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Honda VT1100C Shadow, Aero, Sabre SPECIFIC-FIT SADDLEBAGS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-04-2011

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The saddlebag supports are hinged 3 so they can adjust to any variance in your motorcycle’s fender strut bolt locations. The supports have a one-inch offset 4 that angles the supports outward so they space the bags away from the motorcycle’s chassis components, wheels, brakes, and moving parts. Before removing or changing any hardware, hold the supports next to the motorcycle to familiarize yourself with how they will be installed. Remove the original fender mounting bolts from one side of the fender strut and temporarily mount one support with a 10mm bolt, a plastic and steel spacer, and two washers into the front fender stay bolt hole. Then insert an 8mm bolt, a plastic and steel spacer, and two washers into the rear fender stay bolt hole. Verify that each bolt is the proper length. IMPORTANT: The VT1100 Shadow Classic, Aero, or Sabre models have 10mm (front) and 8mm (rear) threaded holes in the fender strut. Use care to not insert the wrong size mounting bolt in the strut. When installing a bolt into the fender strut, check to be sure that it does not extend inside the fender further than the original fasteners. If it does, the excess length of the bolt must be cut off, or exchanged for a shorter bolt you obtain from the hardware store or a motorcycle shop. After verifying the mounting bolts are the proper length, remove the support from the motorcycle’s fender strut. Install a grommet in each of the large holes 5 on the back side of each saddlebag. Then insert a plastic spacer 6 in each of the grommets TIP: Use soapy water to lubricate the grommets so they will slip into the holes in the bag. The vehicle images in this instruction set may be different than your motorcycle. Continued on next page… 3 Lay a support 7 (with the joint towards the rear of the bag) on the back of a bag. Temporarily put the mounting bolts 8 through the support’s holes and into the plas- tic spacers in the grommets. Place one of the support clips 9 over the center of the lower portion of the support, so the two holes in the clip align with the predrilled holes in the bag. Use the 3/16” screws and nuts from the hardware kit to attach the support clip to the backup plate inside the bag. Place the nuts on the outside of the bag. Do not over- tighten the hardware, as this may cause damage to the saddlebag. Remove the mounting bolts from the support and the plastic spacers

VT 1100 TEARDROP SPECIFIC-FIT SADDLEBAGS INSTALLATION

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Filed Under (Honda) by admin on 23-11-2011

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The saddlebag supports are hinged 3 so they can adjust to any variance in your motorcycle’s fender strut bolt locations. The supports have a one-inch offset 4 that angles the supports outward so they space the bags away from the motorcycle’s chassis components, wheels, brakes, and moving parts. Before removing or changing any hardware, hold the supports next to the motorcycle to familiarize yourself with how they will be installed. Remove the original fender mounting bolts from one side of the fender strut and temporarily mount one support with a 10mm bolt, a plastic and steel spacer, and two washers into the front fender stay bolt hole. Then insert an 8mm bolt, a plastic and steel spacer, and two washers into the rear fender stay bolt hole. Verify that each bolt is the proper length. IMPORTANT: The VT1100 Shadow Classic, Aero, or Sabre models have 10mm (front) and 8mm (rear) threaded holes in the fender strut. Use care to not insert the wrong size mounting bolt in the strut. When installing a bolt into the fender strut, check to be sure that it does not extend inside the fender further than the original fasteners. If it does, the excess length of the bolt must be cut off, or exchanged for a shorter bolt you obtain from the hardware store or a motorcycle shop. After verifying the mounting bolts are the proper length, remove the support from the motorcycle’s fender strut. Install a grommet in each of the large holes 5 on the back side of each saddlebag. Then insert a plastic spacer 6 in each of the grommets

Ducati Sport Clutch Lever INSTALLATION INSTRUCTIONS

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Filed Under (Ducati) by admin on 26-10-2010

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1 To remove your stock lever, use a 19mm wrench or (adjustable wrench) to remove the large sheet metal nut attached to the main pivot bolt that holds the lever. (Photo 1a) Once the locknut is removed, push the main pivot bolt out with your finger or if necessary tap lightly with a rubber mallet or plastic handle end of a screwdriver (Photo 1b) After the pivot bolt is removed, the lever will detach from the master cylinder. (Photo 1c) 1a See other side for further instructions INSTALLATION INSTRUCTIONS FOR PART # CRC552 ® C/5 Sport Clutch Lever Part # CRC552 1b 1c INSTRUCTIONS_CRC552 12/27/07 10:05 AM 23 4 2 Included with your ASV lever is a plastic bag that contains a custom pivot bolt, spacer & locknut. These parts will replace the OEM Brembo parts that were used with your stock lever. 3 Carefully place the lever into the master cylinder while aligning the plunger rod into the plunger cup on your ASV lever as shown in photo 3. 4 Align the lever and the master cylinder pivot bolt holes and Install the main pivot bolt, you will need to pre-load the lever into the master cylinder to get the bolt through the holes. The bolt head has two cut outs on the sides that need to be aligned with the matching area on the master cylinder. Be sure the head of the bolt seats down into the slotted area of the master cylinder. It may be necessary to use a rubber mallet or Plastic end of a screwdriver (Photo 4) to tap the head of the bolt down into its slot. 5 On the other side of the pivot bolt where the threads are, you will see that there is space around the pivot bolt. You will need to install the aluminum spacer that was supplied in the plastic bag with the pivot bolt and locknut. The spacer has a small flange on one side. The flange should be on the outer side when installing it into the hole surrounding the bolt. (Photo 5a) You may need to use pressure to seat the spacer fully into the hole surrounding the pivot bolt. You should be able to do this by using your fingers or thumbs as shown in photo 5b.

1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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HARLEY DAVIDSON PIVOT BOLT COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-02-2011

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This kit fits all 2004 and later XL (Sportster®) model motorcycles INSTALLATION Right-Side Pivot Bolt Cover Installation Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. See Figure 1. Start a set screw (2) from the kit into one of the pivot bolt covers (1) about two or three turns. 2. Note the position of the bottom-most flat on the rear-fork pivot hex-head bolt (3). Line up the pivot bolt cover over the bolt head so the set screw is centered on the hex flat. Use the 3/32 inch hex key from the kit to tighten the set screw securely to the head of the rear-fork pivot bolt. 3. Make sure the pivot bolt cover is clean and free of any oil or grease. Remove the protective backing from the adhesive disk on the back of the decorative insert (9). Install the decorative insert onto the end of the pivot bolt cover with the image or text upright and parallel to the ground. Press the insert firmly against the end of the pivot bolt cover and hold pressure for 30 seconds. After releasing pressure, avoid direct contact with the insert for about 20 minutes. Left-Side Pivot Bolt Cover Installation 4. Models without passenger footrests: Use an 8 mm hex key to remove the bolt (5) retaining the double-tube clamp (4). Models with passenger footrests: Use an 8 mm hex key to remove the two bolts (5) and the left-side passenger footrest and bracket assembly (6). 5. Start a set screw (2) from the kit into one of the pivot bolt covers (1) about two or three turns

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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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HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

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HARLEY DAVIDSON REAR SWINGARM AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) NOTE XL Sportster 883 and XL1200R models may require loosening or removal of the rear muffler in order to install the right side rear axle cover. See the EXHAUST SYSTEM REMOVAL section of the Service Manual. 1. Support the vehicle, and loosen or remove the rear muffler if necessary. XL Sportster 883 and XL1200R models: Remove the right-side lower shock absorber mounting bolt. Save for re-installation. All other models: Remove and discard the right-side lower shock absorber mounting bolt. 2. Swing the bottom of the shock absorber out of the way. Position the right-side swingarm axle cover (2) over the swingarm and behind the shock absorber. 3. Reposition the shock absorber. XL Sportster 883 and XL1200R models: Install the shock absorber mounting bolt removed in Step 1. All other models: Install the shoulder bolt (3) from the kit. All models: Tighten the bolt to 45-50 ft-lbs (61-68 Nm) . NOTE When torquing the bolt, align two of the bolt-head flats parallel to the ground. This will allow proper orientation of the bar and shield logo on the bolt cover. 4. Position the bolt cover (4) over the bolt head (3) with the Bar-and-Shield logo oriented upright, and lock in place with the set screw (5). Tighten securely. Reposition and tighten the muffler per the Service Manual instructions. 5. Remove and discard the left-side lower shock absorber mounting bolt. Move the bottom of the shock absorber out of the way. Position the left-side swingarm axle cover (2) over the swingarm and behind the shock absorber. 6. Reposition the shock absorber and install the shoulder bolt from the kit. Tighten to 45-50 ft-lbs (61-68 Nm) , aligning two of the bolt head flats parallel to the ground. 7. Position the bolt cover over the bolt head with the Bar-and- Shield logo oriented upright, and lock in place with the set screw. Tighten securely

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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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1999-2002 Kawasaki ZX6R Engine Protection Cage installation instructions

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

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1. Follow installation instructions for extended frame sliders. (See page 1) Note: Do not attach delron tips or tighten extended frame sliders until all components are installed. 2. Place the cage loop inside short telescoping tubes on sliders (See fig. G) , push the º”-20 x 1 Ω” bolts through the bolt holes on the telescoping tubes from the outside and start the º”-20 lock nuts to hold cage loop in place. Do not tighten lock nuts at this time. 3. Remove the lower sub frame bolt on the left side of the motorcycle. Install the M10- 1.5 X 88mm stud in place of the sub frame bolt. Place an M10 flat washer and M10-1.5 hex nut on the stud on the interior side of the sub frame. Slide the following components over the stud on the outside of the sub frame in this order: 1.1″ spacer, side strut, (marked with “L”) and M10-1.5 hex nut. (See fig. I) Do not tighten the hex nuts at this time. Repeat for other side using side strut marked with “R”. 4. Push the bottom of the cage loop towards the rear of the motorcycle while pulling the bottom of the left side strut towards the front until the bolt hole on the side strut meets the threaded hole on the tab welded to the cage loop. Attach the side strut to the outside of the tab on the cage loop with a 3/8″-24 x æ” bolt. (See fig J) Do not tighten the bolt at this time. Repeat for other side. 5. Once all components are attached tighten all bolts and nuts. Be sure to torque all engine mount bolts to factory specifications.

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