impact tool and placed the adapter and the Allen socket on it. I began to hammer on the end of the tool, trying to loosen each of the six bolts. None of them seemed to move, even though it seemed the impact tool was turning. Finally, I put the Allen socket on the breaker bar and found that all of the bolts had actually come loose. The tension from the clutch spring made it nearly impossible to see, however. I removed three of the bolts in a triangular pattern. Into these empty holes I threaded the fine- thread 40mm bolts with nuts attached and tightened them evenly. I was now able to remove the remaining Allen bolts. By slowly turning and loosening the nuts evenly on the 40mm bolts, I relieved the pressure from the clutch spring until the cover plate was free. I removed the cover plate, the clutch, the pressure plate, and finally the clutch spring. I had already marked each of the elements with Whiteout to insure that they would fit together the same way on installation. Apparently, this is essential as the flywheel could be rendered out-of-balance if the clutch components are not installed correctly. The flywheel itself was now exposed. I could see the five bolts that attached it to the crankshaft. I now used a tool I had fabricated. Although the manual describes two possible tools that can be fabricated, I found a piece of metal that resembled the tool and decided to use it. Unfortunately it was not strong enough and broke. I turned and looked at my workbench, and noticed a bracket which I had previously fabricated for mounting a mirror on my Vespa. The piece of steel was extremely strong and was already pre-drilled with correct-sized holes. It fit perfectly, so I placed it over the exposed bolt which protruded from the case, and placed the other end on one of the 40mm bolts, which I then bolted into the flywheel itself. I used the breaker bar again and removed the five bolts. The flywheel came loose after inserting two more 40mm bolts and tugging on them evenly

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HONDA VT-600 Front Wheel Adapter kit Installation Instructions

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

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1. Using a 6mm Allen wrench, loosen the 2 front axle pinch bolts on the right side of the lower fork leg. Loosen bolts 4 or 5 turns. 2. Using a 17mm Allen wrench, slightly loosen the front axle from the right side of the bike. Having the front wheel on the ground will help you in loosening the axle. Do not remove the axle at this time! 3. Loosen and remove the speedometer cable from the back of the speedometer on your handlebars. Pull the speedometer cable all the way out of the front fork. Remove the cable from the speedometer drive on your front wheel (note the position of the connection as it will be similar on your new drive installation). This speedometer cable or speedometer drive will not be needed on your new wheel installation. 4. Block the back wheel to prevent the bike from rolling backwards, and raise the motorcycle’s front wheel off of the ground, so the wheel spins freely. You can do this with a motorcycle lift placed under the front portion of the motorcycle frame. Contact Scootworks to purchase a lift if you don’t have access to one. Ensure the bike is stable and will not fall before proceeding further! Scootworks, Inc. 3 5. Using the 17mm Allen wrench, finish loosening the front axle until it is completely free from the left side of the lower fork. Hold onto the front wheel and slowly remove the axle from the front fork. Be careful not to let the wheel drop. Having a helper hold the wheel for you as you remove the axle will ease the removal. Slide the brake rotor out of the calipers. NOTE: be careful not to operate the front brake controls with the brake rotor removed from the calipers. 6. With the wheel removed from the front forks, lay the wheel on a padded or cushioned surface with the brake rotor facing upwards. Using a 6mm Allen wrench, remove the 5 Allen bolts from the brake rotor. (The bolts are sometimes installed with loctite, and may require heating with a small torch to loosen the loctite). Remove the brake rotor from the wheel. Place the wheel to the side. Clean up the bolts as you will reuse them later. 7. Take your new custom wheel that you will be installing on your bike and place it on a cushioned or padded surface to prevent scratching. Turn it so that the side where the brake rotor attaches is facing upward. 8. Ensure the brake rotor mounting holes on the wheel are clean and free of oil or grease. Clean with alcohol if needed, then let dry. Place your new brake rotor adapter plate onto the wheel with the flat side against the wheel. Apply a small amount of medium strength (blue) loctite on each of the 5/16″ Allen bolts supplied with your kit and install through the new rotor adapter plate and into the wheel. Tighten with a 3/16″ Allen wrench until snug. When all bolts are installed, tighten in a star pattern, and torque to 25-30 ft. lbs. 9. Install your brake rotor onto the new brake rotor adapter using the original bolts you removed in step 6. Apply a small amount of medium strength loctite to each bolt and install through the brake rotor into the new brake rotor adapter. Tighten in a star pattern, and torque to 25-30 ft. lbs. 10. It is now time to install your new wheel/rotor adapter onto your bike. It is easiest to accomplish this with a helper, as it takes some coordination to get the wheel, brake rotor and spacers into place. Apply a thin coat of grease to the axle. Lift the front wheel into place between the front forks, aligning the brake rotor into the caliper. The caliper floats from left to right and can be moved into the proper position. If the caliper is closed, pry the brake pads apart so that the rotor will slide into the caliper.

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Honda 2007-2010 Rancher 420 ATV Rear Bumper Installation

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Filed Under (Honda) by admin on 22-12-2011

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Honda Rancher 420 ATV Rear Bumper (2007-2010) Installation Instructions 1. Attach top bumper attachments to top rack. 2. Attach the rear bumpers lower attachment point to vertical bars

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HONDA VTX1800R & HONDA VTX1800N BIG SHOTS EXHAUST SYSTEM

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Filed Under (Honda) by admin on 10-11-2011

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harness. Remove wire tie (take note of harness routing for reassembly). Un-route wires and drape over right side of pipe. 3. Remove entire right side floorboard assembly, (three bolts) (Figure 1). 4. Remove exhaust port flange nuts.
5. Remove flange bolts securing rear muffler mount to exhaust system mounting bar. 6. Remove complete exhaust system. Start by removing front head pipe from exhaust port (assistance may be required). 7. Remove rectifier from mounting bar. 8. Remove stock (cast iron) exhaust system mounting bar.

1995 – 1999 HONDA CBR 900RR AKRAPOVIC BOLT-ON STREET LEGAL EXHAUST SYSTEM Installation instructions

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Filed Under (Honda) by admin on 12-12-2010

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REMOVAL OF STOCK EXHAUST SYSTEM 1. put the motorcycle on a side stand, we recommend a racing stand 2. unscrew and remove bolts from the muffler at the muffler – link pipe (header assembly) connection (Figure 1) 3. unscrew and remove the bolt from the metal hanging bracket and remove the muffler (Figure 2 & 3) INSTALLATION OF THE AKRAPOVIC BOLT-ON EXHAUST SYSTEM installing the muffler: 1. remove the stock gasket and install the copper gasket from the Akrapovic kit in the groove in the CNC ALU flange (Figure 4) 2. correctly orient the muffler and place it near the link pipe/header assembly 3. when the muffler and the link pipe are together, attach using the titanium bolts from the Akrapovic kit. Coat each bolt individually with bolt sealant before installing. (Figure 5) Tighten the bolts only hand tight – do not fully tighten! (Figure 6) 4. correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp viewed from the rear (Figure 7). WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! (Figure 8) 5. tighten the carbon-fiber clamp onto the stock bracket on the frame – use the stock bolts or the replacements from the Akrapovic kit, if supplied (Figure 9) 6. make sure that the BOLT-ON system is not touching any other parts of the motorcycle ! 7. example of the correct position of the installed Akrapovic BOLT-ON system (Figure 10) final installation: 1. Tighten the titanium bolts on the CNC ALU flange at the muffler – link pipe connection and also tighten the bolts on all of the brackets and clamps to which the exhaust system and the other dismounted parts of the motorcycle are attached 2. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. muffler – carbon-fiber outer sleeve: use 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. 3. 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.