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Kawasaki Prairie 360,650,700 ATV PLOW Plow Mounting Kit INSTALLATION INSTRUCTIONS

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

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Mount Installation Note: There are different hole locations on the plow mount depending on the bike model. For Prairie 360 use the middle hole locations (B), for Prairie 650 and Twin Peaks 700 use hole locations (A) on mounting plate, as shown in Figure 1. Figure 1 Hole Locations WARN INDUSTRIES PAGE 3 67954 Rev A3 To install the plow mount to the underside of the vehicle install the front two U-bolts PN 60869, and loosely tighten the 5/16″ nuts. Pull the plow mount back in the furthest position and then fully tighten, as shown in Figure 2. For the Kawasaki Prairie 360 use the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (B) . For Kawasaki Prairie 650 and Suzuki Twin Peaks 700 drill a 3/8″ hole through the aluminum skid plate, using the plow mount as a template, as shown in Figure 3. Repeat the same process on the other side. After both holes are drilled attach the mounting plate with the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (A) . Tighten all fasteners securely. Torque 5/16″ Bolts: 20ft. lb.

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HARLEY DAVIDSON TOURING LAYBACK LICENSE PLATE MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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This kit fits all 1999 and later FLHR (Road King®) models, FLTR (Road Glide®) and FLHT (Electra Glide® standard) models having license plates measuring a maximum of 7-1/4 x 4-1/4 inches (184 x 108 mm). Also fits 2003 FLHRSEI2 (Screamin’ Eagle® Road King). Does not fit with Detachable Tour-Pak Rack, part number 53276-04. Does not fit 2002 FLHRSEI (Screamin’ Eagle Road King). Kit Contents See Figure 1. INSTALLATION 1. Remove the license plate from the vehicle (if installed). Remove the two hex head bolts holding the original equipment (O.E.) license-plate bracket in place. The bolts and license-plate bracket can be discarded. 2. See Figure 1. Install the new layback license plate holder (1) using the button-head hex socket screws (3) from the kit. Tighten the screws to 19 ft-lbs (25.8 Nm) . 4 1 3 7 5 2 6 is02737 1. License plate holder, layback 2. Foam pad (6) 3. Screw, button head, hex socket (2) 4. License plate frame 5. Set screw, socket head (2) 6. Hex key 7. Reflector assembly, Part Number 59365-07 Figure 1. Layback License Plate Mount Components 3. Position the license plate onto the foam pads (2) of the license plate holder, centering and aligning the plate parallel to the holder edges for best appearance. NOTE Slots in the inside top edge of the license plate frame (4) fit over the two tabs on the top edge of the license plate holder. 4. Hook the top of the license plate frame over the top edge of the holder. Swing the bottom edge of the frame inward, holding the license plate in position against the pads. 5. Use the hex key (6) from the kit to securely fasten the license plate frame to the holder with the two socket head set screws (5)

Kawasaki KVF650/ 700, KSV 700 Camshaft Installation Instructions

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Filed Under (Kawasaki) by admin on 29-04-2012

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Liberally apply assembly lube to every surface of the camshaft. Install the camshaft into the cylinder head (the lobes should be pointed down) and align the decompressor shaft dowels with the weight arms. Install one of the camshaft sprocket holder bolts and tighten to less than finger tight, you should be able to move the camshaft very slightly back and forth, roll the crank over until the other bolt hole is exposed and insert the sprocket bolt and tighten to less than finger tight. Install the cam chain tensioner assembly, do not install the spring, spring dowel, washer, and bolt. Using the spring from the cam chain tensioner very slowly push the tensioner shaft in until the cam chain slack has just been taken out, this is witnessed by the very slight lifting of the opposite end of the cam out of the cylinder head cam journal, do not over tighten the cam chain at this point, if you do, remove the tensioner assembly and retract the plunger again and start over. (If it stays too tight it will stretch the cam chain prematurely and cause cam sprocket damage when the engine is assembled) Roll the camshaft toward the back of the machine (clockwise) loading the sprocket bolts against the back of the sprocket bolt holes, while holding the camshaft in that direction, tighten the sprocket mounting bolt to 14 ft/lb of torque. Rotate the engine in the opposite direction that you rotated it earlier and align the TDC mark, tighten the other sprocket-mounting bolt to 14 ft/lb of torque. Verify the cam timing and crankshaft TDC marks are in alignment

HARLEY DAVIDSON DYNA REAR STOP/ TAIL/ TURN SIGNAL RELOCATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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PREPARATION NOTE Position the motorcycle upright using a suitable lift or jack. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow instructions to remove the main fuse. 2. Follow the service manual instructions to remove the seat. 3. Raise the rear of the vehicle to allow access to the underside of the rear fender. LICENSE BRACKET AND ILLUMINATOR REMOVAL For Models WITHOUT a Center Tail Lamp NOTE See Figure 1. The reflector mounting block (2) is held to the fender (1) with double sided tape. Remove with care to avoid scratching paint. 1 3 2 5 4 6 7 is06256 1. Rear fender 2. Rear reflector and mounting block 3. Wire channel (2) 4. License plate bracket mount 5.5/16-18 screw (2) 6. License plate illuminator 7. M4 screw (2) Figure 1. Rear Fender, Models Without Center Tail Lamp 1. Remove the rear reflector and mounting block (2) from the underside of the rear fender (1). 2. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. NOTE Before removing rear wiring, note wire routing. -J04856 1 of 10 3. Remove the rear lamp wiring from behind the wire channels (3) on the underside of the fender. 4. Disconnect the two-way license lamp connector [93] and the four-way right [18] and left [19] stop/tail/turn (STT) lamp connectors from the STT module in the area under the seat. 5. Remove the two 5/16-18 screws (5) retaining the license plate bracket mount assembly (4) to the fender support. 6. Remove the license plate illuminator (6) from the license plate bracket mount assembly. Save the illuminator. The bracket mount (4) and four screws (5, 7) can be discarded. 7. Proceed to License Bracket and Illuminator Assembly . For Models WITH a Center Tail Lamp NOTE On these models, the license plate illuminator is part of the center tail lamp and is not removed. 1. Remove the three screws retaining the license plate bracket to the tail lamp housing. Remove the bracket and set aside for later assembly. 2. Proceed to Rear Lamp Wiring, For Models WITH a Center Tail Lamp and RED Stop/Turn Signals or AMBER Turn Signals . LICENSE BRACKET AND ILLUMINATOR ASSEMBLY For Models WITHOUT a Center Tail Lamp 1. See Figure 7. Get the new license plate bracket (3), illuminator cover (4), spacer (6) and two M4 screws (5) from the kit, and the license plate illuminator (A) removed from the original equipment (OE) license plate bracket. 2. See Figure 2. Assemble the illuminator (1), spacer (2) and cover (3) to the license plate bracket (5) in the sequence shown, and tighten the screws (4) securely. 3. Get the STT relocation weldment (6), two screws (7) and two flat washers (8) from the kit. 4. Apply a few drops of Loctite 271 – Red to the clean screw threads. Assemble the license plate bracket to the weldment as shown, and tighten the screws to 120 in-lbs (13.6 N-m) . NOTE If using a metal tool to install the black nuts, protect the finish with cloth or paper to prevent damage. 5. Loosely install the black painted nuts (9) onto the threaded studs on each side of the STT relocation weldment. 6. Remove the wires and socket terminals from the two-way license plate illuminator socket housing. Set the socket housing aside for later installation

BMW Motorcycles R 850/ R 1100 Series and K 1200 RS – New Clutch and Pressure Plate

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Filed Under (BMW) by admin on 16-11-2010

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Details: All R 850/R 1100 and K 1200 RS models produced from December 1997 have received a new clutch disc, manufactured by VALEO, and a new pressure plate (see applicable part numbers below). Earlier production for both series can be fitted with the new parts. However, due to changes in specifications (a thicker pressure plate, a thinner clutch disc), the new VALEO clutch disc is not compatible with the old pressure plate. In this application, the new clutch disc and pressure plate must be replaced as a pair. Series Production: R 850/R1100 models: Starting with December 1997 production. K 1200 RS: Starting with December 1997 production. Part Number: R 850/R1100 Models: VALEO Clutch Disc: 21 21 2 325 864 Used only in conjunction with Pressure Plate: 21 21 2 325 863 R 850/R1100 models: VALEO Clutch Disc with reduced play on gearbox input shaft (KD – Scheibe): 21 21 2 325 862 Used only in conjunction with Pressure Plate: 21 21 2 325 863 K 1200 RS: VALEO Clutch Disc: 21 21 2 332 973 Used only in conjunction with Pressure Plate: 21 21 2 332 974 Attention: For R 850/R1100 and K 1200 RS models with production dates of 12/97 and later, all clutch parts can be replaced individually, as the new pressure plate will already be installed. On earlier production examples, installing the new VALEO clutch disc without replacing the pressure plate will not allow the clutch to completely disengage.

Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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Filed Under (Kawasaki) by admin on 30-11-2010

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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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

Kawasaki Exhausts – ZX-6 ZX-10 Zx-14 Exhaust – Slip-ons INSTALLATION MANUAL

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

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Our favorite exhaust options for Kawasaki ZX Ninjas – ZX-10,ZX-6r, and the new horsepower king, Zx-14.. Grab your horsepower today. We love Rob Muzzy and Muzzy Exhausts.Going back to Doug Chandler and Scott Russell, Muzzy has been synonomous with Kawasaki and performance – and for years, if you rode Kawasaki,and you were on the podium, Muzzy was on your exhaust. We also feature Arrow and Yoshimura exhausts for your ZX-6R, ZX-10 and ZX-14. We love the sound of a Yosh exhaust on any Kawasaki Ninja. Yoshimura Oval (RS-3) Race Slip-On for Kawasaki ZX14R 2006 The easiest and least expensive way to experience Yoshimura performance is with our Slip-On/Bolt-On lines. Bolt-On style bolts to the O. E. M. mid-pipe Slip-On style with its stainless steel easily attaches to the mid-pipe RS-1 is available where noted Usually, no jetting or re-programming is required and installation is a snap Hindle Stainless Exhaust High Head Pipes – Kawasaki ZX6R-RR 03-04 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo North Denver News http://northdenvernews.com Powered by Joomla! Generated: 19 October, 2010, 12:28 Hindle Stainless Exhaust Low Head Pipes – Kawasaki ZX9R 00-03 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo

Kawasaki 650/360 Prairie Lift Kit Installation and removal Instructions

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

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1) Place jack under center of ATV front end and lift until front wheels clear the ground. Be careful to support ATV properly so that it is securely supported but so that A-arms and shocks can droop to full extension. 2) Remove front wheels. 3) Remove or loosen front plastic. 4) Remove C-clip and nut at the top of the strut. 5) Screw bracket “A” on top of strut to the same torque specifications as the nut. 6) Place the top adapter “A” through the top of the strut mount, and screw the original nut on the top of bracket “A” securing it to the strut mount. Tighten this nut to the required manufacturer specifications and replace the factory C-clip. 7) Repeat the procedure for the other side. 8) Install the wheels, torque wheel lug nuts to manufacturer’s specifications, lower and remove jack. Check for clearance problems or misalignment. Rear Lift 1) Place jack under ATV at the rear of the bottom skid plate and lift until the weight is off of the suspension. Be careful to secure the ATV properly so as not to fall off the jack. 2) Remove the bottom of the shock from the shock mount on the axle. 3) After removing the shock, jack the ATV up 1″-2″ further. 4) Place Bracket “B” between the shock and shock mount with the notched out ends facing downward. Insert stock bolt to secure bracket “B” to the shock mount and the shock. Fasten nut. 5) Insert the new 12x75mm Bolt to the top of bracket “B” and the shock eyelet and secure with a new 12mm nut. 6) Tighten all nuts and bolts to manufacturer’s torque specifications. 7) Install the wheels, torque wheel lug nuts to manufacturer’s specifications, lower and remove jack. Check for clearance problems or misalignment.

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