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TRIUMPH AMERICA AND SPEEDMASTER HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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

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1. Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Loosen the two 14mm riser mounting nuts located on the bottom side of the upper steering head. Loosen the four handlebar top clamp 6mm socket head screws. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four screws from the clamps and then remove the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the nuts from the bottom of the risers and remove the risers carefully without allowing the risers to rotate, as this will scratch the clear coating on the upper steering head. Using the bolts, lock washers and washers supplied install the new risers making the bolts finger tight only. (NOTE; again, take care not to allow the risers to rotate as this will scratch the clear coating on the upper steering head). 4. Place the handlebars back up onto the new risers. Install the new top clamps supplied using the four M8 X 30mm socket head screws supplied. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs.) (There should be no gap between the riser and clamp at the front side) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. YOU MUST! Check to see that the throttle returns freely on its own when the handlebars are at full left and full right turn THIS STEP IS VERY IMPORTANT FOR OBVIOUS SAFETY REASONS! If you have a windshield installed it may be necessary to reroute the throttle cables, wires or hoses around the other side of the windshields mounting hardware to obtain adequate free play and free throttle return. You may also wish to remove the plastic clips or cable tie which secure the wiring to the handlebars and secure them to the brake hose and clutch cable (not the throttle cables) for a cleaner appearance

HARLEY DAVIDSON FXD HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-12-2010

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Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Using a æ” socket loosen the two riser mounting bolts located on the bottom side of the upper steering head. Using a º” hex key wrench loosen the four handlebar top clamp bolts. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four bolts from the top clamp and then remove the clamp. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the bolt from the bottom of one of the risers and remove the riser while keeping the bolt in place. Place one of the supplied Ω” washers onto the protruding bolt, and then the new riser (Note; There are LEFT & RIGHT risers.) and mount the bolt finger tight. (Take care not to scratch the top surface of the upper steering head while installing the new risers.) 4. Place the handlebars back up onto the new risers. Install the top clamp using the supplied four black 5/16-18 X 1 º” bolts. Set the height of the handlebars to the desired position; tighten the clamp bolts evenly making sure the gap between the clamps & risers are the same. (15-18 ft. lbs.) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. Also check that the throttle returns freely on its own

YAMAHA ROAD STAR HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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

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1. Place a blanket folded several times over the fuel tank to prevent any damage during the installation of the risers. Loosen the two 19mm riser mounting nuts located on the bottom side of the upper steering head. Pry out the chrome plugs from the heads of the four handlebar top clamp bolts using a knife blade. Loosen the four handlebar top clamp 6mm socket head screws. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four screws from the clamps and then the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the nuts from the bottom of the risers and remove the risers. Insert the two supplied spacer tubes into the riser mounting holes on the upper steering head. Using the bolts, lock washers and washers supplied install the new risers making the bolts finger tight only. (Take care not to scratch the top surface of the upper steering head while installing the new risers.) 4. Place the handlebars back up onto the new risers. Reinstall the top clamps using the four socket head screws removed earlier. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs. There should be no gap between the riser and clamp at the front side.) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.) 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. Also check that the throttle returns freely on it’s own

Triumph Rocket III Touring HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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

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1. Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Using a small screwdriver pry out the plastic caps covering the handlebar clamp bolts. 2. Reroute the clutch cable behind the steering head as follows. Remove the clutch cable from the lever and perch. To do this first loosen the cable adjuster lock nut and then the adjuster as far as possible to give its maximum free play. Align their slots with the slot in the perch so that the cable may slide out. Standing in front of the handlebars grasp the clutch cable firmly trying to pull it out of the adjuster with one hand while pulling in the lever with the other hand. Now release the lever rapidly. Repeat several times if needed while keeping outward tension on the cable until the cable is out of the adjuster then slide it out thru the slots and remove the cable end from the lever. Reroute the clutch cable behind the steering head this will allow the additional slack needed when moving the handlebars back with the new risers (see photo). Replace the cable into the perch in the same manner. 3. It will help having a second person to hold the handlebars while you change the risers. Remove the four Allen bolts from the clamps and then remove the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 4. Remove the Allen bolts from the center of the risers while holding the 14mm nut on the bottom side of the steering head with a wrench. Remove the risers leaving the large washer on the top side of the steering head in place. Using the bolts and lock washers supplied and the original heavy or thick washer install the new risers making the bolts finger tight only. 5. Place the handlebars back up onto the new risers. Install the new top clamps supplied using the four Allen bolts remover earlier. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs.) (There should be no gap between the riser and clamp at the front side) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). Replace the plastic bolt caps.

HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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HARLEY DAVIDSON PULLBACK RISER KIT FOR 1.25-INCH HANDLEBARS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVAL NOTES Cover the fuel tank with clean shop towels to prevent scratching. If replacing the handlebar, refer to the service manual to remove controls, hand levers, handlebar and risers. If only the risers are being replaced, proceed as follows: 1. Remove the two hex head cap screws and split lock- washers on the underside of the upper fork bracket that hold the currently installed risers in place. Discard the screws, but retain the lockwashers for assembly. Retain all additional components from the riser assembly when the screws are removed. 2. Remove and discard the four screws that fasten the currently installed handlebar upper clamp(s) to the risers. Remove and discard the clamp(s). Remove the handlebar from the risers and carefully set the handlebar on the fuel tank. INSTALLATION NOTES See Figure 3. The upper cup washer (A) must be oriented with the flat side up and the lower cup washer (D) with the flat side down. 1. See Figure 3. Align the components as shown, and install the risers (2) to the upper fork bracket. The ground wire (G) and the lock washer (F) are located on the right side only. Do not tighten the riser mounting screws (4) at this time. 2. If an appropriate Harley-Davidson 1-1/4 inch handlebar has not been installed, install one according to the Instruction Sheet included with the kit, or install the handlebar assembly onto the risers. 3. Loosely install riser caps (1) onto the handlebars and risers with the Bar & Shield toward the front of the motorcycle (Figure 1, Item 1). Install four socket head screws (3) with four washers (6). 1 is05253 1. Bar & Shield (install toward front of motorcycle) Figure 1. Bar & Shield on Riser and Cap 4. Check that the risers stay properly aligned with the handlebar and tighten the riser mounting screws following the instructions in the service manual. 5. Adjust handlebar to the desired position, verify that it is centered on the risers, then tighten the front socket head screws (3) to 12-15 ft-lb (16-20 Nm) . There should be no gap at the front of the risers.

HONDA VTX1300, VTX1800 R, C & S MODEL HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 27-12-2010

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1 .Lay a blanket folded several times over the fuel tank to protect it. 2. Notice on the 1800 models that there is a small punch mark on the handlebars located on the right hand, front side of the handlebars where the risers meet the top clamp/speedometer housing. This is to reference the handlebar position when re-assembling. On the 1300 models there is a punch mark on the forward facing side of the clamp, these must be installed the same way. 3. Loosen the two 19mm nuts holding the risers to the upper triple clamp (steering head). 4. Pry out the four chrome caps covering the handlebar bolts. Remove the four handlebar clamp bolts. (6mm allen wrench). While sitting on the motorcycle, pull the handlebars and upper clamp off of the risers. They may be slightly stuck and require some force to get free. Lay the handlebar and/or upper clamp/gauge assembly carefully on the blanket. 5. Remove the 19mm nuts and the risers from the triple clamp. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Place the thin flat washers provided into the recess at the top of the riser bolt holes on the triple clamp. Assemble the lock washers provided and then the original flat washers onto the bolts provided. Install the new risers onto the triple clamp and snug the bolts. 6. Re-install the handlebars and upper clamp/gauge assembly. ( Remember the punch marks) Tighten the front bolts first closing the gap at the front, and then tighten the rear bolts. Tighten the two 19mm riser-mounting bolts securely. Check for adequate clearance and proper routing of cables and hoses.

KAWASAKI VULCAN 1500, 1600, 2000 HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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

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1. Lay a blanket folded several times over the fuel tank to protect it. 2. Loosen (do not remove) from underneath, the two hex nuts holding the risers to the upper triple clamp. (Steering head) 3. Remove the four handlebar clamp bolts. (8mm allen wrench) While sitting on the motorcycle, pull the handlebars and upper clamp off of the risers. They may be slightly stuck and require some force to get free. Lay the handlebar and/or upper clamp/gauge assembly carefully on the blanket. 4. Remove the nuts and risers from the triple clamp. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Assemble the supplied lock washers and flat washers onto the supplied bolts. Install the new risers onto the triple clamp and finger-tighten the bolts. 5. Re-install the handlebars and upper clamp/gauge assembly. Tighten the front bolts first closing the gap at the front, and then tighten the rear bolts. Tighten the two riser-mounting bolts securely. Check for adequate clearance and proper routing of cables and hoses.

HONDA VTX1300 "C" MODEL HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Lay a blanket folded several times over the fuel tank to protect it. 2. Remove from underneath, the two hex nuts holding the handlebars to the upper triple clamp. (Steering head) Remove handlebars & carefully set on blanket. 3. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Assemble the supplied lock washers and flat washers onto the supplied bolts. Install the new risers onto the triple clamp and finger-tighten the bolts. 4. Re-install the handlebars onto the risers & finger tighten the nuts. Align handlebars & risers to be parallel & centered. Tighten the two riser-mounting bolts securely. Tighten the handlebar mounting nuts securely. Check for adequate clearance and proper routing of cables and hoses

2004+ Victory motorcycles PGR-1000 SERIES Programmable Gear Readout Installation

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Filed Under (Victory) by admin on 31-10-2010

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1. Turn the key on and make sure the transmission is in neutral and ‘n’ is displayed on the readout. (Please leave the key ‘ON’ for about 5 seconds before continuing) 2. Turn the key off (.1 seconds) and then back on (1 second) again rapidly. The display should show 1 bar. If you wait too long before continuing the readout will exit the setup routine. (If the unit has already been cleared, it will immediately jump to step 6.) 3. Repeat step #2. The display should show 2 bars. 4. Repeat step #2. The display should show 3 bars. 5. Repeat step #2. The display should show 2 bars. 6. Repeat step #2. The display should show ‘n’ with a bar over it. If the display is upside down then kick the transmission out of neutral and the display will invert and show ‘C’. Tach adapter(for open-collector tach signal from ECM w/out pull-up resistor) ( 2004+ Victory motorcycles use this option , most other bikes use application on front page) VSS Notes: The PGR-1000 is designed for motorcycles with an Electronic VSS signal. Most modern motorcycles use a 3-wire hall-effect type speed sensor in the transmission with a power, ground, and a signal wire. The SEN-1019 is available for motorcycles without a factory VSS signal, fabrication will be required for sensor mounting