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HARLEY DAVIDSON SOFTAIL CHROME REAR AXLE ADJUSTER AND COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Block the motorcycle underneath the frame so the weight of the vehicle is off of the rear wheel, but do not raise the rear wheel off the ground. 2. Some models require loosening or removal of the muffler or mufflers in order to remove the rear axle. See the EXHAUST SYSTEM REMOVAL section of the Service Manual. Remove the saddlebags if desired for extra working clearance. See SADDLEBAG REMOVAL in the Service Manual. 3. See Figure 1. Remove the original axle adjustment bolts (1) and jam nuts (2) from both sides of the motorcycle and discard. NOTE On a bike that has been previously serviced, ensure that the axle has not been removed and re-installed from the left side (with the castle nut to the right of the wheel). If it has, the axle MUST be inserted from the right side of the motorcycle. 4. Remove the retaining pin (7), castle nut (5) and washer (4) from the left side of the axle (6). Discard the washer, but save the pin and nut for later re-assembly. 5 7 1 4 6 2 3 is04101 1. Axle adjust bolt 2. Jam nut 3. Axle adjuster collar 4. Washer 5. Castle nut 6. Rear axle 7. Retaining pin Figure 1. Rear Axle Hardware (Left Side Shown) 5. Tap the axle toward the right side of the motorcycle and remove. The belt adjuster collars (3) will fall loose as the axle is removed. The collars can be discarded. The wheel bearing spacers may also fall loose or be dislodged. Be sure to return these to their original position on the vehicle (short spacer on the right side, long spacer on the left). 6. Inspect axle components for damage or excessive wear, and replace as required

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Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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HARLEY DAVIDSON SOFTAIL REAR AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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INSTALLATION 1. 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. 2. All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. 3. 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. 4. All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. 5. All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. 1 2 4 3 is04788 1. Axle adjuster screw 2. Jamnut 3. Castle nut 4. Cotter pin (or spring clip) Figure 1. Rear Axle Hardware

HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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1999-2008 FLHT Series Harley- Davidson Trike Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 04-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect negative Battery Terminal. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Save the Passenger Handrail and two nuts. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove five ¼ – 20 HHCS, ¼ – 20 nyloc nuts, and Aluminum Spacers. 13. Remove Tour Pak from Top Support Tube. 14. Loosen Muffler Clamp on both Mufflers and remove 2 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 15. Remove and discard Muffler Support Plates. 16. Remove both ¼ – 20 HHCS and Front Saddle Bag Brackets. 17. Remove the twelve 5/16 – 18 Torx HCS six 5/16 – 18 nuts, and the Left and Right Saddle Bag Guards. 18. Remove the Air Line Junction from the Rear Fender. 19. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip.
6 20. Remove two 5/16 – 18 Phillips head screws. Remove the Left and Right Frame Covers. 21. Remove two 5/16 – 18 Torx HCS. Remove and save the Top Tour Pak Support Tube Top. 22. Remove four 5/16 – 18 Torx HCS. Remove the Left and Right Rear Saddle Bag Guard Support Bracket. 23. Remove four 5/16 – 18 HHCS. Remove and save the Tour Pak Support Tube Bottom. 24. Remove and discard the Air Valve Assembly Bracket. 25. Remove four ½ – 13 HHCS and washers. Remove and discard both Rear Air Shock Absorbers. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. 26. Drain all Brake Fluid from the Rear Brake System. 27. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 28. Remove the 10 – 24 flanged HHCS and Rear Brake Hose Clamp from the Right Rear Fork Bracket. 29. Remove ¼ – 20 SHCS from Rear Stop Lamp Switch Bracket. 30. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 31. Remove the Spring Clip and nut from the Rear Axle. 32. Remove Rear Axle and Rear Wheel Spacers. 33. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 34. Remove Rear Brake Caliper. 35. Slide Rear Wheel Assembly rearward. Remove one 5/16 – 18 Torx HCS from inside the Rear Fender well. 36. Slide Rear Wheel Assembly forward. Remove two 5/16 – 18 Torx HCS. Remove Rear Fender. 37. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate

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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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HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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HONDA AERO 750 Front/ Rear Exhaust System Removal And Installation Instruction

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

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Remove your stock exhaust system and large muffler bracket. 2. Attach the supplied Cobra bar mount bracket to the outside of the frame using the stock M10 bolts & nut along with the supplied M10 nut (See figure 1). DO NOT TIGHTEN at this time. 3. Loosen and move the right side floorboard out of the way to ease installation of the exhaust. 4. Install the rear head pipe using the stock acorn nuts but DO NOT TIGHTEN at this time. 5. Slide one supplied clamp #27-61MSC onto each muffler and position as shown in Figure 2. 6. Slide the rear muffler over the rear head pipe. Place one slider bracket inside the muffler bracket with the flat side of the bracket against the muffler bracket (see figure 2) and install two 5/16 x 5/8 hex bolts thru mounting bracket , muffler bracket and into the slider brackets. 7. Repeat step 6 for front head pipe and muffler making sure the front and rear mufflers are parallel. 8. Unscrew the remaining hose clamps and feed the tail end of the clamp through the clips on the inside of the heat shields. The screw end of the hose clamp should be accessible for tightening but not visible when the heat shields are mounted to the pipes. 9. Place the heat shields onto the head pipes and align on muffler as shown in Figure 2. You may need to loosen the muffler bolts to adjust the position of the muffler to the heat shields. Snug the heat shield clamps onto the head pipes but DO NOT TIGHTEN at this time. Rotate the muffler clamps so they don’t interfere with the heat shields but are still accessible to tighten. 10. Tighten mount to frame and then the acorn nuts on the head pipes making sure to tighten evenly. Now, tighten the muffler clamps. (NOTE: If the muffler clamps are slid to far up on the muffler or past the three slots, the clamps will not tighten.) Next tighten mufflers to mount bracket. 11. Reinstall the right floorboard and tighten to factory specifications . 12. Make sure all hardware is tight before starting your motorcycle.

Honda Goldwing GL1800 Independent Rear Suspension Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm . 5.1 Explanation of OEM brake system and changes From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Trike Conversion Kit.

HONDA FURY FRONT HEADPIPE W/HEATSHIELD, REAR HEADPIPE / MUFFLER W/HEATSHIELD INSTALLATION MANUAL

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

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Remove your stock exhaust system and stock exhaust mount. Save the (4) acorn nuts that attach the headpipes to the cylinders for later use during installation. 2. Install exhaust mounting bracket onto outside of frame, where stock mounting bolts were removed, by inserting the supplied M10 x 70 mm bolt into the top mounting hole and the shorter M10 x 45 mm into the lower and thru the frame, see Figure 1. Start threading the supplied M10 Nylock nut onto lower and upper bolts but DO NOT FULLY TIGHTEN. 3. Loosen the right footpeg/floorboard assembly to help provide installation clearance for the front headpipe. 4. Slide the supplied exhaust flange over the front headpipe and bolt to cylinder using stock hardware from Step 1. DO NOT TIGHTEN at this time. 5. Place the supplied 27-61msc clamp onto the lower muffler slip collar then slide the rear headpipe / muffler assembly onto the front headpipe and into the rear exhaust port. Bolt rear headpipe to the rear cylinder using the stock acorn nuts from Step 1. See Figure 2 for clamp orientation. 6. Bolt the muffler assembly to the mounting bracket using the supplied 5/16 bolts. DO NOT TIGHTEN . 7. Make sure the front headpipe is inserted properly into the rear assembly and make sure the pipes are parallel with each other. Fully tighten the exhaust bracket to the frame first, then the front and rear cylinder acorn nuts attaching the exhaust flanges, then the muffler to the exhaust bracket. Then tighten the 27-61msc clamp last. (NOTE: If the muffler clamp is slid past the slots on the slip collar the clamp will not tighten properly.) 8. Unscrew the remaining hose clamps and feed the tail end of the clamp through the clips on the inside of the heatshields, the larger clamps go to the rear of the heatshields where they will rest on the muffler bodies, smaller ones to the front for the headpipes. The screw end of the hose clamp should be accessible for tightening but not visible when heatshields are mounted to the pipes, see Figure 3. 9. To install the front heatshield, first slide the rear portion of the heatshield over the muffler, continue to slowly slide it forward pushing the front of the shield gently into place between the frame and motor (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes). Make sure the muffler clamp doesn’t interfere with the heatshields and is aligned as shown in Figure 2. Snug the heatshield clamps but DO NOT TIGHTEN . 10. Install the rear heatshield in the same manor as the front heatshield. Tighten all hose clamps.

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