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Air Shock Installation Instructions

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Filed Under (Tips and Review) by admin on 24-11-2010

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Air HoseInstallation. Choose the most convenient loca- tiononyour motorcycle for the air fill valve. Drilla 5/16″hole and install the air fill valve as shown in Figure 3orsecure air fill valve to frame tube. 2. Keep hose ends clean during installation because dirt can cause air leaks. 3. Install hose connector, tube clamp and two O-rings onto one end of the air hose (See Figures4&5) Apply rubber lubricant (soap solution, not oil) to the O-rings to ease installation on the air hose& into the shock absorber inlet. Plastic connector should just bottom on fitting. Do not overtighten! The function of the nut is to hold everything together in place, the O- rings do the sealing. Fin- gertightenonly (10 in/lb maximum). 4. After routing the air hose, trim the length to fit air fill valve. Install hose connector, tube clamp, and twoO-rings onto end of hose (See figures 4&5). Lubricate as above and assemble to air fill valve. Use the same procedure formating hose. Important —leaveasmall amount of slack in hose near shock absorber to allow for the slight move- mentofthe shock. Caution! Do not install hose near ex- haustsystem, battery or any other sharp edges or seat movement. Keep hoses clear of moving parts such as wheels or suspension components. Do not allow hoses to have excess slack and sag below the motorcycle. The hoses could catch on road surfaces or debris and could be damaged while the motorcycle is in motion. 5. If necessary the air hose can be secured along the motorcycle’swiringharness with tie-wraps. 6. Testing: Inflate system to 50 psi. Apply soapy water solution to all connections and check for air leaks. If there are any leaks, disconnect the suspected fitting and check for dirt or damage to the air line or the O-rings. Remove any dirt or foreign matter, re-lubricate the O-rings and reinstall. If unable to locate the leak, remove rubber boot from shocks and submerge pressurized components under water (in- cludingT-Valve) and check for leaks. If you cannot solve the air leak problem, please contact our technical staff for assistance

Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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Triumph Bonneville America And Speedmaster The Freak Installation Instructions and Parts List

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Filed Under (Triumph) by admin on 29-10-2010

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INSTALLATION In order to install The Freak, the factory air-box must be removed. Because of it’s design, the factory air-box is not an item that is easily removed. There are several parts that must be removed in order to get the air-box out of the bike in one piece. We recommend using the following method to remove your air box without having to cut it into smaller pieces in order to get it out of the frame. 1. PARTS REMOVAL In order to gain access to the air-box, it is necessary to remove certain parts of the motorcycle to gain access to the air-box area of the frame. Removing the following parts should be the first steps you take. A. Seats – Remove both seats starting with the passenger pillion, if applicable. B. Side cover and grommets – Remove the plastic side cover on the right side (throttle side) of your motorcycle. This is the faux oil-tank cover that has the name of your bike on it. Underneath the side cover there are three rubber grommets (1 on the frame tab, and two on the air-box) that support the side cover. Remove the two that are on the air-box and leave the one on the frame. You will attach the two that you removed to the right side bracket in Section 4C . C. Faux air filter covers – On the right side of the bike, remove the chrome faux air filter covers, by removing the one allen head screw that holds it onto the air-box. On the left hand side (clutch side) remove the faux air filter cover in the same manner, you removed the one on the right. D. Plastic shrouds – on the left side, remove the black plastic air-box shroud, by removing the two allen head screws holding it in place. Then remove the plastic shroud covering your fuse box (this is the piece that surrounds your ignition terminal next to the battery). E. Battery – Remove the battery by unscrewing the torx-head bolt that holds the chrome bracket in place. Remove the chrome bracket and the black plastic cap. Tilt the battery out of the box with the top towards you. Disconnect both battery terminal connectors, negative (-) terminal first. Remove the battery. F. Battery box – Remove the two bolts that hold the battery box to the frame. Pull the battery box out as far as you can, then remove the the ignition terminal from the battery box, by removing the two allen screws that hold it in place from the back. Next, remove the fuse box from the battery box, by pushing it out from the back. It is not necessary to disconnect any of the wiring going to the fuse box, or the ignition terminal. G. Rear fender – Remove the rear fender, by first disconnecting the taillight wires. Follow the wires from the tail light assembly on the inside of the rear fender (left side) towards the front of the bike until you come to the box connector. Disconnect the tail light wires at this connector, being careful not to break it. Once the wiring is disconnected, remove the 6 bolts that hold it to the struts. Have someone hold the fender for you while you are removing all of the bolts so that it does not drop once the bolts are removed. Slide the fender out the rear of the bike. 2. PREPARE THE MOTORCYCLE FOR AIR-BOX REMOVAL To remove the factory air-box without damaging it, it is necessary to lift the bike. We recommend the use of a multi-position ATV/motorcycle jack with a minimum lift height of 10″. A. Setting up the lift – Place the lift under your bike and secure your bike to the lift according to the lift manufacturer’s instructions. B. Raise slightly – Lift the motorcycle to the point where the rear springs are without tension, but NOT to where the rear tire is off the ground. C. Remove the rear springs – Take off each of the rear springs by removing the the two bolts on each spring. Once all the bolts are removed gently pull the springs out off of the studs. If they do not pull off easily, you can raise or lower the bike slightly with the lift to ease tension on the spring. Remember, you should not have the rear tire off the ground at this point. The bike should only be raised enough to relax the tension in the springs. D. Remove the mufflers – Remove the mufflers by loosening the clamp at the exhaust header, and by removing the rear foot peg hangers. If the mufflers are not removed, they can become damaged by the axles in Section 2H . E. Disconnect the carburetors – With a small flathead screwdriver, pull the retainer springs out of the channel of the carburetor intake tubes (the two large black tubes coming from the air box into the back of each carburetor), and simply push them towards the air box off of the carbs

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2009 Kawasaki ULTRA 250X/ 260X FUEL INJECTION CONTROLLERS And REGULATORS INSTALLATION MANUAL

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

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The R&D high performance Air Filter Kit will improve acceleration and top speed performance by increasing air flow and reducing air temperatures that enter directly into the Ultra 250X’s air plenum box area. The O.E.M. air plenum box on the Ultra 250X is a great design that will flow plenty of air. However, the air that feeds the plenum box is heated by the engine. R&D has created an easy to install “flat filter” that installs directly in place of the large center access inspection cover located directly under the main glove box. The R&D Flat Air Filter insert will allow unrestricted fresh and cool air to enter the air plenum box area which will add power you can feel and a nice high performance tone. The R&D Performance Filter Kit also features two filters, one for each of the surge and blowoff protections valves. The O.E.M. surge valve recycles compressed hot air back into the air box plenum at idle and under deceleration conditions. The R&D surge and blowoff valve filter kit removes the air recycling hoses which will keep the hot air from entering the air plenum box reducing the engines intake air temperatures. The R&D Ultra 250X Air Filter Kit offers great performance tips on how to remove the restrictive air vent hoses which will further reduce the under seat ambient air temperatures. The R&D Filter system does not remove or alter the O.E.M. plenum box in any way, therefore there are no questions to be answered regarding water ingestion

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AIR / HYDRAULIC MOTORCYCLE LIFT REMOVABLE INSPECTION PLATE

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Filed Under (Tips and Review) by admin on 19-11-2010

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For best service, you should incorporate an oiler, regulator, and inline filter, as shown in the diagram on the next page. Hoses, couplers, oilers, regulators, and filters are all available at Harbor Freight Tools. NOTE: If an automatic oiler is not used, put 3-5 drops of pneumatic Tool Oil (not included) in the Motorcycle Lift’s Quick Coupler (38A) before each use. (See Figure B, next page.) To Check The Level Of Hydraulic Oil: 1. The Motorcycle Lift already contains some hydraulic oil in its Hydraulic Pump Reservoir (32P). Even so, it is recommended that you check the oil level in the Reservoir and, if necessary, top off the Reservoir with the proper amount of 15/40 hydraulic oil (not included). (See Assy. Diagram, page 15.) 2. Make sure to screw the two Adjusting Screws clockwise enough to lift the two Caster Wheels (14) off the floor so as to provide stability for the Motorcycle Lift. (See Figure A.) 3. To check the level of hydraulic oil, remove the Sliding Plate (36) from the Platform (35) to expose the Hydraulic Pump Reservoir (32P). (See Assy. Diagrams, pages 13 and 15.) 4. Remove the rubber Filler Plug (33P) located on the top of the Reservoir (32P). If necessary, top off the Reservoir with hydraulic oil. (See Assy. Diagram, page 15.) 5. Connect the air compressor’s hose to the to the Air Motor assembly. Then turn on the air compressor and set its regulator at 120 PSI. (See Assy. Diagram, page 14.) 5. Insert the Lift Foot Pedal (11) onto the Pump Piston Spindle (9), and slowly pump the Lift Foot Pedal until a slight amount of hydraulic oil begins to leak out of the Reservoir (32P). Discontinue pumping the Lift Foot Pedal. Then, replace the Filler Plug (33P) on the top of the Reservoir. (See Assy. Diagram, page 15.) REGULATOR OILER FILTER TO QUICK COUPLER (38A) OF MOTORCYCLE LIFT FIGURE B 6. Insert the Release Foot Pedal (10) onto the Release Valve Spindle (5). Pump the Lift Foot Pedal (11) until the Platform (35) of the Motorcycle Lift reaches its maximum height. Then press down slightly on the Release Foot Pedal until the Platform is fully collapsed to the floor. Repeat this procedure several times to ensure the Motorcycle Lift is operating properly. (See Figure E, page 10.)

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MOUNTAIN BIKE AIR SHOCK SET-UP AND TUNING GUIDE

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Filed Under (Tips and Review) by admin on 01-12-2010

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DETAILED SET-UP 2. Installing Air Pressure – Remove the air cap from the Schrader valve on the end of the shock body. Attach the pump to the Schrader valve. Some people damage their pumps by screwing them on too far. As soon as the gauge registers pressure, screw 1/2 turn more and pump to the desired level. Use the release button on the pump to reduce air pressure. The hiss you hear when unscrewing the pump is only the air from the pump and not from the shock! Likewise, when you install the pump again, you will also hear a hiss as air from the shock fills the pump and reduces the registered pressure you previously installed. All perfectly normal when pressurizing the shock! After removing the pump, be sure to reinstall the Schrader valve cap. If the shock does not dampen properly after pressurizing, the air pressure may have been lost during pump removal as a result of a worn pump fitting o-ring that needs replacement. Do not ride the bike until the shock is properly pressurized. 3. Main Air Spring Pressure Adjustments – Air Spring adjustments are made by inflating or deflating the main air spring chamber. Since your IFP air pressure adjustment (outlined above) also affects your starting spring force, you should always adjust your IFP pressure before adjusting the main air spring pressure. You can refer to the online Quick Start guide at: www.progressivesuspension.com/literature.html for accurate main air spring pressure and sag settings matched to your bike model and body

HARLEY DAVIDSON TOURING SUSPENSION AIR PUMP KIT OPERATION/ INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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OPERATION 1. Remove cap from air suspension air valve and connect pump by threading the air valve adapter (1) on the pump as shown in Figure 1. When adapter is threaded properly, the current air pressure in the system will be indicated on the gauge of the pump. Do not exceed maximum air pressure for rear suspension. Air components fill rapidly. Therefore, use low air line pressure. Failure to do so may result in possible damage to components. (00165a) NOTES See the motorcycle’s Owner’s Manual or, if installed, the air suspension lowering kit’s instruction sheet for the recommended air pressures. Using pressures outside the recommended loading range will result in a reduction of available suspension travel and reduced rider comfort. 2. To increase pressure, operate the air pump handle (4) until the desired pressure is indicated on gauge (2). Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) NOTE The pressure release button is designed to release pressure slowly. If the button is completely or rapidly depressed, no air will be released. For the best results, depress the pressure release button slowly and only partially. 3. To decrease pressure, slowly depress the pressure release button (3) on the pump until desired pressure is indicated on gauge (2)

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1300 Yamaha V-Star Installation Manual

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Filed Under (Yamaha) by admin on 07-11-2010

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1) Place motorcycle on a firm level surface and secure in a upright position. 2) Remove saddle bags and saddle bag hardware (Tourer model only) Also remove rear riders pegs (Tourer model requires removal of rear footpeg offset hardware as well) 3) Attach bracket A (right) / B (left) to rear footpeg attachment point using new bolts provided. Remount footpegs/saddlebag hardware over top of brackets A/B. NOTE: Do not attach leveling stand bracket at this time 4) Attach bracket C(right) / D(left) to rear fender sub frame using new bolts provided. (Tourer model only – Saddle bag hardware mounts to the outside of brackets C/D. Brackets C/D mount between chrome side rail and saddlebag hardware.) NOTE: Brackets C/D have welded spacers which attach in toward rear fender 5) Attach top of Bracket E(right) / F(left) to rear of brackets C/D. Brackets E/F mount to the inside of brackets C/D. NOTE: Use ½ inch spacer between brackets E/F and C/D on Tourer model ONLY
6) Attach rear of brackets A/B to TOP of forward hitch arms. Attach bottom to brackets E/F to rear hitch plate. 7) Carefully tighten all bolts at this time ensuring hitch is square with motorcycle. Hitch Bracket Identification Leveling stand screw jack installation 1) Attach leveling stand brackets to brackets A and B 2) Thread right side screw jack into threaded hole on leveling stand bracket attached to bracket A sand adjust leveling jack bolt out. 3) Push motorcycle over from left side until right screw jack is touching floor. 4) Thread left side screw jack into threaded hole on leveling stand bracket attached to bracket B and adjust out until motorcycle will rest upright on both screw jacks. 5) Adjust screw jacks until motorcycle is level. 6) After InstaTrike is attached to or removed from receiver hitch, be sure to remove leveling stands and leveling stand brackets. CAUTION – Use screw jacks to hold motorcycle upright and level ONLY. Do not lift motorcycle with screw jacks. CAUTION – Use care when installing screw jacks. Be certain that motorcycle is always in a stable balanced position.
INSTALLATION OF THE TOW-PAC HITCH CART. 1. Place your motorcycle on a smooth flat surface, like a garage floor, and install leveling stands. Install right leveling stand first. Carefully raise motorcycle off of side stand and install left leveling stand. Caution – Use leveling stands to level motorcycle ONLY. Do not raise motorcycle with stands Caution – Be certain that motorcycle is always in a stable balanced position when installing leveling stands. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bolt

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SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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HARLEY DAVIDSON SCREAMIN' EAGLE VENTILATOR PERFORMANCE AIR CLEANER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the main fuse. Refer to the service manual. 2. Remove the existing air cleaner backplate. Refer to the service manual. Save the original equipment (OE) button head screw that secures the air cleaner cover. Discard the remaining parts. 3. Remove the fuel tank. Refer to the service manual. 4. See Figure 1. Remove and discard the induction module support bracket. is05912 Figure 1. Remove Induction Module Support Bracket INSTALLATION Air Cleaner Installation Use only supplied air cleaner cover. Use of another air cleaner cover could cause element failure and detachment of the air cleaner cover, which could distract the rider and result in death or serious injury. (00596b) NOTE When servicing the air cleaner, apply Loctite 243 – Blue to the threads of all fasteners. 1. See Figure 3. Install two O-rings (1) from the kit in the grooves around the breather bolt holes on the induction module side of the backplate assembly (2). Install the remaining two O-rings in the grooves in the underside of the heads of the breather bolts (5). 2. Remove the liner from the adhesive backing of the gasket (3). Carefully position the adhesive side of the gasket to the backplate, aligning to the equally spaced screw holes, and press the gasket firmly into place. 3. Insert new breather bolts (5) through the backplate. 4. Apply Loctite 243 – Blue to the breather bolt threads and the mating tapped holes in the cylinder head. 5. Thread the bolts into the cylinder head, but do not tighten. 6. Thread the air cleaner mounting studs (4) all the way through the backplate (2) until the screw threads are captured in the induction module. Do not tighten completely at this time. 7. Alternately tighten the two breather bolts to 120-144 in- lbs (13.6-16.3 Nm) . 8. Tighten the three air cleaner studs to 55-60 in-lbs (6.2- 6.8 Nm) . 9. Install the fuel tank. Air Cleaner Element and Cover Installation