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KYMCO MXU 375 ATV WINCH MOUNT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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WINCH MOUNT INSTALLATION INSTRUCTIONS 1. Remove molded plastic bumper guard from the ATV. 2. Mount the winch mount weldment (Item 1) to the ATV as shown below. 3. Mount the roller hawse to the winch mount weldment as shown above. 4
4. Mount the winch to the winch mount weldment and route the winch cable through the rollers. (Installer may need to remove rollers to allow cable end to pass through). 5. Wire the winch according to the manufacturer instructions. 6. Re-install the molded plastic bumper guard. 5 *CAUTION BE AWARE OF WHEN THE CABLE STOP CONTACTS THE ROLLER HAWSE AS CABLE IS WOUND IN. FAILURE TO RELEASE MAY CAUSE DAMAGE TO WINCH PARTS OR TO THE ATV. When using the winch to raise and lower a blade a cable stop must be installed. Carefully raise the blade until the top of the push tube’s are no closer than 1″ anywhere on the ATV. Place the Cable Stop onto the Winch Cable up against the Winch Hawse. Secure the Cable Stop to the Winch Cable using the Cable Clamp Assembly as shown in the pictures below.

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HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

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2002 Kawasaki 360 ATV WINCH ACCESSORY INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 08-05-2012

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1. Remove the two 8mm bolts that attach the front bumper assembly to the ATV frame see figure 3. 2. Place Winch mounting plate (A1) into position and fasten the two bent down tabs to the ATV frame using the two 8mm bolts removed in step one, see figure 4, and figure 5. Do not tighten fully at this time. 3. Attach the front of the mounting plate using four 1/4-20 u- bolts (B1), eight lock washers (B2), and eight 1/4-20 hex nuts (B3), see figure 6. 4. Tighten all fastners for the mounting kit at this time. 5. Place winch into position behind the mounting plate. Attach the top two feet of the winch using two 5/16-18 hex cap screws and lock washer. These fasteners will be found in the hardware kit that came with the winch. Note: The winch has floating nuts in its feet. In some instances, a nut may be moved off to one side making it impossible to screw a bolt in. If this becomes the case, take a screwdriver and center the floating nut in the winch to the bolt hole opening. Now attach the bolt through the Winch Plate and into the winch. 6. If using a Cast Hawse Fairlead: It may be neccasary to remove the cast hawse fairlead from the fairlead mounting plate that came with the winch.

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KAWASAKI 400 PRAIRIE ATV WINCH MOUNT INSTALLATION ISTRUCTIONS

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

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1. Place the mounting plate into position on the front bumper tube assembly and attach with the four ¼- 20 u-bolts, hex nuts, and lock washers. See the illustration below for detail. 2. Place winch onto the mounting plate and attach with the four 5/16-18 hex bolts and lock washers that came with the winch. See the illustration below for detail. NOTE: There are two sets of mounting holes to accommodate the 3.0ci winch, A2000 and A2500 winches. 3. Tighten all fastners securly at this time. Place the vinyl caps on the ends of the ¼-20 u-bolts, to cover up the sharp edges of the u-bolts that are exposed. 4. Make all electrical connections. Use the winch manuel that came with the winch for instructions to make all electrical connections

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Kawasaki Winch Mount Installation Manual

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

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1. You will need to remove the lower Front Moulding of the ATV for installation of the Winch Kit. 2. Position the Winch with the motor on the LEFT side in the mounting location and slide the Winch Mount Plate in under the winch. Attach the Winch Mount Plate to the frame with the U-bolts and Nylock Nuts provided. Tighten at this time. See Picture Winch Mount Plate 3. Install the Roller Hawse Bracket to the Lower Winch Plate and to the front bars (behind the bars) of the ATV using the U-bolts, Carriage Bolts and Nylock Nuts. See Picture Below. Winch Mount Plate Roller Hawse Bracket 4 4. After winch installation is complete, reinstall lower Front Moulding of ATV. Remove one of the long rollers and the two side rollers and feed the winch cable through the roller hawse. Reinstall the rollers and be sure rollers move freely. Attach the Roller Hawse to the Roller Hawse Mount Plate using the 3/8″ x 1″ Bolts and Nylock Nuts provided with the winch. Tighten all hardware

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Kawasaki KVF 360 Winch Mount Installation Manual

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

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1. Remove the bottom and middle bumper mounting bolts. 2. Pull the front bumper outwards while sliding the winch mount behind the bumper with the roller fairlead mount tabs facing downward and towards the front. Slide the roller fairlead mount tabs through the upper opening of the bumper. 3. Bring the back of the winch mount up to the bottom of the middle bumper mounting tubes and install the (2) 5/16″ x 1-1/8″ x 1-3/4″ u-bolts over the tubes and through the winch mount. Install (4) 5/16″ flat washers and Nylock nuts. 4. Install the (2) 5/16″ x 1-1/4″ x 2″ u-bolts over the middle bumper cross tube then through the winch mount. Install (4) 5/16″ flat washers and Nylock nuts and tighten all nuts. 5. Install the winch to the bottom of the mount using the hardware provided with the winch. Be sure the winch winds in the correct direction. 6. Install the roller fairlead using (2) 5/16″ x 3/4″ hex bolts and 5/16″ Nylock nuts provided (rollers should turn freely). Note: Bottom roller may need to be removed to run wire rope through. 7. Push the bumper back into place and reinstall the original bolts. 8. Using the instructions provided with the winch, wire accordingly

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HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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HONDA WINCH MOUNT KIT REMOVAL AND Installation

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

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Remove the front Plastic Bumper Guard. Remove the U-Bolts from the Winch Mount Plate and place the Winch Mount Plate on top of the horizontal bumper support tubes as shown in picture below. The U-Bolts will be placed around the tubes and up through the plate and are secured with Nylock Nuts. Tighten Fully. (Pictured Below). Mount the Winch to the underside of the Winch Mount Plate using the mount holes in the plate and the provided bolts. Tighten hardware at this time. 3. Using the two 5/16” x 1” bolts supplied with kit, mount the Winch to the Winch Mount Plate. Be sure that when the Winch is mounted to the ATV, the Winch Motor is on the RIGHT side of the machine. 4. Place the front Plastic Bumper Guard back onto the ATV, place the Roller Hawse Mount Bracket against the front Plastic Bumper Guard using the 7/8” Steel Bushings as spacers. Attach using the 6 x 30mm Bolts and Flat Washers. See picture on next page 5. String the Cable through the hole in the Hawse Mount Bracket. Remove one of the long rollers and the two side rollers of the Roller Hawse and feed the winch cable through the Roller Hawse. Reinstall the rollers and be sure rollers move freely.

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1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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Type 11 Honda Motorcycle Audio system installation

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Filed Under (Honda) by admin on 02-11-2011

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This section gives general information needed for mounting the individual radio components on and in the fairing.
A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts.3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing.
7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wire

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