removing the baffles out of a 2012 wide glide 103 cubic inch motor

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HARLEY DAVIDSON SOFTAIL SADDLEBAG KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION Do not exceed saddlebag weight capacity. Put equal weight in each bag. Too much weight in saddlebags can cause loss of control, which could result in death or serious injury. (00383a) NOTES Maximum saddlebag weight capacity is 7 lbs (3.18 kg) for each bag. Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. 2000-2002 Models with Wide Tire Kit 1. See Figure 1. Remove and discard stock screws (1) and washers (2) from fender support. Button head screws from wide tire kit must be installed with button heads on inside of fender. Fastener contact with tire can lead to premature tire failure, which could result in death or serious injury. (00417b) 2. See Table 3. Determine appropriate screw from wide tire kit. 3. See Figure 2. Install saddlebag using screw (from wide tire kit) (1), washer (2) and nut (3). The screws are installed from inside to outside of fender. NOTE If you do not have the appropriate screw from the wide tire kit, it can be purchased from a Harley-Davidson dealer. Table 3. Wide Tire Kit Screws (3/8-16) Wide Tire Kit 44490-00, Hardware Kit 43763-00 Wide Tire Kit 44490-00, Hardware Kit 43761-00 Part Number and Length X X 4030 – 2-1/2 inch X X 4225 – 3-1/2 inch X X 4224 – 1-1/2 inch X X 4044 – 1-1/4 inch X 4215 – 2 inch X 3912 – 2-3/4 inch X X 4228 – 2-1/4 inch X X 4229 – 3-1/4 inch Failure to tighten saddlebag mounting bolts to specified torque could result in damage to saddlebags. (00406c) 4. Tighten all saddlebag hardware to 22 ft-lbs (30 Nm). NOTE Check that front screws have at least one thread exposed beyond the nut after proper torque has been applied. 5. Install reflectors on saddlebag. Refer to Install Reflectors subtopic.

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Commonwealth of Massachusetts Registry of Motor Vehicles Motorcycle Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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DEFINITIONS MOTORCYCLE Any motor vehicle having a seat or saddle for the rider that is designed to travel with no more than three wheels contacting the ground, including any bicycle with a motor or driving wheels attached. MOTORIZED BICYCLE A pedal bicycle which has a helper motor, or a non-pedal bicycle which has a motor, with a cylinder capacity not exceeding fifty (50) cubic centimeters, an automatic transmission, and which is capable of a maximum speed of no more than thirty (30) miles per hour (mph) . OPERATION OF MOTORIZED BICYCLES Under Massachusetts law, mopeds fall into the category of “motorized bicycles”(with or without pedals) and are therefore regulated by the Registrar of Motor Vehicles. Individuals must have a valid learner’s permit or driver’s license to operate a motorized bicycle or moped. Mopeds must have automatic transmissions and cylinder capacities of no more than 50 cubic centimeters. In addition, mopeds must meet all federal motor vehicle safety standards and have maximum speeds of no more than 30 mph. The following limitations apply:  Individuals may not operate at speeds greater than 25 mph;  Individuals may not operate on state highways or limited- access roads with signs prohibiting bicycles;  Individuals may not operate on off-street recreational paths;  Individuals may use bicycle lanes along roadways;  Individuals must use the proper hand signals before stopping or turning;  Individuals and their passengers must wear United States Department of Transportation (US DOT) approved helmets when operating;  Individuals may not carry passengers while operating on a permit.

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1995 Camry WIPER MOTOR CIRCUIT BREAKER INSPECTION PROCEDURE

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Filed Under (Toyota Manuals) by admin on 15-10-2011

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INSPECTION PROCEDURE: Inspect the Wiper Fuse. Verify there is power and ground to the Wiper Motor on all speeds (including “Intermittent” or “Mist” if applicable). After verifying power and ground to the Wiper Motor, follow the procedure below to prevent unnecessary Wiper Motor replacement because of a temporary open in the Wiper Motor Circuit Breaker. 1) Disconnect the Wiper Motor Harness Connector. 2) Wait (10) minutes before checking continuity. 3) Check the continuity of the motor with an ohmmeter. REPRESENTATIVE CHECKING PROCEDURE: NOTE: Continuity check can be performed between either the low speed or high speed terminal and the ground terminal of the wiper motor. The standard resistance of a good wiper motor is approximately 1.5 to 4.5 ohm

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Harley-Davidson Camshaft TC, EVO, Shovelhead, XL EVO, Iron Head, XR Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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EVO Black Widow PP8833-2 – 29 55 62 25 264 267 54 103 109 105.8 0.600 0.602 EVO Black Widow PP8826-2 – 27 61 63 29 268 272 56 107 107 107.0 0.602 0.602 EVO Black Widow PP8817-2 – 254 254 0.590 0.590 EVO Carl’s Speed Shop CM4 – 28 44 52 20 252 252 48 98 106 102.0 0.495 0.495 EVO Carl’s Speed Shop CM495F Y 19 47 50 16 246 246 35 104 107 105.5 0.495 0.495 0.179 0.168 EVO Carl’s Speed Shop CM580 – 19 47 50 16 246 246 35 104 107 105.5 0.580 0.580 0.194 0.163 EVO Carl’s Speed Shop CM612 – 36 60 68 28 276 276 64 102 110 106.0 0.612 0.612 0.277 0.235 88 EVO Carl’s Speed Shop CM660 – 38 62 68 28 280 276 66 102 110 106.0 0.660 0.660 0.314 0.277 90 EVO Carl’s Speed Shop CM774 – 284 284 0.784 0.784 0.277 0.236 EVO Carl’s Speed Shop CM780F – 34 70 74 30 284 284 64 108 112 110.0 0.774 0.774 103 EVO Crane EVR0020 – 31 64.5 77 23 275 280 54 107 117 112.0 0.608 0.589 88 EVO Crane Fireball 2000 Y -12 22 20 -10 190 190 -22 107 105 106.0 0.490 0.490 0.026 0.032 EVO Crane Fireball 300 Y 12 34 41 15 226 236 27 101 103 102.0 0.490 0.490 4000 EVO Crane Fireball 310 Y 16 40 43 19 236 242 35 102 102 102.0 0.490 0.490 1500 4500 75 EVO Crane Fireball 316 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane Fireball 326 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H286 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane H290 – 17 43 45 23 240 248 40 103 101 102.0 0.581 0.581 1800 5200 EVO Crane H296 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H304 – 24 50 55 25 254 260 49 103 105 104.0 0.600 0.600 2500 5800 EVO Crane H306 – 28 54 69 23 262 272 51 103 113 108.0 0.500 0.510 0.224 0.195 3000 6000 EVO Crane H310 – 23 63 68 28 266 276 51 110 110 110.0 0.550 0.550 0.229 0.229 3000 6500 88 EVO Crane H314 – 26 54 65 21 260 266 47 104 112 108.0 0.600 0.600 2800 6000 EVO Crane HEV0042 – 27 59 71 23 266 274 50 106 114 110.0 0.600 0.576 0.226 0.194 3000 6000 100 116 EVO Crane HEV0067 – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 0.128 0.113 EVO Crane HEV0098 – 36 62 72 34 278 286 70 103 109 106.0 0.650 0.650 0.171 0.156 96 EVO CycleRama CR-E550 – 24 52 53 23 256 256 47 104 105 104.5 0.550 0.530 EVO CycleRama CR-E581 – 22 46 53 23 248 256 45 102 105 103.5 0.581 0.550 EVO CycleRama CR-E600A – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 EVO CycleRama CR-E600B – 23 51 54 22 254 256 45 104 106 105.0 0.600 0.550 EVO CycleRama CR-E617 – 22 50 50 22 252 252 44 104 104 104.0 0.617 0.617 EVO CycleRama CR-E630 – 18 60 63 13 258 256 31 111 115 113.0 0.630 0.630 EVO CycleRama CR-E660 – 27 59 71 23 266 274 50 106 114 110.0 0.660 0.660 3500 6500 140 EVO Dave Mackie DM500 Y 22 38 52 12 240 244 34 98 110 104.0 0.500 0.500 0.189 0.138 EVO Dave Mackie DM500X Y 25 40 55 20 245 255 45 98 108 102.5 0.500 0.500 0.208 0.178 EVO Dave Mackie DM530 – 28 42 55 15 250 250 43 97 110 103.5 0.530 0.530 0.221 0.141 EVO Dave Mackie DM580 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 113 EVO Dave Mackie DM581 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 EVO Dave Mackie DM595 – 21 49 57 14 250 251 35 104 112 107.8 0.595 0.595 0.192 0.150 EVO Dave Mackie DM635 – 20 56 59 18 256 257 38 108 111 109.3 0.635 0.635 0.194 0.176 EVO Edlebrock 1740 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 0.176 0.203 EVO Edlebrock 1741 – 20 46 52 22 246 254 42 103 105 104.0 0.600 0.600 0.183 0.187 EVO Head Quarters HQ-23 – 19 47 52 24 246 256 43 104 104 104.0 0.600 0.530 EVO Head Quarters HQ-24 Y 20 36 52 19 236 251 39 98 107 102.3 0.500 0.500 EVO Head Quarters HQ-25 – 18 38 42 14 236 236 32 100 104 102.0 0.550 0.550 EVO Head Quarters HQ-26 – 20 54 53 22 254 255 42 107 106 106.3 0.600 0.530 89 EVO Head Quarters HQ-27 – 26 60 70 24 266 274 50 107 113 110.0 0.650 0.575

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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TRIUMPH ROCKET III TIP OVER BARS INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-12-2010

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1. Starting on the right side (towards the front of the motor) locate the three mounting bolts that secure the brake assembly bracket (a chrome tube) to the bottom of the motor. Remove the bottom and front bolts. Repeat for left side. 2. Locate the front motor mount bolt. This is the black bolt located at the very front of the engine about halfway down behind the radiator. Remove the nut from this bolt on the left side. Properly secure the bike and use a jack to lift up on the motor to release the pressure from the motor mount bolt. Remove the bolt. 3. On the right side place the motor mount bolt thru the upper mounting hole of the right tip over bar. Install the tip over bar by feeding the motor mount bolt thru the original hole and inserting the two bolts (supplied) into the bottom mounting holes. (Do not tighten yet.) 4. On the left side install the top of the left tip over bar by inserting it into the right side tip over bar. Align the tip over bar so that the motor mount bolt extends thru the upper mounting hole. Thread the original locking nut onto the motor mount bolt a couple of turns. Now align the bottom of the tip over bar and install the remaining two bolts (supplied). Tighten the motor mount bolt (torque to 28-32 ft/lbs) and the lower four bolts (torque to 14-18 ft/lbs) securely. 5. Re-check all hardware for tightness

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HARLEY DAVIDSON TIMKEN BEARING CONVERSION TOOL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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2-ton press (must be square to within .010″, ram to table) Inch-lb torque wrench Foot-lb torque wrench T15 TORX® drive socket (for inch-lb torque wrench) 5/32 inch hex drive socket (for inch-lb torque wrench) 5/16 inch hex drive socket (for foot-lb torque wrench) 5/64 inch hex key wrench 1/16 inch hex key wrench 3/8 inch drive hand drill small tap handle (suitable for #8-32 tap) Tapping Fluid Press Fit Lube (non-drip) Loctite® 620 threadlocker and sealant The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 21 and Table 3. If replacement parts are needed contact JIMS® at 805-482- 6913 or INSTALLATION 1. Remove and disassemble the engine as necessary to remove the left side engine case. Bearings and seals must be removed from the left case. Refer to the service manual for the disassembly procedures. 2. Use an appropriate solvent to clean the left engine case. Also clean the bearing sleeve (1) supplied in the kit. 3. Apply Loctite 620 to the smaller inside diameter portion of the left case bearing bore. 4. See Figure 1. Apply Loctite 620 using a cotton swab to the smaller portion of the outside diameter (2) surface of the bearing sleeve (1). 5. Apply a spare amount of non-drip press fit lube (3) to the larger outside diameter of the bearing sleeve. 6. See Figure 2. Fit the bottom locater plate (1) to the to the outside of the case over the bearing bore. The word “BOTTOM” will be at the bottom of the case when installed at the 6 o’clock position

HARLEY DAVIDSON FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION Removing Outer Fairing 1. Standing at the front of the vehicle, use a T-27 TORX® drive head to remove the three outer fairing screws (with flat washers) just below the windshield. 2. Moving to the inner fairing side, use a T-27 TORX drive head to remove the two fairing screws just above the wind deflectors on the left and right side. 3. Turn the handlebar to the right and remove the outer fairing screw (reach in below the fairing cap). Turn the handlebar to the left and remove the fairing screw on the opposite side. 4. Tilting the outer fairing toward the front, squeeze the two external tabs to remove the wire connector at the back of the headlamp assembly. 5. Lift the fairing (with headlamp assembly) off the motor- cycle. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 6. Remove the Windshield. Installing Mirrors 1. See Figure 1. Place template on inside of fairing as shown to locate mounting holes for mirror. 2. Begin by drilling a 1/8 inch pilot hole at each location marked on the template. For the center hole (2) where the 3/8 inch threaded stud passes through the fairing use a 13/32 inch diameter twist drill to drill the hole to its final size. For the alignment hole (1), use a 7/32 inch diameter twist drill to drill the hole to the final size. 2 1 is 02115 1.7/32 inch hole location 2.13/32 inch hole location Figure 1. Positioning Template 1 is06315 1. Auxiliary mirror Figure 2. Orientation of Auxiliary Mirror NOTE The flange nut is a self locking nut and must not be tightened more than 30 in-lbs (3.4 Nm). 3. See Figure 3. Place mirror (2) in position and install backing plate (4) with the raised post (B) (with the L and R marking) toward the nut surface. Install the flange nut (6) and tighten nut to 20-30 in-lbs (2.3-3.4 Nm). 4. See Figure 2. Position the mirror so the round auxiliary mirror is in the upper inside corner position. 5. Repeat for right side

YAMAHA YFM 350 Removing stock carburetor and cables.

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Filed Under (Yamaha) by admin on 19-01-2012

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Remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Preparing motor for carburetor install 1. Remove stock manifold from cylinder head. 2. Place supplied o’ring into aluminum flange as pictured in figure 1. Figure 1. 3. Install aluminum and rubber flange to motor using supplied bolts. See Figure 2. The shorter 25mm bolt will need to be placed in the bottom hole. IMPORTANT NOTE: Install the aluminum flange with the o’ring towards the motor and the thick side up.

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