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HARLEY DAVIDSON THROWOVER SADDLEBAGS REMOVAL AND INSTALLATION MANUAL

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

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Installation 1. Place the saddlebags on the vehicle so the straps are positioned over the top of the passenger seat. 2. Lace saddlebags together. 3. Adjust the leather straps so the saddlebags ride high and fit snugly and evenly against the side of the seat. Top of saddlebags may be replaced to achieve snug fit. NOTE On some models, the rear turn signal lights may interfere with mounting of saddlebags. To correct this, a new directional set-back kit is available under part number 90504-82. This kit allows the rear signal lights to be mounted in the rear positions on the fender support, on 1982 and later FXR and XL models. Contact your Harley- Davidson Dealer to obtain this kit. If rear turn signal lights interfere with saddlebags, see your Harley-Davidson Dealer for a turn signal set-back kit. Proper turn signal operation and visibility is a major concern for motorcyclists. Failure to have visible, operational rear turn signals may result in death or serious injury. 4. The front securing straps must be fastened to a point on the motorcycle which is forward of the saddlebags, such as the upper shock mount or fender brace. Be certain the straps so not interfere with any moving parts. Improper positioning or fastening of these saddlebags could cause them to interfere with the operation of the vehicle, possibly causing a hazardous condition. The fastening straps and the saddlebags must be clear of the rear wheel, drive chain or belt, sprocket and rear brake components. Location of the saddlebags should not interfere with the operation of the swingarm and rear shocks and the turn signals should remain clearly visible from the rear and side of the vehicle. Improperly positioned or fastened saddlebags could interfere with the operation of the motorcycle, which could result in death or serious injury. 5. The rear securing straps must be fastened to a point which is rearward of the saddlebags such as the rear turn signal light support. 6. Check that saddlebags are mounted with ample clearance between the bags and the brake caliper and disc so they do not contact each other, even when the swingarm deflects under full load. 7. Once both saddlebags are mounted correctly, check all securing straps to be certain they are not interfering with or exposed to any moving parts. Tuck the tails of the leather straps underneath the portion of the straps that connect the two saddlebags. NOTE On some motorcycles, it will be necessary to mount the saddlebags over the outside surface of the rear shock. This is acceptable if all CAUTIONS and WARNINGS are observed

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1988-2000 Honda Goldwing GL 1500 Signal Mirror Installation Instructions

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Filed Under (Honda) by admin on 29-01-2011

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Start on either the left or right side mirror. These instructions start with the right side mirror. Pull back the rubber boot covering the mirror mount. 1 2 3 Remove the accessory compartment cover. Remove the four screws on all sides of the accessory compartment. Remove the accessory compartment from the motorcycle fairing and set it aside. 4 The motorcycle’s electrical wiring for turn indicators is located forward of the accessory compartment cavity and behind the front amber turn indicator light. Disconnect the wire connected to the turn indicator light. 5 There are three screws holding the mirror housing to the mirror mount. Remove the three screws. Set the mirror housing aside.
Mirror Replacement – 2 – Remove the three screws holding the hinge to the mirror housing. Remove the hinge and remove the rubber boot surrounding the mirror housing. 1 Match the base of the hinge up to the new Signal® mirror housing. Mark the place on the hinge where the Signal® mirror wire will go through. Drill a ¼” hole in the hinge. 2 Position the rubber boot over the Signal® mirror housing. 3 Guide the Signal® mirror wire harness through the drilled hole in the hinge. Mount the hinge on the Signal® mirror housing using the original three screws.

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SHOCK CUTAWAY SADDLEBAG INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 10-11-2010

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1. Saddlemen saddlebags mount over the back of the seat or rear fender of most motorcycles. When properly installed there will be one saddlebag on each side of the motorcycle with the split yoke resting on the fender or the seat. Both saddlebags must be securely mounted and tied down in a manner that does not interfere with any part of the motorcycle’s operation. Be certain the saddlebags or their mountings do not contact brake components, turn signals, taillight, brake light, suspension, swingarm, or drivetrain. These Shock Cutaway saddlebags have been designed to fit over your bike’s shock absorbers (see Fig. A), which allow for larger bags on bikes otherwise limited by shock and turn signal location. 2. We highly recommend that your bike be equipped with Saddlemen’s S4 saddlebag supports (see Fig. B) or equivalent. Saddlemen also offers Quick Disconnect rigid-mounting hardware kits for most bikes, that allow easy on, easy off bag installation and eliminate the yoke. For more information, see your dealer or contact Saddlemen at 310- 638-1222. 3. Your saddlebags must be at least two inches away from any exhaust pipe while the motorcycle is stationary or moving. You can adjust the split yoke to change the height of the bag on the motorcycle by adjusting the position of the hook and loop fastening system (Fig. C). Adjust the split yoke shorter to raise the height of the saddlebags, and longer to lower the height of the saddlebags. The split yoke can also be reversed by unbolting each yoke half from each saddlebag, and reversing the yoke’s position on your bike. This allows for the offset in the yoke to be positioned either forward or backwards providing clearance for the motorcycle’s components (Fig. D). 4. In addition to the hook and loop fastener, the bags rely on a nylon safety strap system to ensure proper and secure installation. This strap must be used, and tightened snugly. Assure that the strap’s short end with D-rings is pushed through the slot in the split yoke and resting on the topside it. Once the split yoke is set to the proper position, run the long safety strap over the top of the split yoke and secure it to the D-rings (see Fig E and F), and tighten it. 5. Once you’ve placed the saddlebags on your bike and have them adjusted properly, use the straps located on the bottom of each saddlebag (see Fig. E and G) to connect the saddlebag to the saddlebag support (if you are using Saddlemen’s S4 Saddlebag bracket refer to the instructions shipped with it). These lower straps adjust in length to assure a tight fit. Wrap them around the saddlebag support, snap the buckle halves together, and adjust the length of the strap assuring the strap is tight and supporting some of the saddlebags’ weight. Repeat this step on the other saddlebag.

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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 RIGID MOUNT SADDLEBAGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION NOTE Maximum saddlebag load is 10 lbs. (4.5 kg) for each bag. Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTE Saddlebag hangers must be mounted with the bend in the hanger facing out from the motorcycle. NOTE The saddlebags are symmetrical and can be mounted on either side. 1. See Figure 1. Remove the fender support cover screws from locations shown for mounting saddlebags. 2. Place lock washers (6) on two cap screws (5) and insert through the top holes of the saddlebag hanger. NOTE The FXSTC Does Not use narrow spacers (8) in Step 3 for the saddlebag installation. 3. With the cap screws in place on the hanger, place a wide spacer (7) followed by a narrow spacer (8) on each screw. 4. Thread the cap screws into the location of the original screws previously removed in Step 1 and tighten screws to 22 ft-lbs (30 Nm) . 5. From the inside of the saddlebag install two button head screws (2) with washers (3) through the upper mounting holes in the saddlebag and the hanger. 6. On the backside of the hanger install hex nuts (4) to the screws from previous step and tighten to 22 ft-lbs (30 Nm) . 7. Insert two button head screws through the lower two holes on the backside of the hanger and into the saddlebag. 8. From the inside of the saddlebag install washers and hex nuts to screws and tighten to 22 ft-lbs (30 Nm) . 9. Repeat Steps 1 through 8 for installation of the other saddlebag. Installation with Docking Points 1. If you choose to use the docking points from Kit 53930- 03, repeat the installation of previous Steps 1-8 and substitute the front and rear docking points for the spacers (7) in this Kit. You must use narrow spacers (8) from this kit for both the FLSTSB and the FXSTC when using the docking points. Install Reflectors

1999-2004 Kawasaki 1500 Drifter Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1 Remove the seat. 2 Remove the left side cover. 3 Remove the speedometer assembly. 4 Unbolt the fuel tank. NOTE: It is not necessary to remove the fuel tank. It does however make the installation easier. If you do remove the tank, pay attention to the vent hose routing. Pressing the tabs on the black fuel line connector will allow the fuel line to be disconnected (Fig. A) 5 Remove the battery/ECU hold down bracket (Fig. B). 6 Unbolt and move the bank angle (tip over) sensor out of the way (Fig. C). Fig. A Fig. B Fig. C i201-411 www.powercommander.com 1999-2004 Kawasaki 1500 Drifter – PCIII USB – 2 Bank angle sensor (tip over switch) Remove these 2 bolts 7 Loosen the bolts holding the plastic tray on the left side of the bike (under the left side cover) (Fig. D). 8 Route the wire from the PCIII behind the plastic tray and under the frame side rail (Fig. E). 9 Retighten the bolts holding the plastic tray. 10 Continue routing the wires from the PCIII under the frame near the lower fuel tank mount and go up to the throttle body area (Fig. F). Fig. D Fig. E Fig F i201-411 www.powercommander.com 1999-2004 Kawasaki 1500 Drifter – PCIII USB – 3 Route PCIII harness between plastic tray and frame Route wires under frame Loosen these bolts 11 Disconnect the injector connector from the rear injector (Fig. H). 12 Plug the female PCIII connector with ORANGE/WHITE wire onto the rear injector (Fig. H). 13 Connect the male PCIII connector with ORANGE wire onto the stock injector connector (Fig. H). 14 Repeat steps 11 thru 13 for front injector using the PCIII connectors with the YELLOWcolored wires. 15 Locate the wires coming from the throttle position sensor. (Fig. H). The throttle position sensor is located on the right hand side of the throttle body. It is between the frame and engine

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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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2004 Honda CRF450R OWNER'S MANUAL

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Filed Under (Honda) by admin on 21-11-2010

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motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick- starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever 1. Shift the transmission into neutral. 2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting the engine excessively charged with fuel by throttle blipping or other reasons: 1. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine. 3. Pull the hot start lever and kick-start the engine (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. Stopping The Engine 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle 2 – 3 times, and then close it. 4. Depress and hold the engine stop button until the engine stops completely. NOTE: • Failure to close the fuel valve may cause the carburetor to overflow. (1) THROTTLE GRIP (2) ENGINE STOP BUTTON Break-In Procedure Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: • Piston is replaced • Rings are replaced • Cylinder is replaced • Crankshaft or crank bearing are replaced

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2007 – 2009 KAWASAKI Z 1000 RACING AND EVOLUTION EXHAUST SYSTEM

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Filed Under (Kawasaki) by admin on 05-11-2010

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The Akrapovic RACING OPEN & EVOLUTION OPEN line is the highest level of Akrapovic exhaust systems and with hexagonal shaped muffler fits perfectly with the aggressive character of the ‘Z’. The conical tubing with interference crossover tubes between the header tubes work exceptionally well. With the Akrapovic exhaust system you will get massive power boost, more torque, a sportier sound and an even more aggressive top- level look on this muscular roadster. You can choose between classy titanium or carbon- fiber mufflers that stand out through their excellent quality. The systems are available in open version only. Besides great power and torque, you will also save in overall weight, as the Akrapovic system weighs 10.21 kg (RACING) or 11.5 kg (EVOLUTION) less than the stock assembly. PERFORMANCE Measurements of the Akrapovic RACING OPEN & EVOLUTION OPEN system on the Ka- wasaki Z 1000: The power curve shows a huge increase over the stock performance figures. It is much more linear, which means the engine is pulling strong and consistently right from the lowest rpm to the highest part of the overrev range. We measured a maximum increased power of 10.0 HP at 10270 rpm. The same goes for torque, which is also increased through entire rpm range. The drop-outs in the stock curve are filled and like the power curve, there is a major increase from 4000 rpm on. CONFIGURATION The configuration of the Akrapovic RACING OPEN & EVOLUTION OPEN system for the Z 1000 is 4-2-1, made of conical stainless steel or titanium tubes. The system includes interference crossover tubes between the header tubes, giving the Kawasaki increased performance characteristics. The muffler is available with either a titanium or carbon-fiber outer sleeve, attached to the motorcycle with an Akrapovic carbon-fiber muffler clamp. The individual elements of the system – header tubes, collector, link pipe and muffler – are connected with sleeve joints, secured with silicon-shielded springs.

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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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