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HARLEY DAVIDSON BRAIDED OIL HOSES INSTALLATION MANUAL

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

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery negative cable. 2. Drain engine oil according to Service Manual instructions. 3. Removing the rear exhaust pipe may aid in giving access to the oil lines and fittings. If necessary, remove the rear exhaust pipe according to Service Manual instructions. 4. See Figure 5 and Figure 1 for description and location of the three oil hoses that are replaced with the braided hoses in this kit. Remove the original equipment oil feed, return and vent lines. 5. See Figure 2. Remove and discard the original hex threaded quick disconnect fittings (1), (2) and (3) at the engine for each of the hoses removed in Step 4. To remove the fittings, turn the hex in a counterclockwise direction until free. 6. See Figure 5. Install the threaded adapter from the kit onto the corresponding oil line. The adapters for the return and vent lines are the same size. The adapter for the feed line is larger in size. Coat the male threads of the adapters with Loctite 565 thread sealant. NOTE Be sure to install hoses on the correct fittings. If you mix up the hoses, you will change the direction of the engine oil flow, causing severe engine damage. 2 3 1 is04165 1. Oil Return Hose 2. Oil Feed Hose 3. Oil Vent Hose Figure 1. Installed Oil Hoses

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HONDA GL18000 DRIVER BOARDS REPLACEMENT RUBBER PADS INSTALLATION INSTRUCTIONS

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

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1. Remove any loose pads, remove any remaining rubber & glue using a blade screwdriver or razor blade. 2. Rough up the chrome surface with sand paper or by scratching with the tip of a screw driver. 3. Clean any remaining glue residue off using acetone solvent or nail polish remover. 4. Clean both the floorboards and the back side of the rubber pad with rubbing alcohol. 5. Using the supplied small brush and tube of 3M weather strip adhesive, apply a thin layer of glue to both the floorboard and the backside of the rubber pad or pads. Allow to dry for 10-15 minutes or until tacky to the touch. Apply a second thin coat to both surfaces and while still wet press the rubber firmly into place and keep pressure applied evenly for 45-60 seconds

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YAMAHA PRO-R AIR CLEANER REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 07-01-2012

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STEP 1 Remove the seat, fuel tank, and OEM air cleaner assembly. Disconnect the hoses connected to the air cleaner while leaving them connected to the motorcycle. Save the clamp that secures the air duct to the carburetor and the OEM fasteners used to secure the stock air cleaner assembly to the motorcycle as some will be reused. STEP 2 Remove the carburetor according to the section in your Road Star factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. Now is a good time to proceed with re-jetting the carburetor. We have supplied jets to cover many common configurations. For jet locations and jetting recommendations with various exhaust combinations see Addendum I. Since the OEM screws retaining the float bowl are easily damaged, we have included replacement M4 socket head cap screws to replace them, if necessary. STEP 3 Insert the rubber intake duct into the main support bracket as shown in PIC. 1. The rubber nipple should be pointing toward the longest leg of the bracket. STEP 4 Insert the rubber intake duct into the Pro R-series Hypercharger in the same fashion it was installed in the main support bracket. See PIC.2. You may need to use a screwdriver to help “poke” the flange of the Rubber Intake Boot into position inside the Pro R-series Hypercharger. STEP 5 Line up the three holes in the back plate of the Pro R-series Hypercharger and the three holes in the flange of the rubber intake duct with the three holes in the main support bracket. Insert the three supplied 1/4″-20 x 5/8″ socket head cap screws from inside the Pro R-series Hypercharger and secure on the back side of the main support bracket with the 1/4″-20 thin nylock nuts. You will need to pull back the inner flange of the rubber intake duct to access the holes. Hold the nylock nuts with a 7/16″ wrench as you tighten the socket head cap screws with a 3/16″ hex key. Be careful not to over tighten and cause the rubber intake duct to pucker around the nylock nuts. See PIC.3.

Installation Instructions S&S Billet Air Cleaner Kit for Victory Motorcycles

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Filed Under (S&S) by admin on 29-10-2010

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory motorcycle following your Victory service manual for the specifi c model you are performing the work on. Picture 1 WARNING 3 Key Switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. Picture 2 illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. Picture 3 points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and Throttle Position Sensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. Picture 4 points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. Picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. Picture 4 points out the IAC rear delivery hose

Victory Motorcycles Lloydz Motorworkz Billet Air Cleaner Kit Installation Instructions

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

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory® motorcycle following your Victory service manual for the specific model you are performing the work on. Key switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. picture 2 below illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. picture 3 below points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and throttle position s ensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. picture 4 next page points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. picture 4 points out the IAC rear delivery hose

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

2006 Kawasaki Ninja 650R DOT Racer Front Brake Hose Kit INSTALLATION INSTRUCTIONS

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

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1. Remove factory brake hoses, noting routing. Cap off master cylinder and caliper ports. 2. Install straight-bent banjo ends of Russell Left and Right hoses onto their respective calipers. Use factory single-banjo bolt from master cylinder to install Right hose onto caliper (See Fig. 1) . 3. Route hoses up through factory wire retainers to master cylinder (See Fig. 2, view from top). Use factory double-banjo bolt to install hoses onto master cylinder. Side-bent banjo of Right hose goes next to master cylinder, points toward center of bike, and rests against stop. Orient Left hose banjo so that hose runs parallel to Right hose (See Fig. 3) . 4. Locate hoses to fender using factory plastic clips around grommets on hoses at factory mounting points (See Fig. 4, Right side shown). 5. Check hose clearance throughout entire steering and suspension travel range. 6. Bleed the system and check for leaks while applying pressure

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

kawasakI 9400 hyPercharger kIt INSTALLATION MANUAL

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

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steP 1 Remove the seat. steP 2 Remove the bottom of the three dash plaque bolts (8mm). steP 3 Lift up on the dash panel and unscrew the speedometer cable (knurled nut). steP 4 Unplug the three electrical connections. steP 5 With a 12mm socket, remove the tank-mounting bolt under the dash and at the rear of the tank. steP 6 Close the fuel valve and clamp off the fuel line. Disconnect the line from the fuel valve. steP 7 Raise the rear of the tank, and disconnect the two vent hoses, and remove the tank. steP 8 Refer to the section of your factory service manual that deals with removal and installation of the following components. • Remove the two round chrome “air cleaner covers”, their backing plates, the stock black plastic air box (air inlet under tank), and the crossover tube. • Remove the intake manifold to remove and crossover tube. Use extreme care when replacing the intake manifold. Uneven torque, damage to the intake gaskets, or contamination can cause an intake leak that will result in very poor running, and nearly impossible jetting!! • Unplug all hoses or lines from these components. You may want to label these hoses at this time. The Largest of these hoses (3/4″ I.D.) is for the fresh air injection system; the second largest (3/8″ I.D.) is the crankcase breather. The smallest of the hoses is a drain. steP 9 Remove the brackets that held each round backing plate. The right hand bracket is also a carb stabilizer. This function is duplicated with one of the included brackets. steP 10 Remove the carburetor according to the section in your factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. We recommend that you label each hose or fitting as they are removed to make reassembly easier. An example of hose labeling is shown in PIC. 1. carburetor re-jettIng Procedure note Different combinations of aftermarket exhaust and air cleaners will have a significant impact on carburetor jetting. The supplied jetting components have been tested and found to be a good combination to produce drivability and performance with stock or free flowing, muffled/baffled exhaust pipes. We highly recommend NOT using drag pipes (open style). Using drag pipes in conjunction with our air cleaner will require additional jetting above and beyond the components included in this kit. a) Consult your factory service manual for details of this procedure. We have supplied jets to cover many common configurations. Remove the four Phillips head screws securing the plastic carb top to the carb body. Carefully remove the plastic carb top making sure not to damage the rubber diaphragm.

Air Shock Installation Instructions

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

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

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