installing baffels in screaming eagle pipes

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Express ATVS -250cc Cobra Setup/ Installation Manual

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

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Unpacking your Cobra Installing the front shock Installing the front tires Installing rear shocks Installing the rear tires Installing seats and harnesses Steering wheel installation Roll cage installation Safety checks / Adjustments General maintenance Unpacking your Cobra First off you should pull the carton off from your new 250 Cobra cart. Inspect the cart thoroughly to make sure that your new Cobra has not been heavily damaged. You will notice that the product has a metal frame holding it in place; you may want to start removing bolts from the shipping steel frame. The next step is to remove the metal frame and lift it off of the cart. Remove any of the metal frame that may afford resistance when working on the cart it self. Be careful the metal frame may be heavy and sharp. Now would also be a good time to inspect your Cobra a little more thoroughly. In the box with the Cobra you should have found a box containing miscellaneous hardware. Installing the front shock Using some of the bolts you found in your box, install the front shocks sliding the bolt through the brackets and tighten the nut down. Next, you will need to place the ball head into the turning arm, then tighten the castle nut and insert a cotter pin so that the castle nut doesn’t loosen and become a hazard. Installing the front tires
Find the front tires and place them on the front hub and place the lug nuts on the studs. Tighten them down. Make sure that all of the lug nuts are on tightly. Installing the rear shocks Moving to the rear of the Cobra you will notice the rear shocks are not inserted. Place the rear shocks into the bracket on the rear of the Cobra. Slide one of the provided bolts through the bracket and shock eyelet and tighten the bolt down. Installing the rear tires Now that the shocks have been placed properly you can install the rear tires, place the tires onto the axle then place the rear rim lined up onto the axle and tighten the provided castle nut down. Place the cotter pin through the axle and bend off to the side. This is so the castle nut does not loosen under load. Installing the seats and harnesses
(The arrow points to an example of where the seat bolts mount) Find the two racing seats shipped in the box with the Cobra. You will need to affix them to the frame by sliding the bolts up through the bottom of the frame. This can be tricky so have patience. Once both seats have been placed in the cart and tightened find the harnesses. Once found the harnesses mount to a bracket behind the seats. Place a bolt through the bracket and bolt the harnesses down tightly. Installing the steering wheel Find the steering wheel and place it onto the steering wheel mount. Grab the six small screws and place them through the steering wheel and mount, tighten them down but also make sure the top of the wheel is facing up. Installing the roll cage

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HONDA GL1800 LED LIGHTED FRONT FENDER EAGLE INSTALLATION MANUAL

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Filed Under (Honda) by admin on 03-03-2011

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GL1800 LED LIGHTED FRONT FENDER EAGLE Note: Read instruction thoroughly before installing. Drilling required. 1. Place bike on center stand. 2. Remove front fender. 3. Measure from the tip of the front fender towards the bike 3 inches and mark. 4. Center eagle on fender and mark fender for drill location under the eagle head. 5. Drill a 1/8″ hole. 6. Clean area. 7. Put the light wires through the hole and secure the wires to inside of fender so wires will not touch any moving parts. 8. Remove the tape covering from the light and press on firmly. 9. Replace fender. Attach the black wire to ground and red wire to a running light

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HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

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2006 Harley Davidson VROD / Screamin' Eagle VROD Installation Manual

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Filed Under (Harley Davidson) by admin on 01-03-2012

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Check top clamp holding on rear heat shield be sure this is mounted forward not in middle of pipe. 2. Slide rear head pipe into collector and leave loose. 3. Mount head pipes into exhaust ports using stock Harley gaskets hand thread nuts onto head studs, leaving play in pipes. 4. Slip muffler onto collector and leave loose. 5. Slide D&D bracket included with kit onto chassis and muffler together. 6. Hand thread nuts onto chassis studs 7. Align muffler flush with bracket, hand thread bolts onto muffler.
8. Push system together tightly, Tighten rear head pipe collector clamp. 9. Holding muffler into place (finger width between shock bolt) tighten down muffler clamp all the way. 10. Snug (do not torque) chassis bracket bolts, snug muffler bolts until all is correctly aligned, then tighten down bolts. 11. Tighten head bolts down using factory torque specs, as you tighten the pipe check muffler clearance. If to close to swing arm push in on head pipe. If to far away push in on head pipe. 12. Once all is tight start bike and check for leaks This system is designed to be used with a high flow air filter and D&D VRDSEDD2.MT4 Race Tuner map.

HARLEY DAVIDSON EFI SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

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Kawasaki ZRX-1100 / 1200 exhaust system Installation Instructions

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

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1. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 2. Inspect the exhaust gaskets. Replace if necessary. 3. Attach the head pipes 1, 2, 3 , and 4 to the exhaust ports of their respective cylinders, using the flange nuts saved from step 1 above. Loosely apply the flange nuts for now, allowing for ome adjustment. 4. Attach the Y-pipe collectors to the head pipes. Please note that one collector goes to pipes #1 and #4 and one collector goes to pipes #2 and #3 (collectors are labeled). Make sure the ends of the head pipes fit flush and snug in the ports. Do not install the springs at this time. 5. Install the S-Bend to the rear of the two Y-pipe collectors. Do not install the springs at this time. 6. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes are centered in each port. 7. Slide the TiForce end can into place on the S-bend pipe. 8. Loosely attach the two rubber bands, stainless steel bands K, and the stay / hanger G, to the end can using the supplied 6mm hardware H. (See figure 1) . Make sure that the rubber bands fully cover the stainless bands to prevent scratches to the can. 9. Place the bands approximately 108mm from the edge of the end can. (See figure 2) . 10. Go back and tighten the exhaust flange nuts per factory specification. Do not over tighten. 11. Using the stock provided mounting point on the right passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 12. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 13. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 / figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 15. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 16. Check that all hardware is properly tightened, and then start the motor and check for exhaust leaks

Kawasaki 2000- ZX-12R Ninja exhaust system Installation Instructions

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

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1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1, 2, 3, and 4 by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. Place a billet aluminum Mouthpiece ring Z on each TiForce head pipe. (see figure 3 for details) . 6. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the head pipes fit flush and snug in the ports and Mouthpiece ring Z before tightening. 7. Install the S-Bend to the front section of the head pipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes and Mouthpiece ring Z are centered in each port. 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. (See figure 1) . 11. Place the bands approximately 118 mm from the edge of the end can. (See figure 2) . 12. Using the stock provided mounting point on the passenger foot peg, and using the stock-mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance

victory 650 And 750 twIns specification

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Filed Under (Victory) by admin on 13-11-2010

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Super Sport. The example tested by Cycle World magazine in August 1968 looked identical to the European specification 750 except for higher handlebars, a 35/35 watt headlight, larger round CEV taillight, 120mph Smiths speedometer, and an American Eagle tank badge. The headlamp shell was also different, with an additional warning lamp, and the American Eagle headlight shell featured the large hole and rubber plug (with Laverda logo) as on some early 650s. When tested by Cycle magazine in January 1969 (now called the American Eagle ‘Classic’) there was a different colour scheme, with pinstriping on the fuel tank and sidecovers (although this colour scheme also appeared in some Italian advertising and official photos). Optional for the American Eagle was a large chrome-plated engine protection bar with chrome Vitaloni rear vision mirrors attached on each side. In McCormack’s advertising the bore and stroke of the American Eagle were listed as 79.5 x 76.2mm, and this was obviously incorrect as the engine specifications were the same as the European versions. The claimed power by McCormack for the American Eagle was also Below: This Super Sport, number 1646, is based on a 750 GT, but others were converted 750 Ss. ** t he l AverdA t wIns & t rIples B IBle top triple clamp from the top. A round reflector was situated on the headlamp mounts. As there was no room for all the wiring inside this smaller shell, the electrical connectors were moved underneath the fuel tank, and there were thick grey wires leading to the Lucas switches. When turn signals were fitted these were also Lucas, the handlebar switch being on the right. The throttle was now a chrome-plated, dual-cable Tommaselli Daytona 2C, without a throttle stop, with the handlebar also Tommaselli. The dual seat on a fibreglass base, or solo seat with locking compartment, continued as before. The 750 SF1 continued to be sold in the UK, where the price was £998, but at that time a 750cc Triumph Bonneville T140V sold for £625 so the Laverda was never going to be a volume seller. In Italy, the SF1 was still one of the most popular large capacity machines available, selling for L1,227,200 when the Triumph T140V sold for L1,357,000

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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HARLEY DAVIDSON SCREAMIN' EAGLE PERFECT FIT PUSHRODS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the service manual and follow the instructions given for disassembling the motorcycle for service and to gain access to the top end overhaul disassembly of seat, rocker cover, breather assembly, rocker arm support plate and pushrods. 2. Place the motorcycle on a center stand with the rear wheel raised off the ground. Remove the spark plugs. 3. With the transmission in gear, use the rear wheel to turn the engine over until both front cylinder tappets are at their lowest point. Remove and discard the pushrods. 4. Install the new pushrods into the pushrod covers using the appropriate service manual procedures. Be sure the larger end of the tapered pushrods are installed to the tappet sockets. 5. Repeat step 4 for the rear cylinder. NOTE Check for contact between the pushrods and the upper pushrod covers. Check by rotating the engine slowly until both valves have fully opened and closed on the cylinder you are checking. If contact is observed, the rocker arm supports should be shifted toward the engine’s cam side. 6. Complete all the appropriate service manual procedures for assembling the engine. 7. Complete all service manual procedures for the assembly of the motorcycle. 8. Return the transmission to neutral and install the spark plugs. 9. Connect the negative (-) battery cable. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 10. Install the seat

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