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Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

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

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Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

2000-2010 KTM X2 SWITCH WIRING HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 25-01-2012

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The included 3600-SWHA switch harness is intended for use with offroad models that do not come with a Hi/Low beam switch from the factory. The harness is compatable with stock AC lighting electrical systems as well as high output DC electrical systems. 1. Remove the stock numberplate or headlight. Remove the stock kill switch from handlebars and replace with the 3600-SWHA switch. 2. Remove the gas tank. Route the white and black leads from the 3600-SWHA under the tank following the wires from the stock kill switch. Disconnect the stock kill switch bullet and connect the white wire of the 3600-SWHA to the wiring harness. Disconnect the stock kill switch ring terminal and connect the ring terminal of the 3600-SWHA. Fully remove the stock kill switch. Be sure all the wires are safe from being burned or pinched and re-install the gas tank. 3. Disconnect the two female spade terminals from the stock headlight switch (if present). Connect the terminal with the yellow wire to the red power lead from the switch. Connect the white wire to the blue accessory output from the switch. Be sure the clear silicone sleeves are covering the stock plastic housings. 4. Connect the X2 headlight to the switch headlight plug. Note: The stock headlight plug will not be used for the X2 installation, but is still functional for connecting the stock headlight. The stock plug will turn on and off with the new headlight switch, and will be powered in either of the Low or High Beam positions

Yamaha FZ-1 TiForce exhaust system Installation Instructions (Slip-on)

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Filed Under (Yamaha) by admin on 03-01-2012

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Loosen the clamp where the stock tailpipe connects to the stock collector. 2. Remove the bolt holding the stock muffler assembly to the footpeg/exhaust bracket. 3. Remove the stock tailpipe and exhaust assembly as one piece. 4. Remove the nut securing the right side center stand support bolt. Install the new supplied bracket as shown in (See figure 1) 5. Remove the right rear footpeg assembly complete, bolt the new footpeg mounting bracket in place of the stock one using supplied bolts. 6. Carefully unbolt the footpeg from the bracket (Be careful there are springs and washers that will fall out if you are not careful), bolt the footpeg into the new billet footpeg bracket. Bolt the footpeg bracket to the footpeg- mounting bracket. (See figure 2) 7. Remove the stock exhaust gasket from the stock tailpipe and installthe gasket into the new tailpipe. 8. Slide the supplied clamp over the new tailpipe and slide the new tailpipe onto the stock collector. 9. Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stayarm / hanger G to the end can using the supplied 6mm hardware H. See figure 4. 10. Place the bands approximately 150mm from the edge of the end can. See figure 5. 11. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 12. Attach the supplied springs to connect the tailpipe and muffler assembly. 13. Make sure the exhaust system is free and clear, if necessary jigglethe system to adjust for proper clearance. 14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (figure 5), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure thatthe rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 15. Tighten the supplied clamp to secure the new tailpipe to the factory collector. 16. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 17. Check that all hardware is tightened, then start the motor and check for exhaust leaks.

Steering Stem Nut Installation Instructions & Owners Manual

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Filed Under (Tips and Review) by admin on 26-11-2010

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Sport Bike Damper Kit Installation Instructions DISCLAIMER: All GPR Sport Bike damper kits are manufactured to be used ONLY w/ the stock top triple clamp and frame. If either is modded, aftermarket or crash damaged, the kit will not install properly and GPR will not be held responsible for the consequences of improper installation due to this or any other improper mounting or modifying. The provided instructions must be followed precisely, as failure to do so can result in the GPR damper kit being installed incorrectly. An improper installation may lead to a variety of undesirable steering problems. Please take your time and carefully follow the installation instructions. As always, give us a call if you have any questions, we’re more than happy to assist you in getting the damper kit mounted on your bike properly 1. Remove the stock Steering Stem Nut (SSN) and washer from the stock top triple clamp steering stem. Carefully set the stock nut aside, as you may be using it later. Bikes requiring a specific GPR SSN to replace the stock SSN are listed at the end of this installation sheet. If your bike is on the chart, throw you stock SSN in the toolbox along w/ the washer, as you may need it at a later date if for any reason you need to remove the GPR kit from your bike. Stock SSN’s that are either ‘domed’ at the top or ‘flanged’ at the bottom will definitely NOT work, may lead to problems and should NOT be reinstalled during the baseplate installation. See #2 below for further instructions about both SSN/Steering stem and arm clearance issues 2. With the stock SSN and washer removed, place the GPR Baseplate over the steering stem on the top triple clamp and reinstall either the stock SSN or the GPR SSN provided. Torque SSN down to the recommended specs as per the owner’s manual for your particular bikes make and model. NEVER reinstall the stock washer that came on the bike! The baseplate is now your new washer. If you do accidentally use the stock washer, the arm on the stabilizer will most likely ‘rub’ on the nut. It will be too high, potentially locking the steering and handlebars, thus making your bike un steerable and unridable. DO NOT ride your bike until all installation steps have been completed and you can visually verify that there is clearance between the arm of the stabilizer and the steering stem and/or SSN. Once the installation is complete, at the #1 setting you

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Honda VTX1800F Left/ Right Floor Board Assembly Installation Manual

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Filed Under (Honda) by admin on 14-11-2010

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1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

HARLEY DAVIDSON RONT & REAR HEADPIPE AND HEATSHIELDS INSTALLATION

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Filed Under (Harley Davidson) by admin on 10-11-2010

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1. Remove both left and right saddlebags and set them aside. 2. Remove the right side floorboard from the frame and set aside. 3. Unplug the O 2 sensors on front and rear headpipes from motorcycle wire harnesses. 4. Remove the stock exhaust system. It may be necessary to lubricate the slip joints of the exhaust with WD-40 or similar lubricant to aid in disassembly. The stock muffler slide hangers may be left in place in the rubber mounts for later reinstallation of the mufflers. 5. Remove the stock rear headpipe support-mounting bracket by removing the two starter mounting bolts, this bracket will not be reused. Note: Use caution when removing the bolts so that any tools used do not come in contact with the positive post on the starter. Install the Cobra supplied, exhaust support-mounting bracket, see Figure 1. 6. Remove the stock exhaust flanges, retaining rings and O 2 sensors from the stock headpipes and headpipe support clamp from the front headpipe. Remove the new front headpipe from packaging and install the stock flange, retaining rings and O 2 sensor on to the pipe. 7. On the front headpipe slide the stock headpipe support clamp over it. Install the front headpipe on the motorcycle using the stock flange nuts to secure it to the exhaust port studs, but do not tighten at this time. Slide the headpipe support clamp forward on the headpipe and over the stock exhaust mount on the right side engine case, make sure the clamp’s rectangular hole is on top and the flat part of the clamp is downward, see Figure 2. Install the carriage bolt and nut to secure the tube clamp but do not tighten at this time. 8. Reinstall the muffler onto the front headpipe using one muffler slip clamp. Reinsert two stock 5/16- inch bolts into rear muffler mount, tighten to factory torque specs, do not tighten front muffler slip clamp at this time. (NOTE: On some models equipped with saddlebags the bag rail may need to be adjusted outward to allow proper clearance between muffler body and swing arm / axle nut.) 9. Tighten front headpipe flange nuts then headpipe support clamp to factory torque specifications. 10. Remove front heatshield and hose clamps from packaging. Unscrew the hose clamps and feed the tail end of the clamps through the clips on the inside of the heatshield from the bottom, so the screws are facing toward the bottom and accessible with a screw driver once the heatshield is installed. Install the heatshield over the front headpipe. (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes.) Align heatshield with headpipe and snug clamps but do not tighten .

Honda VTX1800C/ J Left/ Ringht Floor Board Assembly Instruction Manual

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Filed Under (Honda) by admin on 14-11-2010

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Left Side 1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

HONDA SHADOW ACE TOURER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Honda) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the pinch clamp bolt on the left hand muffler crossover pipe. (Located on the right of the motorcycle, where both mufflers merge with the head pipes). 2. Remove the two 8mm bolts that mount the left hand muffler to the frame. Drop the muffler down to clear the mounts and pull out from the collector. 3. Remove the right hand frame cover to avoid damaging it. 4. Remove the 8mm nut holding the head pipe flanges to the cylinder heads. Remove the 8mm bolts that mount the right hand muffler to the frame. 5. Remove the remainder of the exhaust system from the motorcycle and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Be sure to check that the stock exhaust gaskets are in good shape. If you have any doubts as to their condition, replace them. 2. Install the chrome exhaust flanges (supplied) over the front and rear head pipes. 3. Install the rear head pipe to the rear cylinder using the stock 8mm acorn nuts. Route the pipe approximately 3/4″ beneath the swingarm, leaving the nuts finger tight at this time. 4. Install the front head pipe to the cylinder head using the stock 8mm acorn nuts. Its routing follows the stock head pipe, leave the nuts finger tight at this time. 5. Your Vance & Hines mufflers use the stock mounting locations and rubber grommets. Remove the steel spacers and rubber grommets from your stock mufflers and install them into Vance & Hines mufflers in the same locations. 6. Slip a chrome muffler clamp onto the inlet end of each muffler. Install the clamp hardware as shown in figure 1 (hardware supplied). Leave them loose at this time. 7 Slide the left hand muffler assembly (stamped H641) onto the rear head pipe approximately two inches. Mount the mufflers to the motorcycle using the stock bolts, in the stock locations. 8. Repeat the above step with the right hand muffler (stamped H640). 9. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edges of the heat shields with the location of the mounting clips that are welded to the back side of the heat shield. Position the right rear heat shield (stamped H226) over the rear head pipe and feed the tail end of the hose clamps into the clips. Be sure that each clamp is engaged into both clips. Repeat this procedure with each heat shield.

HARLEY-DAVIDSON SOFTAIL MODELS STEALTH AIR SHOCK MOUNTING

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Filed Under (Harley Davidson) by admin on 16-12-2010

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INSTALLATION 1. Remove the seat, inner fender, and ignition coil cover. Removing the rear wheel assembly is recommended for ease of installation, but not absolutely necessary. Remove the nut cup and outer grommet on each of the Works shocks. If you intend to leave the ride height at stock height for road riding, position the inner nut cup SHOC KS SHOC KS WORKS PERFORMANCE PRODUCTS, INC. 21045 Osborne St., Canoga Park, CA 91304 818.701.1010 fax 818.701.9043 STEALTH AIR SHOCK MOUNTING FOR HARLEY-DAVIDSON SOFTAIL MODELS 2000-ON #HDAIR-00 – 02/15/2006 WARNING! THESE SHOCKS MUST ONLY BE USED WITH STOCK SWINGARMS AND ON STOCK FRAMES WITH THE STOCK BOTTOMING BUMPERS ON THE CHASSIS TO LIMIT THE TRAVEL OF THE SHOCKS. AFTERMARKET SWINGARMS, OR MODIFIED SWINGARMS THAT DO NOT HAVE THE UPPER BRACE THAT ACTS AGAINST THE BOTTOMING BUMPERS CANNOT BE USED WITH THESE SHOCKS. INCREASING THE TRAVEL BY ELIMINATING THE BUMP STOPS OR A NON-STANDARD SWINGARM DESIGN WILL ALLOW THE TIRE TO MAKE CONTACT WITH THE FENDER OR OTHER CHASSIS COMPONENTS, AND CAN DAMAGE THE SHOCKS. 19. Lock Washers 20. Long Bolts (2) 21. Short Bolts (2) 13. Din Plug Screw 14. Din Plug Gasket 15. Cap 16. Eye Spacers (4) 17. Cotter Pins (2) 18. Switch Bracket 7. Compressor Bracket 8. Harness 9. Fuse Block 10. Din Connector 11. Solenoid 12. Hose 1. Damper Shock 2. Air Spring Shock 3. Nut Cup 4. Grommet 5. Hose 6. Compressor 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 14 18 19 20 21 Fig. 1–Nomenclature on the damper shock up against the ring nut. The shocks are now ready to install. 2. Place the motorcycle on a suitable frame stand allowing unrestricted access to the shocks. 3. Place a small screw jack under the swing arm to support the weight as well as allow you to position the swing arm correctly to line up the shock mounting bolts. Remove stock shocks. 4. Install the left side (damping) shock with the stock mounting bolt. Make sure that the bolt threads and threaded portions of the frame are free of oil and grease. Grease the shoulders of the bolts and use thread lock compounds on the threads. Discard the stock shock washers on both shocks. Do not use any washers- -including the stock washers on these bolts. Use only the spacers included. The 3/16-inch wide spacers are used on each side of the shock eye. Do not “double-up” the spacers together on either side of the shock eye, as this will cause misalignment of the shocks which can lead to premature wear or damage to the shocks. 5. Put the supplied spacers on each side of the eye. The shoulder of the bolt must protrude a small amount through the shock eyes in order to allow the shock to pivot freely. This is extremely important. With the shocks fully tightened, the spacers should be free to rotate with finger pressure. If the washer is used or a non-stock bolt is used, the bolts will work loose or break because the shocks are in a bind.

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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