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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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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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HARLEY DAVIDSON SADDLEBAG LID COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION NOTE To avoid failure, the fastening tab adhesive must be allowed to cure for 24 hours before installing these Lid Covers. NOTE Lid Cover installation may be easier with the saddlebags removed from the motorcycle. 1. See Figure 1. Open the saddlebag lid. Remove the two T-20 TORX® screws (5) attaching the check strap (3) to the lid. 2 4 2 3 1 6 7 4 4 6 5 is02962 1. Saddlebag lid cover 2. Hook and loop fastener, 1.5 inch 3. Check strap 4. Hook and loop fastener, 4.0 inch 5. Torx screws (2) 6. Hook and loop fastener, 6.0 inch 7. Anchor tab (install first) Figure 1. Saddlebag Lid Cover Installation 2. Wash the entire saddlebag lid, inside and out, with warm, soapy water. Rinse and dry thoroughly. 3. Use the alcohol prep pad provided in the kit to further clean the inside of the lid in the areas where the hook and loop strips will be attached. NOTE The Saddlebag Lid Covers are side-specific. A Bar-and-Shield logo is stitched into the rear face of each cover. NOTE DO NOT fasten the Saddlebag Lid Cover tabs to the hook and loop strips until the adhesive has cured for 24 hours. 4. Place the correct Saddlebag Lid Cover (1) over the saddlebag lid in its proper position. Bring the cover tabs over the edge of the lid to serve as a guide in positioning the hook and loop strips on the inside of the lid. Remove the protective backing from one hook and loop strip at a time. Use the corresponding tab on the cover only as a positioning guide, then fold it back out of the

V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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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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HARLEY DAVIDSON DERBY COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits are designed for installation on all 1999 and later 1340 Evolution and Twin Cam equipped models.INSTALLATION For models equipped with left side exhaust pipe: 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 Remove clutch inspection (derby) cover with motorcycle upright, not on side stand. If cover is removed with motorcycle on side stand, primary fluid will leak out of primary chaincase. 1. On models so equipped, remove the left-side passenger footboard. Using a T27 TORX® drive head, remove the derby cover from the primary chaincase. Discard the derby cover and fasteners. NOTE The gasket between the clutch inspection cover and the chaincase cover must be removed and all oil must be wiped from the gasket and groove in chaincase cover each time the cover is removed. 2. Remove the gasket from the groove in the chaincase cover and mounting surface. 3. Inspect gasket for tears or damage. Replace as required with gasket 25416-99C (sold separately). NOTE If installing the Derby cover on a 2006 and later Dyna, 2007 Softail, or 2007 Touring model, the original equipment gasket must be discarded and replaced with Derby Cover Gasket 25416-99C (sold separately). 4. To avoid punching holes in the clutch inspection cover gasket or enlarging the existing holes, install the new derby cover and gasket as follows: a. Align the triangular shaped hole in the gasket with the top hole in the derby cover. Be sure the rubber molding and the words “towards clutch” face the motorcycle. b. See Figure 2. Place a washer (2) from the kit onto the threads of one of the new screws (3). Insert the screw threads through the top hole in the derby cover, and carefully thread it all the way through the triangular shaped hole in the gasket. Do not push the screw through the hole. c. Hang the derby cover on the primary chaincase cover flange by starting the top cover screw. d. Start the remaining four screws and washers. 5. Install gasket (part number 25416-99C) and derby cover (1) on primary chaincase cover using screws and washers from the kit. Tighten screws to 84-108 in-lbs (10-12 Nm) in the sequence shown in Figure 1

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HARLEY DAVIDSON EFI INTAKE MANIFOLD COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 1. Remove screw (A) that holds the air cleaner cover (B) and seal (C). 2. Remove three T27 TORX® screws (D) to release the cover bracket (E) from the filter element (F). 3. Remove the filter element, pulling the two breather tubes (G) from hole on the inboard side of element. 4. Remove the two breather tubes (G) from the fittings on the two cylinder head breather bolts (I). 5. Remove the two breather bolts (I) and O-ring seals (K) from the air cleaner backplate (J) with a 7/16 inch deepwell socket. 6. Remove the backplate and gasket (H) from the injection module. 7. Aligning the flat edge of a new cover gasket (2) with the backplate molded tab, install a gasket (2), chrome cover (1) and second gasket, in order, on the air cleaner back- plate. 8. Install the breather bolts through the air cleaner backplate. Re-install O-ring seals onto each breather bolt. Install a washer (3) from the kit on each breather bolt. Apply Loctite 243 to the breather bolts and align holes in the backplate with the holes in the cylinder heads and install the breather bolts. Use a 7/16 inch deepwell socket and alternately tighten the breather bolts to 120-144 in-lbs (13.6-16.3 Nm) . 9. Slide gasket over the sleeve on the inboard side of filter element. 10. Install breather tubes about 1/4 inch (6.4 mm) into holes on inboard side of filter element. 11. Install breather tubes onto fittings of two cylinder head breather bolts. NOTE Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into atmosphere in violation of legal emissions standards. 12. Place the filter element onto backplate, with the flat side down, so that the hole on the inboard side of element fits over the molded boss in the backplate. 13. Align holes in cover bracket with those in filter element and start three screws. Stamp on cover bracket points downwards. Use a T27 TORX drive head, alternately tighten screws to 20-40 in-lbs (2.3-4.5 Nm) . 14. Make sure that the rubber seal is proper seated around perimeter of air cleaner cover and place cover on back- plate. 15. Fit the air cleaner cover onto backplate. Apply Loctite 243 to the threads of air cleaner cover screw. Install screw through cover and tighten to 36-60 in-lbs (4.1-6.8 Nm)

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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HARLEY DAVIDSON VRSC FUEL TANK SIDE COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Note the left and right areas on frame where the covers will be installed. Using a 50/50 mixture of isopropyl alcohol and water, thoroughly clean the frame tubes surrounding the fuel cell on the left and right sides. Let dry completely. 2. Unlock and open seat. NOTE Loosening the ignition/light switch screw (in the following step) will allow much easier alignment of the ignition/light switch cover and ignition/light switch during installation. 3. See Figure 1. At area inside of frame rail just above the ignition/light switch housing, loosen the ignition/light switch screw just enough to allow the ignition/switch switch to move slightly from side to side and up and down. Do not completely remove screw 4. See Figure 4. Obtain the right side cover bracket (ignition/light switch side) from kit. 5. Remove the strips protecting the adhesive at all of the raised sections on the cover. 1 2 is 02045 1. Ignition/Light Switch Screw 2. Ignition/Light Switch Figure 1. Loosen Ignition Switch Assembly 6. See Figure 2. Carefully align the right side cover between the three frame tubes. Beginning with the left portion of the cover, press the cover between the upper and lower frame tubes until the raised portions of cover (with adhesive) begin to snap into place. While carefully aligning the right portion of the cover, move the ignition/light switch as necessary until centered within hole in cover, then firmly press into place. Adjust ignition/light switch until the switch is centered within cover. Make sure all raised locations (with adhesive) are firmly contacting the upper and lower frame tubes and that cushion rests against front vertical frame tube. 7. See Figure 1. Tighten the ignition switch screw to 6-10 Nm (53-88 in-lbs ) . NOTE The right side (ignition/light) switch cover surface can be damaged by the key fob (from vibration) when the key is in the ignition and the bike is running. You can either remove the key fob so it does not damage the cover surface, or you can install the plastic clear sheet (included in kit) onto the side cover for protection. 8. If desired, perform the following to install the plastic clear cover onto the ignition/light switch cover. a. Obtain the plastic (rhino) sheet and hold up to the switch cover to determine proper orientation and spacing. b. Carefully peel the adhesive backing from the plastic sheet and position onto the cover. Use a wet sponge, and working out from the center, rub out any bubbles or overlapped areas under the sheet. Allow to dry completely.

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