set valves on 2012 suzuki boulevard m50

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Suzuki C50/ M50 Boulevard BIG AIR KIT INSTALLATION

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Filed Under (Suzuki) by admin on 13-03-2012

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1. Remove the (2) Bolts at the top of the stock air cleaner to the left and right of the oval rubber hose coming from under the fuel tank. 2. Loosen the hose clamp at the base of the oval rubber hose on the top of the air cleaner. 3. A male barb protrudes from the rear of the air cleaner that inserts into a rubber grommet mounted to the cylinders. Pull the air cleaner away from the cylinders firmly and you will feel the barb release. Now pull the upper section of the air cleaner downward to remove it from the oval snorkel tube from under the fuel tank. 4. Now you can reach to the rear of the box and unplug the electrical lead for the Air Sensor” which sits just about in the middle of the rear of the air cleaner. Now remove the breather hose at bottom of the air cleaner. 5. Set the air cleaner aside and turn it over to access the back. Remove the single bolt that secures the Air Sensor” (This sensor will be installed into the Aluminum Manifold of your new BAK assembly later) 6. Remove the lower mounting arm assembly from the cylinders. (You will not reuse this). 7. Using the (2) Dome head m6 x 15mm screws install the (2) #1 Arms to the rear (the side without the groove) of the backing plate, the shiny/chrome side of the arms should face outward. The smaller of the two holes in each arm is the one you place the screws through. Use the m6 Flange Nuts to secure the bolts at the rear of backing plate. Snug these up but do not tighten fully.

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SUZUKI MOTORCYCLES Gsxr 600, Gsxr 750, Gsxr 1000 teak the lead

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Filed Under (Suzuki) by admin on 12-11-2010

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The launch of the sixth generation of Gsxr marked a shift in Suzuki’s emphasis on two fronts. One, the Gsxr 1000 now took the upper hand in the development stakes. Historically, the Gsxr 750 led the march-arriving first, gaining the most recent technology, absorbing the lion’s share of corporate pride-but by 2003 the Gsxr 1000 was in the lead. Two, the Gsxr 1000 represents another, more subtle shift for Suzuki engineering, in which the designers-the lucky guys who get to clothe these amazing machines-have more freedom of expression. With this generation, the designs turned edgier, sharper, more aggressive looking than ever. What’s more, the Gsxr 1000 K3 would be the proving ground for a host of changes brought to the Gsxr 600 and Gsxr 750 for 2004. In fact, nearly every upgrade to the smaller bikes appeared on the Gsxr 1000 a year before. But the real impetus for driving the Gsxr 1000 to the head of development and, indeed, shortening its development cycle was competition both on the track and in the showroom. For the track, it was understood that Superbike racing would revert to allowing 1000 cc four-cylinder bikes in place of the 750s that had been the limit since 1982. In 2002, Yoshimura and Mat Mladin barely lost the AMA Superbike crown to Nicky Hayden aboard the Honda RC5!. But it would be the RC’s swan song of competitiveness with the change to 1000 cc fours. To keep speeds in check, the AMA Superbike rules would require 1000 cc fours to have some additional limitations compared to the twins and triples. For example, “Cylinder heads may be ported and machined, but altering of valve angles will not be permitted; aftermarket valves, springs, retainers, and other valve-train components will be permitted; valves must be stock size and same basic material as original equipment; aftermarket camshafts will be permitted, but earn lift and resulting valve lift must be no greater than stock. “In addition, the “stock crankshaft must be retained, The only allowable modifications are balancing, polishing of bearing surfaces and attachment of accessory drives. Homologated transmission gear sets (one optional set of ratios per approved model) will be permitted. Optional sets will be price-controlled and must be available to any legitimate AMA Superbike competitor. Homologated fuel-injection throttle-body assemblies (one optional type per approved model) and aftermarket airboxes will be permitted. Modifications to throttle bodies will not be permitted. Optional throttle bodies will be price-controlled and must be available to any legitimate AMA Superbike competitor.” The thinking was simple: keep the liter bikes from sucking through massive throttle bodies, and the horsepower might not (and, it was hoped, would not) go through the roof. In preparation for racing, Suzuki moto wanted to make a host of small changes to the Gsxr 1000, but its motivation was also to keep the bike at the forefront of open-class street bikes. Suzuki engineers knew that Honda and Kawasaki were readying all-new models-the CBR 954 RR and the ZX 9 R had long since been vanquished-and rumor had it that Yamaha was ready with yet another push with the R1.It was the right time to make alterations to the Gsxr 1000. Heading the list was, as one might expect, a revised engine.

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SUZUKI SV650 REAR SET POWERLET Installation Manual

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Filed Under (Suzuki) by admin on 15-02-2012

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STEP #1 – Remove the seat. See the Suzuki service manual. STEP #2 – Stretch out the wiring harness. Run the harness down the LEFT side of the battery cover, between the frame and the plastic water protectors/inner fender. There is a hole through which the harness may pass, visible when looking down to the left side of the battery cover, and toward the rear [B]. Insert a tie wrap, upward, though the black ring behind the silver footpeg bracket [A]. Let the wire hang down by the rearset for now. Next remove the negative battery connection, followed by the positive battery connection. Route the red lead forward toward the battery through the “notch” on the left side of the battery cover. Connect the red & black wire as follows: RED WIRE = BATTERY POSITIVE BLACK WIRE = CHASSIS GROUND Chassis bolt [D]. Tuck the fuse holder into a cavity in front of the plus terminal of the battery [C] under the battery cover. Ty-wrap the fuse-holder to the nearby wiring. STEP #3 – Apply either dielectric grease or Vaseline to the terminals. The center terminal is plus and the outer ring is negative (see dwg below). Install the fuse in the fuse holder. Connect the red wire to the positive terminal & the black wire to the negative terminal. Use a voltmeter to check if the polarity is correc

SUZUKI M50 / C50 Fuel Injected Models INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 19-02-2012

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1. Remove seat and left side covers. 2. Remove fuel tank. We highly recommend you consult the factory service manual for proper removal of fuel tank. Remove fuel tank rear mounting bracket 3. Route wiring harness under frame by fuel tank rear mounting bracket and up left side of the engine. (Fig. 1) 4. Unplug the TPS connector (black) and connect the two white 3-pin connectors in-line with the factory TPS connector. (Fig. 2) 5. Disconnect the factory connector from rear injector and connect to Fuelpak connector. (Fig. 3) 6. Connect other Fuelpak connector to injector. (Fig. 4) 7. Route black wire to battery negative connection as shown. (Fig. 5) 8. Attach Fuelpak to Fuelpak harness and mount next to battery with Velcro. (Fig. 6) 9. Follow the service manual to reinstall the fuel tank.

SUZUKI VOLUSIA 800, C50, M50 Left/ Right Saddlebag Installation Manual

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

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Your saddlebag supports will install in just a few minutes using common tools. Read all instructions carefully and completely before installing your new saddlebag supports. 1. Remove your stock fender rail bolts. 2. Install your Cobra saddlebag supports using the supplied 8mm x 65mm button head bolts (where the stock bolts were removed), the saddlebags should hang towards the rear and away from the motorcycle. 3. Torque bolts to factory specifications Cobra recommends you always wear a helmet while riding. Please never operate your motorcycle while under the influence of alcohol and/or drugs. Enjoy the new look of your motorcycle and please ride safely

SUZUKI BOULEVARD M109R Fuel Injected Models INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 16-02-2012

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1. Remove seat, right and left side covers, and fuel tank. 2. Remove airbox. We highly recommend you consult the factory service manual for proper removal of airbox. 3. Route wiring harness as shown in the picture. (Fig 1) 4. Unplug stock wiring harness from injectors and plug in the connectors from Fuelpak as shown. (Fig 2) 5. Unplug the TPS connector (grey) and attach T-tap connectors to the two outside wires. (Fig 3) 6. Route Fuelpak green wire to T-tap on the factory black wire with brown stripe. Routh the Fuelpak violet wire to T-tap on the factory pink wire with black stripe as shown (Fig 3) 7. Reattach the TPS connector. 8. Route red wire to the front of engine and down to the horn. (Fig 4) 9. Disconnect the two position connector from horn and snip connector in half so you have two one-wire connections. 10. Reattach factory grey wire to horn. Attach Fuelpak red wire to the other horn connection. Plug the factory horn orange wire to the male connection on the Fuelpak red wire. 11. Route black wire to battery negative connection as shown. (Fig 5) 12. Attach Fuelpak to Fuelpak harness and mount to bracket under the left side cover as shown. (Fig 6) 13. Before reassembling the bike, make sure handlebar switch is in the engine-not-running position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the red wire connection on the horn and that it is connected to the orange wire from the factory harness. 14. Follow the service manual to reinstall the airbox and gas tank.

1994-2003 Suzuki GSXR750 and 1997-2004 Suzuki GSXR600 Superbike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 10-01-2011

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Step 1: Identify the key components that complete our Superbike kit: You should have 2 lines (front kit), 1 double banjo bolt and 2 lower adapters. There are also a total of 7 washers. 5 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. Inspect your brake system after every race. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. (See picture S4) Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt (see picture S5) is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, straight banjo (from right line), washer, 12-degree banjo (from left line), washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. ( See picture S6) Make sure that the 90-degree fittings on each caliper are pointing away from the bike just a little bit (see pictures S7 through S9 of calipers) . Thread each banjo end into the adapter, and torque to 6 ½ Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, we recommend using a zip-tie to bring the lines together about an inch above the lower triple clamp area. (Picture S10) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with DOT 4-brake fluid is recommended.

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SUZUKI PUTS THE 'STYLE' IN LIFESTYLE WITH CUSTOM ACCESSORIES INSTALLATION

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Filed Under (Suzuki) by admin on 14-02-2012

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Suzuki Genuine Accessories are available for the all-new Equator midsize pickup truck, four-door SX4 Sport, five-door SX4 Crossover, XL7 midsize crossover and rugged Grand Vitara. The accessories can be purchased through local Suzuki dealers. Suzuki Equator  All-weather floor mats – Rubberized all-weather mats, ideal for keeping dirt, moisture and harsh debris from coming in contact with the vehicle’s carpet interior.  Bluetooth® module – The Suzuki-integrated hands-free Bluetooth phone system features a clean installation, fresh look and works with most Bluetooth-enabled mobile phones. Quality sound plays through the vehicle’s factory stereo and speakers, and the phone system automatically mutes the radio during phone calls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)  Body side moldings – Durable polyurethane molding set helps protect exterior paint from door dings and road rash.  Hood mask – Durable vinyl, custom-fit mask helps protect the front end of the vehicle from damage caused by minor road debris.  iPod® interface kit – Provides a seamless connection from an iPod to the vehicle’s radio and/or steering-wheel audio controls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)

HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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KTM OM-2 Split Body Floating Ball Valves Installation and Maintenance Instructions

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Filed Under (KTM) by admin on 26-01-2012

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Remove the valve from the shipping package (box or pallet) with care taken to avoid any damage to the valve and actuator (plus accessories where applicable). •Before installation, remove the seal discs from the flange. Clean the inside of the valve using an air line that includes an appropriate air-filter. Ensure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on the valve seat. •Confirm that the materials of construction listed on the valve nameplates are appropriate for the service intended for and are as specified. When in doubt contact KTM, or your local Tyco facility. •Define the preferred mounting orientation with respect to the system pressure. The arrow on the body helps to identify the upstream side (high pressure) and downstream side (low pressure). •Ensure that all stud bolts and nuts of the body joint are firmly fastened. Caution •Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional. •See the Actuator User Manual for the actuator preparation. 2.2. Installation Instructions •Ball valves are normally installed in horizontal pipes with the stem facing up. However, there are no limitations regarding the pipe or stem orientation. •Unless otherwise recommended by KTM, the valve should be installed with the ball in the open position, to ensure that the seat rings are not damaged during installation. •Particular care should be taken for valves equipped with “fail-close” actuators. •For operating temperatures above 200°C (392°F), thermal insulation of the valve body is recommended to protect the actuator/accessories from heat beyond the recommended temperature range. •Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in points 1.2. and 1.3

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