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HARLEY DAVIDSON XL BRAIDED FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Drain the brake fluid following the instructions in the service manual. Dispose of waste properly. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Disconnect the battery, negative (-) cable first or remove the main fuse. Follow the instructions in the service manual 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Discard sealing washers, but save bolt for installation. 4. Remove bolt and two sealing washers to disconnect brake line fitting from front brake caliper. Discard sealing washers, but save bolt for installation. 5. Carefully make note of brake line routing, then remove existing brake line. NOTE This kit contains clamps and cable straps to either replace the original equipment clamps and cable straps being removed or to add additional brake line support. INSTALLATION Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 1. Position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Small ID washers are for caliper end, large ID washers are for master cylinder end. 2. Insert bolts (removed earlier) through washers and fittings. 3. Hold new braided brake line in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the same orientation as the stock banjo fitting. 4. Verify there is no twist in the brake line. Adjust brake line if necessary. 5. Install clamps from kit by wrapping clamp around braided brake line at each of the clamp mounting locations. Verify clamps are oriented the same as the stock clamps. Install clamp screws but do not tighten. 6. Check entire length of braided brake line: a. Be sure brake line is not twisted. b. Turn handlebars fully-left and right while checking to make sure brake line does not contact any vehicle components. c. Be sure brake line length between clamps is sufficient. 7. Adjust brake line if necessary. 8. Tighten caliper and master cylinder banjo bolts to 20-25 ft-lbs (27-34 Nm) .

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2008 Kawasaki ZG1400 Concours ABS Front 3-Line Kit and FK003D625R Single Line Rear INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 29-01-2011

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Step 1: Identify the key components that complete our front brake line kit: You should have three (3) hoses, one (1) double banjo bolt, and two (2) single banjo bolts There are also a total of nine (9) washers and (3) brass conic inversors. Seven (7) washers and two (2) inversors will be used; the rest are spares. If you have purchased a rear kit as well, locate the following additional pieces: One (1) hose with bracket and c-clip attached, one (1) single banjo bolt, two (2) brass inversors and three (3) washers. You will use one (1) “olive” conic inversor and two (2) washers, the rest are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. On the front brake line kit, we are replacing three hoses and their respective blocks (see pictures 1-2 for blocks) . For the rear, we are replacing one hose from the master cylinder to the ABS hard line. Take note of how the stock system was routed, in case you need to reinstall it. Step 4: Locate Line A – This will travel from the master cylinder to the ABS Junction. (See picture 3) You will use a single banjo bolt and two washers at the master cylinder, and an “olive” inversor to thread female end to hard pipe for incoming ABS (right side). * We have replaced the block at the upper triple clamp with a c-clip; please use your stock bolt to thread this in. (See picture 4) Locate Line B – This will travel from the ABS Junction to the right caliper. First, thread the female end to the hard pipe for outgoing ABS (left side). There will be a bolt from the OEM blocks at ABS Junction; please use this to thread c-clips into frame as shown in picture 5 . There is another bolt/OEM block located at the lower triple clamp; please use this to thread the c-clip in as seen in picture 6. Locate Line C – This will cross over the front fender using OEM holders, from right caliper to left caliper. Thread caliper banjos from Line B and C using the following sequence: double banjo hex, washer, 40- degree banjo from Line C, washer, 20-degree banjo from Line B, washer, caliper. Please see pictures 7 and 8 for reference. Thread single banjo bolt into left caliper, using two washers and 40-degree banjo. If applicable, locate rear Line D – this will travel from the rear master cylinder to the hard line for ABS. Thread the hard pipe into female end using a “olive” inversor, and attach bracket to swingarm as seen in picture 9 . Use the bolt from the holder for ABS hose, and sit our bracket on top of the OEM holder. Using the bolt from the OEM ABS hose holder in location shown in picture 10 , attach the c-clip on top of holder and tighten. Finally, thread 30-degree banjo in caliper using the following sequence: single banjo hex, washer, banjo, washer, caliper

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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2002-2007 HONDA VFR 800 WITH ABS GALFER BRAKE LINE KIT INSTALLATION MANUAL

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

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Prep the motorcycle for this job A. Park motorcycle on the center stand in a well-lit shop (Fig.A) B. Note: it is not absolutely necessary to remove the fuel tank and body panels. However, brake fluid is VERY CORROSIVE TO PAINT. We decided to be safe (Fig. B) and removed the lower fairing left and right rear sides, fuel tank, front fender, seat, and black A B plastic inner fairing front parts, battery cover, and rear master cylinder cover according to the owner’s manual. This also gives better access to the fittings. (Fig C) C. After safely storing the body panels and fuel tank, remove wind shield, (brake fluid, even a drop, will permanently mark any clear plastic), cover the dash and all gauges with a towel. II. Draining the brake fluid from the systems. A. A copy of the factory instructions has been included with this kit on how to properly and safely drain, fill and bleed the brake fluid from the brake systems. Follow the directions closely and remove the fluid according to the instructions. Dispose of the old fluid properly—DO NOT REUSE. B. If you purchased the clutch line, then perform the following steps (Fig D): In the bag marked Clutch Line: remove the left side lower body panels. Remove vehicle speed sensor, and remove the coolant C D tank. Remove the clutch fluid from the master cylinder on the left clip-on. Remove the fluid from the clutch line and slave cylinder. This factory line is NOT attached along the inner frame spar so here is a little trick that made this a 20- minute job including the bleed: 1. Remove the banjo bolts from the master cylinder and the clutch slave ends. 2. With a nice heavy wire tie, attach the slave end of the new braided line to the lever end of the factory line. Snip off the tail of the wire tie. Wrap this “joint” with electrical tape. 3. Pull from the factory slave end until you get the braided line end to the clutch slave. If it gets caught on something, try turning the end you are pulling from. 4. Remove the tape, carefully cut off the wire tie, install new sealing washers and bolts at both ends and torque to 17-21 foot/lbs. maximum. Bleed the clutch. III. Removing the factory front brake hoses and calipers – Front A. With the fluid drained and disposed of properly, loosen the bolts that hold the right caliper to the right fork leg (Fig E). Also remove the two 8mm bolts from the ABS front wheel speed sensor. Loosen all of the hose mounting blocks on the front forks on both sides; also loosen the blocks for the crossover pipe (Fig F) between the fork legs. Also loosen the frame pipe mounts and the mount for the front lever line that is also E attached to the right side of the frame. Loosen the left caliper mounting bolts (Fig G). B. Remove the calipers and remove the hose mounts under the lower triple tree. Remove the hard pipes from both the left and right hard pipe to soft line frame mounts on the frame (Fig. H). On the front ABS modulator remove the short soft line that is connected to the mount block. (Fig I.a. & I.b.) C. Carefully remove the

Vengeance Motorcycle Specification And Owner's Manual

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Filed Under (Vengeance) by admin on 20-11-2010

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Vengeance Maxis • Vengeance Raven • Vengeance Banshee • Vengeance Whiplash • Hotrod Drifter • Hotrod CalChop • Hotrod Teacher • Hotrod Bone Shifting Gears Starting off and changing gears requires coordination of the clutch and throttle and gearshift lever. If you don’t do things right, the amount of control you have over the bike is lessened. To start off, pull in the clutch, shift into first gear, roll on the throttle a little, and ease out the clutch. You will become familiar with the friction zone (that’s where the clutch begins to take hold and move the bike), and you add a bit more throttle. You don’t want to stall the engine, nor do you want to over-rev it. There’s a sweet spot in there; find it. Shift while traveling in a straight line. Shifting in a curve is not good practice, and something to be avoided. Become familiar with the sound of your engine, so you can tell when you should shift without looking at your instruments. When you downshift to a lower gear, you should (in one swift, smooth movement) be able to squeeze the clutch, rev the engine a little to let it catch the lower gear smoothly, and shift down. When you come to a stop in traffic, leave the bike in first gear with the clutch disengaged (just in case you want to accelerate out of there in a hurry). Who knows what may be coming up behind you. Braking Don’t ever forget: The front brake on your motorcycle can supply as much as 70 percent or more of your stopping power. The single most important thing you can learn about braking is to use that front brake every single time you want to slow down. Turning When you are riding along the road, you lean a motorcycle into a turn. Learning to lean is an essential part of riding a motorcycle. It is a normal function of the bike when you are changing its path of travel – and quite different from turning the steering wheel of your car. To get the motorcycle to lean in a normal turn, press the handlebar in the direction of the turn and maintain slight pressure on that handlebar to take you smoothly through that particular turn. In other words: press right to go right; press left to go left. Your instincts to keep the motorcycle on a smooth path while keeping it from falling over usually take care of this without you even noticing it. (Demonstrate to yourself how a motorcycle moves by pressing a handlebar slightly while traveling in a straight line. The motorcycle will move in the direction of the handlebar you pushed.) • Slow down before you enter the turn; look as far ahead as possible through the turn. • Keep your feet on the pegs, and grip the gas tank with your knees. • Lean with the motorcycle; don’t try to sit perpendicular to the road while the motorcycle is leaning over. • Keep an even throttle through the turn, or even accelerate a little bit. Checking the Bike before the Ride It’s not fun to have things go wrong on a motorcycle, but if you spend a minute before you go off on a ride, you can increase the chances that nothing will.

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HARLEY DAVIDSON SOFTAIL BRAIDED REAR BRAKE LINE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) Drain Brake Fluid 1. Pop off bleeder nipple cap on the rear brake caliper. 2. Install one end of a length of plastic tubing over the caliper bleeder valve. Place the free end of the tubing into a suitable container. 3. Open the bleeder valve about 1/2-turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not reuse brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 2. Disconnect existing brake line from rear brake caliper and rear brake master cylinder assembly. Save banjo bolts, but discard brake line gaskets. NOTE This kit contains all gaskets needed for replacement. 3. Carefully make note of rear brake line routing and orientation of banjo fittings, then remove existing brake line. Save hex head screw holding brake light switch manifold to tab on frame, but discard brake line and attaching parts. 4. Unthread brake light switch from brake line. Save switch for later use.

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1998-2001 HONDA VFR 800 Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 14-12-2011

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Identify the key components that complete our brake line kit: You should have nine (9) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) single bleeder bolt three (3) drawings, and a picture CD. There are also a total of forty (40) washers and two (2) “olive” conic inversors. Thirty six washers will be used, and two olives. The rest are spares.Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G are installed on the front of the motorcycle, while brake hoses (H and I) are installed on the rear. Each label will reference a different drawing, which will show you the location of the key brake system
components.Step 3: To ensure no paint damage from a brake fluid spill, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a couple pictures, in case you need to re-install. Step 4:Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G. Locate lines A. this hose will run from the master cylinder down to the right caliper and across the fender through the C-CLIP down to the left caliper. Line D. will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame female fitting will thread into the male with a (OLIVE) this O.E.M tubing travels to the proportion valve. Line F will run from the left caliper up through the C-CLIP to the left upper frame female fitting and thread to the male with a (OLIVE) this tubing travels to the rear master cylinder. Locate and install line E; this hose will run from the lower delay valve down to the right caliper. locate and install line C& G; line G will travel from the bottom (left) mounting point on the left caliper, to the upper inner mounting point of the left caliper this line joins line C with a double banjo bolt. line C will travel from the inner left caliper through the C-CLIP across the front fender to the inner mounting point of the delay valve

HARLEY DAVIDSON XL PULLBACK HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Installation Removing the Existing Front Brake Line 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 to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) 2. See Figure 1. Open the bleeder nipple cap on the front brake caliper. Obtain a length of plastic tubing. Install one end of the tubing over the caliper bleeder valve (1). Place the free end of the tubing into a suitable container. Open the bleeder valve about 1/2-turn and pump the front-brake hand lever to drain the fluid out of the front brake system. Do not reuse brake fluid. NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch line are clean and undamaged before assembly. (00329a) 3. Disconnect the brake line from the front brake caliper and the front brake master cylinder assembly. Discard the brake line sealing washers, but retain the banjo bolts. The brake line kit contains all new sealing wash- ers. CAUTION 1 CAUTION 1 WARNING 1 WARNING 1 WARNING ® Kit Number 56021-04B 1 of 6 Figure 1. Draining Brake Fluid i01986 i05811.tif 1 1. Caliper bleeder valve NOTE Carefully compare the new brake line to the old line before removing the old linefrom the motorcycle. Make sure the banjo fittings on the new brake line will be oriented the same as the fittings on the old line. 4. Make note of the front brake line routing and the orientation of the banjo fittings, then unfasten the brake line clamps at the right side of the front fork upper bracket and the underside of the front fork lower bracket, and remove the brake line assembly from the vehicle. Save the upper clamp and all attaching parts, but discard the brake line.

2002-2004 TRIUMPH BONNEVILLE AMERICA/ SPEEDMASTER CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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A.) REAR WHEEL REMOVAL- PAGE 14-16 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 12 mm bolt from rear seat section—if you have a pillion pad remove it first by removing the 8 mm bolt, slide forward and lift free of seat catch. Take a position where you can see what you are doing or you will scratch your painted surface. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-14 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 side allen head mount bolts and 2 12mm hex head top front mount bolts– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-11 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove the 12mm rear tank-mounting bolt. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface. E.) REMOVE SIDE COVERS PAGE 15-10 and 9-15 Triumph Motorcycle Service Manual 1.) Loosen and remove left side cover screws on the air filter facade— lift slightly to disengage top mounts and remove—set aside in a safe place to prevent damage to painted surface. 2.) On right side cover simply and gently pull bayonet fittings from rubber slip mounts. 3.) Secure these rubber mounts and remove for later re-assembly with the Bonneville Performance brackets.

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1997-2003 HONDA CBR1100 XX Black Bird Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 05-11-2011

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identify the key components that complete our brake line kit: You should have eleven (11) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) Installation CD. There are also a total of Thirty Six (36) washers and two (2) “olive” conic inversors two (2) c-clips. Thirty Two (32) washers will be used, and two olives. The rest are spares. Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G, H, K, I are installed on the front of the motorcycle, while brake hoses (J and K) are installed on the rear. Each label will reference a different drawing, which will show you the location of each brake line. Step 3: To ensure no paint damage from brake fluid, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a
couple pictures, in case you need to re-install. Step 4: Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G,H,K,I. Locate lline A. this hose will run from the master cylinder down to the Galfer t-block
joining line B to the right caliper upper mounting point. Line C will travel across the fender down to the left caliper upper mounting point. Line D will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE). This O.E.M tubing travels to the rear master cylinder. Line E Travels from the lower delay valve down to the right caliper lower mounting point. Line F will run from the (SECONDARY MASTER CYLINDER) up through the C-CLIP to the left upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE).This tubing travels tothe rear delay vale

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