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HSR Carburetor Total Kits Installation Instructions

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

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 12-11-2010

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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HARLEY DAVIDSON BIG TWIN SPIGET MOUNT CARBURETOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 26-03-2012

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A. BEFORE INSTALLATION OF YOUR NEW ZENITH CARBURETOR, NSPECT THE RUBBER MANIFOLD SEAL FOR NICKS,CRACKS, OR DEBRIS. APPLYING A LIGHT FILM OF PETROLEUM BASED LUBRICANT AROUND THE INSIDE LIP OF THE RUBBER SEAL WILL ALLOW THE CARBURETOR TO SLIP INTO PLACE EASIER. B. BEFORE ACTUAL INSTALLATION OF UNIT INTO MANIFOLD, THROTTLE CABLES SHOULD BE HOOKED TO THETHROTTLEWHEEL.MAKESURETHATTHE PULL CABLE IS LOCATEDPROPERLY TO OPEN THE THROTTLE PLATE (IN SOME APPLICATIONS THROTTLE CABLE SLACK MAY NEED TO BE ADJUSTED FOR PROPER HOOKUP AND OPERATION) SEE FIG. #1 C. AFTER THROTTLE CABLES ARE PROPERLY HOOKED UP,UNITCAN BE INSERTED INTO MANIFOLD. MAKE SURE THAT UNIT IS FULLY SEATED. WITH CARBURETOR SEATED INTO MANIFOLD AND FUEL LINE HOOKED UP TO FUEL INLET, INSTALL CHOKE CABLE AND HOOK TO CHOKE LEVER. PLACE AIR INTAKE GASKET ON END OF CARBURETOR, NEXT PLACE INTAKE ADAPTOR OVER INTAKE GASKET. SEE FIG#2 ZENITH MOD.16P12 SPIGET MOUNT CARBURETOR -HARLEY DAVIDSON ™ BIG TWIN INSTALLATION INSTRUCTIONS FIG. # 1 FIG. # 2 D. WITH ADAPTOR IN PLACE, LOCATE THE STOCK AIR BOX OVER THE ADAPTOR, UTILIZING THE STOCK AIR BOX GASKET (THERESHOULDBENO GAPS BETWEEN ADAPTOR, AIRBOX OR CARBURETOR WHEN PROPERLY INSTALLED) STAND-OFF SPACERS PROVIDED ARE TOBEPLACEDBETWEENAIR BOX& ENGINE HEADS BEFORE INSTALLING THE VENT/RETAINING BOLTS. FOR EVALUATION ENGINES STOCK VENT BOLTS CAN BE USED WITH LARGERI.D. SPACER PROVIDED. SEE FIG#3 E. WITH AIR BOXSECURELY IN PLACE, INSTALL THE AIR FILTER COVER RETAINING BRACKET AND FILTER USING THE STOCKBOLTS, AND REPLACE AIR FILTER COVER AND SECURE WITH STOCK BOLT. SEE FIG#4 F. AFTER INSTALLATION IS COMPLETE AND FUEL FLOW HAS BEEN RE-ESTABLISHED, CHECK FOR ANY LEAKS BEFORE STARTING ENGINE. H. AFTER STARTING ENGINE, SOME ADJUSTMENTS OF IDLE AND MAIN JET MAYBE REQUIRED FOR PROPER OPERATION. AFTER ADJUSTMENTS HAVE BEEN MADE AND WITH ENGINEAT IDLE, TURN WHEEL FULLYTOLEFTANDRIGHT.ANYCHANGEIN IDLE SPEED INDICATES THROTTLE CABLES ARE TOO TIGHT AND MORE SLACK MUST BE PROVIDED.

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Tuning the HSR42/ 45 Carburetor

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Filed Under (Tips and Review) by admin on 31-10-2010

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your Mikuni HSR is fitted with the tuning parts we found to work with the great majority of engine performance modifications. However, the large number of differing exhaust systems and cams available makes it impossible to accommodate all possible combinations with one carburetor set-up. Your HSR will almost certainly run correctly on your engine without exchanging any parts. But, if it doesn’t, you may alter its tuning to suit your engine’s needs by following this guide. Some exhaust system designs strongly interfere with carburetor tuning. For instance, it is very difficult to get smooth and responsive carburetion through the entire rpm range with straight pipes and completely open exhausts. In addition, very small volume, small diameter mufflers are often ‘seen’ by the engine as straight pipes and present the same tuning difficulties. Very long duration cams often cause relatively poor running below about 3,000 rpm, depending upon the individual cam’s intake valve closing point. Such cams cause reverse airflow out the mouth of the carburetor (often called “reversion” or “standoff”) that can be mistaken for a carburetor tuning problem. Harley-Davidson Screamin’ Eagle performance parts are proven and predictable. If you have any doubts about a particular exhaust system, air cleaner or ignition, you may substitute the Harley Screamin’ Eagle parts as a “reality check.” When re-tuning is required, it usually involves small alterations to the idle and/or main system. The following pages supply enough information to make such alterations relatively simple. Please note that there is no point in attempting to tune any carburetor unless the engine is sound and in a good state of tune. If you have any doubts about the general condition of your engine, have it checked by your dealer or an experienced mechanic before attempting to fine-tune your Mikuni.

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HOVELHEAD & IRONHEADXL 42mm Mikuni Carburetor And Manifold Kit INSTALLATION Instructions

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Filed Under (Tips and Review) by admin on 31-10-2010

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THROTTLE CABLE ADJUSTMENT A) Rotate the throttle grip to the full open position, look into the throttle bore and see if the throttle valve (slide) opens completely. If the throttle valve does not open completely unscrew the adjuster on the opening cable until it does. This adjustment should be made carefully to assure maximum carburetor performance. After adjustment tighten the adjuster jam nut. B) After adjusting the open cable, adjust throttle freeplay with the closing (idle) cable to approximately 1/8″ an indicated in the following illustration. note It is very important to adjust the cables in the preceding described manner to ensure that the idle cable operates correctly for safety. It must close the throttle completely 2 PLEASE NOTE USE CAUTION PLEASE NOTE SAFETY WARNING pull open cable pull close cable SHOVELHEAD/IRONHEAD XL Installation Instructions Check and make sure that the throttle cables are routed properly by rechecking the throttle play as the handlebars are turned from side-to-side; the amount play should remain consistent. C) After the throttle cables have been adjusted, make sure that all the lock nuts are securely tightened. 5. AIR CLEANER A) The air filter bracket is attached to the crankcase with 1 long bolt, and a bracket-spacer. Removed the crankcase nut located between the tappet blocks & replace it with the enclosed bracket spacer; tighten the spacer securely. B) Remove the stud protectors from the K&N filter and place the two backing plates on the studs. Now slip the the filter onto the carburetor. C) Attach the 2 long brackets to the air filter studs with the enclosed nuts & flat washers, and to the bracket spacer with the enclosed bolt using the lock washers, and flat washers. When the carburetor and air cleaner are properly aligned, securely tighten all of the mounting hardware including the intake manifold clamps. In some cases it may be necessary to bend the brackets slightly to arrive at the correct fit. D) Use the enclosed hose clamps to secure the fuel hose to the petcock, and the HSR carburetor. The screw clamp goes on the petcock end and the spring clamp attaches to the carburetor end. E) Attach the chrome air filter cover with the enclosed socket head screw. 7. CHOKE CABLE INSTALLATION A) Attach the Mikuni choke cable bracket to the original choke cable bracket on the air cleaner stud with the enclose hardware as illustrated

YAMAHA RAPTOR 350 Removing stock carburetor and cables

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Filed Under (Yamaha) by admin on 18-01-2012

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remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Stuff a clean, dry rag into manifold to keep debris out of motor. 4. Remove stock air box. 5. Remove choke cable from handlebars. 6. Remove carb vent line from bike. Carburetor installation 1. Carefully trim the rubber alignment tab off of the face of the manifold with a razor blade or side cutters. 2. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 3. Attach fuel line to carburetor and secure with clamp. 4. Install remote idle cable into tab on top of carburetor. See main manual for this step. NOTE: Nut must be removed from cable before installation 5. Place carburetor into manifold

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HSR Carburetor Total Kits Installation And Tuning Manual

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Filed Under (Tips and Review) by admin on 31-10-2010

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1. Disconnect the battery ground wire from the battery. 2. Turn the fuel petcock to the “OFF” position. 3. Elevate the rear of the fuel tank for better access to the carburetor area. 4. Remove the coil, horn or other devices on the left hand side of the engine to allow free access to the intake manifold bolts. 5. Remove the complete air cleaner assembly, including the backing plate. 6. Disconnect any vacuum hoses and the fuel hose from the stock carburetor. 7. Disconnect the choke cable from the frame. 8. Remove the stock carburetor. 9. Evo: remove the stock manifold. 10. Twin Cam: unplug MAP sensor, remove manifold and then remove the MAP sensor from the manifold. Installation: Intake Manifold: Twin Cam only: Install MAP sensor in Mikuni manifold. 1. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 2. Attach the rubber flange to the Mikuni manifold with the 5/16″x3/4″ bolts and washers. To ease installation, use liqiud detergent to lubricate the manifold seals. Choke: Evo: We recommend that you use the Mikuni choke cable that is furnished with the carburetor. However, you can use the stock Harley cable (’90-’99 models only) if you follow the Twin Cam choke cable instructions. Twin Cam: 1. Remove the Harley choke cable from the stock carb. 2. Remove the Harley spring and plunger from the Harley choke cable. 3. Remove the Mikuni spring and plunger from the Mikuni carburetor. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut. 6. Install the new assembly into the Mikuni. Be careful to only gently tighten the plastic nut.

S&S Super E and G Series "Shorty" Carburetors REMOVAL, Installation and Jetting Instructions

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Filed Under (S&S) by admin on 29-10-2010

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Remove Old Carburetor WARNINGS ● Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a health and fire hazard. ● If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation. ● Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in inadvertent engagement of starter and personal injury. A. Shut off fuel petcock and disconnect battery. B. Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting hardware NOTE – Removing and tightening hard to reach Allen bolts such as carb-manifold mounting bolts and V2 manifold flange bolts can be greatly simplified by the use of Allen ball-end drivers. These tools are available at most automotive and tool supply houses. See Picture 9. Additionally, Performance Plus of Evansville, Indiana, produces a hex wrench specially modified for accessibility of V 2 manifold bolts. Call 812-963-8854 for further information. As alternative, standard hex wrench can be shortened for convenience. NOTE – Some Buell motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be taken off engine. Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with pliers and snap off, then remove fitting. CAUTION – Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S recommends packing breather fitting with gease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for containment of chips and other debris. Picture 2 Picture 4 Picture 3
5 2. Prepare Air Cleaner Backplate NOTE – Fast idle lever screws, part #11-2384, must not be overtightened. Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose. CAUTION – Overtightening fast idle screws may damage backplate. A. All engines except V2s 1. Knuckles & Pans, 1936 to 1965 – Press plugs, part #50-8312, into holes in air cleaner backplate. See Picture 2 . 2. Shovels, 1966 to 1979, and Ironhead (IH) XLs, 1957 to 1979 – Press plug, part #50-8312, into hole in air cleaner backplate. See Picture 3 . 3. Shovels 1980 to 1984 and IH XLs 1980 to 1985 – Screw crankcase breather vent elbow fitting, part #50-8110, into hole in air cleaner backplate and angle downward as shown in Picture 4 . On 1983 and 1984 Shovels press plug, part #50-8312, into other hole on left. 4. Assemble fast idle mechanism as shown in Figure A . B. FL V2s 1984 to 1992 1. Press plug, part #50-8312, into hole on left in air cleaner backplate as shown in Picture 5 . 2. Screw vent hose elbow fitting, part #50-8110, into remaining hole at right. See Picture 5 . 3. Assemble fast idle mechanism as shown in Figure A . C. XL V2s 1986 to 1990 1. Press plug, part #50-8312, into hole on right in air cleaner backplate as shown in Picture 6 . 2. Screw vent hose nipple fitting, part #50-8111, into remaining hole at left. See Picture 6 . Elbow fitting, part #50-8110, supplied in kit may also be used in this location if required. 3. Assemble fast idle mechanism as shown in Figure A . D. FL V2s 1993 and up and XL V2s 1991 and up 1. Press plugs, part #50-8312, into both holes in air cleaner backplate as shown in Picture 7 . 2. Assemble fast idle mechanism as shown in Figure A . E. Buell motorcycles, 1994 and up 1. Assemble fast idle mechanism as shown in Figure A. 3. Throttle Preparation NOTE – Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when released. Cable routing must be free of tight bends to minimize friction between cable and housing

kawasakI 9400 hyPercharger kIt INSTALLATION MANUAL

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

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steP 1 Remove the seat. steP 2 Remove the bottom of the three dash plaque bolts (8mm). steP 3 Lift up on the dash panel and unscrew the speedometer cable (knurled nut). steP 4 Unplug the three electrical connections. steP 5 With a 12mm socket, remove the tank-mounting bolt under the dash and at the rear of the tank. steP 6 Close the fuel valve and clamp off the fuel line. Disconnect the line from the fuel valve. steP 7 Raise the rear of the tank, and disconnect the two vent hoses, and remove the tank. steP 8 Refer to the section of your factory service manual that deals with removal and installation of the following components. • Remove the two round chrome “air cleaner covers”, their backing plates, the stock black plastic air box (air inlet under tank), and the crossover tube. • Remove the intake manifold to remove and crossover tube. Use extreme care when replacing the intake manifold. Uneven torque, damage to the intake gaskets, or contamination can cause an intake leak that will result in very poor running, and nearly impossible jetting!! • Unplug all hoses or lines from these components. You may want to label these hoses at this time. The Largest of these hoses (3/4″ I.D.) is for the fresh air injection system; the second largest (3/8″ I.D.) is the crankcase breather. The smallest of the hoses is a drain. steP 9 Remove the brackets that held each round backing plate. The right hand bracket is also a carb stabilizer. This function is duplicated with one of the included brackets. steP 10 Remove the carburetor according to the section in your factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. We recommend that you label each hose or fitting as they are removed to make reassembly easier. An example of hose labeling is shown in PIC. 1. carburetor re-jettIng Procedure note Different combinations of aftermarket exhaust and air cleaners will have a significant impact on carburetor jetting. The supplied jetting components have been tested and found to be a good combination to produce drivability and performance with stock or free flowing, muffled/baffled exhaust pipes. We highly recommend NOT using drag pipes (open style). Using drag pipes in conjunction with our air cleaner will require additional jetting above and beyond the components included in this kit. a) Consult your factory service manual for details of this procedure. We have supplied jets to cover many common configurations. Remove the four Phillips head screws securing the plastic carb top to the carb body. Carefully remove the plastic carb top making sure not to damage the rubber diaphragm.

2001-2003 XV16 Fuel Pump and Carburetor Removal

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Filed Under (Yamaha) by admin on 31-12-2011

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Disconnect the carburetor fuel line hose at the fuel pump. •Disconnect the fuel pump wire coupler. •Remove the choke cable from fuel pump bracket. •Remove the upper engine mount, leaving the fuel pump attached to the mount. •Disconnect the TPS and carburetor wire couplers.       Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws. PAGE 3 of 12 HIDDEN 6mm SCREW 6mm BOLT UPPER ENGINE MOUNT/ FUEL PUMP CARBURETOR PAGE 4 of 12 Right-Hand Footrest Removal: •Disconnect and remove the brake light switch. •Remove the forward-most tie wrap around the brake hose and frame. •Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: •Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting. Air Injection System (AIS) Removal: •Remove the electric starter motor. •Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. •Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. •Remove the three Phillips head screws holding    the AIS assembly on the frame. •Remove the AIS assembly from the left side. FOOTREST ASSEMBLY UPPER BANJO BOLT AIS AIR FILTER AIS ASSEMBLY
PAGE 5 of 12 Transfer Case Removal: •Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. •Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. •Remove the drive pulley cover and remove the drive pulley nut. •Loosen the drive belt tension. •Remove the drive pulley, inner cover, collar, and O-ring. NOTE: The collar has a bevel on its inside diameter     for the O-ring facing inward and a bevel on the outside diameter facing the pulley. •Remove the drive and driven sprockets with chain as an assembly. •Remove the collar and O-ring. NOTE: Collar has a bevel on its inside diameter that faces inward for the O-ring. •Remove oil tank filler neck. •Remove the relay bracket on the right-hand side. NOTE: Leave the relays connected. Simply move them out of the way to allow room for transfer case removal. •Slide the transfer case out from the right side.

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