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SUZUKI SV1000 PERIODIC MAINTENANCE

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

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

GL1800 Goldwing Trike Conversion Kit Installation Instructions

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

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Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh

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

2009 – Current Harley Davidson Trike Conversion Kit INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-02-2012

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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 and REMOVE battery. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Remove and save the Passenger Handrail and two ¼ – 20 flanged hex head nuts if equipped. 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 four ¼ – 20 HHCS. 13. Remove Tour Pak from Top Support Tube. 14. Remove both saddlebag support rails. 15. Loosen Muffler Clamps on both Mufflers and remove two 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 16. Remove right side rear heat shield. 17. Remove and discard Muffler Support Plates. 18. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip. 19. Remove four frame cover fasteners and the Left and Right Frame Covers. 20. Remove four Tour Pak Support fasteners and the Tour Pak Support.
7 21. Remove four rear fender fasteners and rear fender. 22. Remove four ½ – 13 HHCS and washers. Remove and discard Rear Air Shocks, Air lines and Air Valve bracket. 23. NOTE: NOTE: NOTE: NOTE: If motorcycle is A.B.S. Equipped refer to A.B.S. Installation Instructions. WARNING: WARNING: WARNING: WARNING: If A.B.S. Equipped DO NOT drain brake fluid. 24. Drain all Brake Fluid from the Rear Brake System. 25. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 26. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 27. Remove the Spring Clip and nut from the Rear Axle. 28. Remove Rear Axle and Rear Wheel Spacers. 29. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 30. Remove Rear Brake Caliper. 31. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate. 32. Remove Rear Wheel Assembly. 33. Remove two 3/8 – 16 SHCS. Remove Passenger Footboards.

HAR:EY DAVIDSON FLHR/C/S (Road King) FRONT END LOWERING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Removal (Left and Right Forks) 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to Touring Model Service Manual and remove front wheel, fender and brakes. 3. Refer to Touring Model Service Manual and remove headlamp nacelle. 4. Loosen fork cap bolt from fork tube plug at top of fork tube, but do not remove. 5. See Figure 1. Standing at front of vehicle, loosen pinch bolt (with lockwasher) on right side of lower fork bracket, but do not remove. 6. Spray glass cleaner on fork tube above the rubber fork stop. After lubricating surfaces, move fork stop up fork tube until it contacts bottom of upper fork bracket. 7. Holding fork slider to prevent fork from dropping, remove fork cap bolt from fork tube plug. Slide fork tube down and out of upper fork bracket, fork stop, lower fork bracket and slider cover. 1 WARNING 1 WARNING 1 WARNING 1 of 5 ® Kit Number 54614-05 Figure 1. Loosen Pinch Bolt on Lower Fork Bracket i04808 1 Fork cap bolt 2 Fork stop 3 Pinch bolt 8. Thread fork cap bolt back into fork tube plug to prevent loss of oil while handling. 9. Move forks to bench area. Place suitable drain pan on floor beneath vise. 10. Repeat Steps 2-6 to remove left fork. Left And Right Fork-Disassembly 1. Remove nuts, lockwashers, flat washers and axle holder from studs at end of fork slider. 2. See Figure 2. Obtain FORK TUBE HOLDER (Part Number HD-41177) and proceed as follows: a. Clamp end of tool in vise in a horizontal position with plastic knobs facing toward you. b. See Figure 3. With the fork cap bolt topside, clamp fork tube between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. 3. Remove fork cap bolt from fork tube plug. Remove quad ring seal. Save bolt but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug from fork tube. Be aware that fork tube plug is under spring pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove 6mm screw from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring. 11. Remove and discard damper tube. 12. Remove wear ring and rebound spring. Discard rebound spring. Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted. 13. Using pick tool, remove retaining clip between fork slider and fork tube. 14. Remove fork tube from fork slider. NOTE To overcome any resistance, use the fork tube as a slide hammer, that is, first push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. 15. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing. 16. Remove the lower stop. Right and Left Fork-Assembly Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. 1. See Service Parts Illustration. Obtain new Damper Tube (Item 7, Part Number 46532-04) from kit. Obtain new Rebound Spring (Item 8, Part Number 46273-02) from kit and install on opposite end. Install wear ring removed in step 12. 2. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube. Install lower stop at end of damper tube. 3. Install fork slider in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (14) (Part Number 45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube. 5. Slide slider spacer down fork tube until it contacts slider bushing.

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