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1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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V-Star 1100 Floorboard/ Foot peg Extension Kit Installation Manual

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

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1. Take notice of the position of the shift peg positions relative to the floorboard or foot-peg. You will be adjusting it back to these locations upon installation of the extended linkage. 2. Loosen the shifter rod jam nuts and remove the OEM shift linkage. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Remove the jam nuts from the OEM shift linkage and thread them gently on to the new shift linkage. 7. Install the new shift linkage by aligning the control swivel and the shifter swivel and turning the linkage. Be careful not to cross thread the linkage. The linkage will thread into both swivels simultaneously. Adjust to the desired position and tighten the jam nuts that you removed from the OEM linkage. Do not over-tighten or damage will occur to the threads. Right Side Installation: 1. Take notice of the Brake pedal position relative to the floorboard/foot-peg before removal, as it will need to be readjusted upon installation of the kit. 2. Remove the cotter pin from the brake linkage and remove the clevis pin. The brake linkage will now be separate from the brake pedal assembly. Do not discard anything. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Loosen the jam nut from the brake linkage and remove the linkage bracket. 7. Assemble the threaded brake linkage extension to the coupling nut and tighten using one of the provided jam nuts. Don’t forget the thread locking compound if your using it. 8. Thread the coupling onto the brake cylinder linkage and install the other end of the assembly into the brake pedal end. Tighten the jam nuts. You should be able to adjust the linkage for proper brake pedal location before tightening the jam nuts. 9. Readjust the brake light switch and your ready to roll

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HARLEY DAVIDSON FL SOFTAIL PROFILE LOW FRONT SUSPENSION KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-11-2010

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Fork Spring Removal 1. Elevate and support the vehicle so the front tire is off the floor and the forks are fully extended. 4 9 3 1 10 11 2 5 6 7 8 is04004 1. Slider tube cap 2. Spacer washer 3. Oil seal 4. Clamp bolt and washer 5. Fork tube plug 6. O-ring 7. Fork spring 8. Tight-wound end of spring 9. Fork slider tube 10. Fork slider 11. Drain screw and washer Figure 1. Front Fork NOTE Remove the brake caliper from the fork slider. DO NOT remove the brake line from the caliper. 2. Remove the front wheel. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. 3. Remove the front fender. See FRONT FENDER in the Service Manual. 4. See Figure 1. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side. Save the cap and spacer. The oil seal can be discarded. 5. Loosen the clamp bolt (4) and pull the fork from the brackets. 6. Repeat Steps 4 and 5 for the other fork side. -J00280 1 of 4 Wear saf ety glasses or gog gles when ser vicing f ork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) NOTE Be careful not to damage the O-ring. 7. See Figure 1. Remove the fork tube plug (5) and O-ring (6). Pull the spring (7) out of the slider tube (9). Remove the drain screw and washer (11), and drain the fork. Reinstall the drain screw and washer, and tighten to 52-78 in-lbs (5.9-8.9 Nm). 8. Repeat Step 7 for the other fork side. NOTE The Profile® Low Front Suspension Kit requires a different amount of H-D TYPE E FORK OIL than is listed in the Service Manual. NOTE Measure the oil level from the top of the fork tube with the fork spring removed and the fork fully compressed. 9. See FRONT FORK OIL in the Service Manual, but substitute the measures below. Fill the forks with Harley- Davidson TYPE E FORK OIL: • 1986 through 1999 models: •11.7 oz (345 cc) of oil, or •5.2 inch (132 mm) from top of oil level to top of tube. • 2000 and later models: •13.4 oz (396 cc) of oil, or •4.1 inch (104 mm) from top of oil level to top of tube. Fork Spring Installation 1. Insert a new Profile Low spring (7) from the kit into each slider tube (9), with the tight-wound portion (8) toward the bottom of the fork slider. NOTE Be careful not to damage the O-ring. 2. Install the fork tube plug (5) and O-ring (6) assembly into the slider tube and tighten securely. Be sure that one flat on each fork tube plug faces toward the inside of the fork. 3. Insert both fork side assemblies up through the slider covers, the fork stem and bracket, and the upper bracket. 4. Obtain two new oil seals (3), H-D Part Number 45733-48, and the spacer washers (2) and slider tube caps (1) saved earlier. Place an oil seal, followed by a spacer washer, onto each fork tube plug. 5. Insert the threads of a slider tube cap through each washer and seal, and into the fork tube plugs. Tighten to 40-60 ft- lbs (54.2-81.3 Nm). 6. Tighten the fork stem bracket clamp bolts (4) to 30-35 ft- lbs (40.7-47.5 Nm). 7. Install the front fender. See FRONT FENDER in the Service Manual. Install the front wheel and brake caliper. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. Jiffy Stand Removal/Installation 1. Move the jiffy stand to the retracted (up) position. Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c) 2. See Figure 3. Unfasten the jiffy stand leg spring (A) from the vehicle. Remove the hex bolt (B), lock washer (C), flat washer (D) and leg stop (E) from the threaded end of the jiffy stand leg. Discard the jiffy stand leg, but retain all other components. 3. Clean and inspect the jiffy stand attaching parts and mounting bracket for wear or damage. If parts replacement is necessary, refer to the Jiffy Stand section of your Service Manual for replacement procedures

DRIVER PEGS HONDA ADAPTOR INSTALLATION INSTRUCTIONS

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

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1. Assemble the peg onto the peg adaptor by removing the allen bolt from the end of the foot peg you are using. Remove the clevis assembly (folding mechanism) from the peg itself. Assemble the peg and allen bolt on to the peg adaptors. 2. The original peg pivots or folds up on a pin and has a return spring. Note how the spring is assembled into the peg. Remove the cotter pin, washer and pivot pin and foot peg. Install the new peg and adaptor assembly onto the motorcycle in the same manner and using the same spring, pin, washer and cotter pin. Set the angle of the new peg as desired and tighten the allen bolt securely. 3. Use the small set screws located at the end of the adaptors to raise and lower the foot pegs resting position.

HARLEY DAVIDSON DYNA GLIDE ADJUSTABLE HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

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

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Installation 1. See Figure 1. Install setscrew (14) into lower hole on frame tube boss (2) leaving .20 in. of setscrew (or three threads) exposed. 2. Place highway peg mounting plate (1) into position. For a lower peg position, place bottom hidden hole in mounting plate over setscrew. For a higher peg position place upper hidden hole in mounting plate over setscrew. Attach mounting plate to frame tube boss using 1 in. long screw (3), lockwasher (4), and flat washer (5) from kit. Tighten screws to 33 ft-lbs. 3. Install footrest support (6) onto highway peg support plate using hex nut (7), lockwasher (8) and flat washer (9) from kit. Tighten nut (7) to 47 ft-lbs. 4. Locate spring washer (10) from kit. While holding spring washer in position on inside of footrest support (with square edge towards motorcycle), position footpeg (not included with this mounting kit) between footrest support mounting tabs, as shown. 5. Insert 1-1/2 in. long screw (12) from kit through footrest support mounting tabs, footpeg, and spring washer. Secure using locknut (13) from kit. 6. Repeat these steps for the other side of vehicle. 1 WARNING These footrest pegs must fold upward and toward the rear at about a 45°angle when retracted. If they do not, peg could contact ground while motorcycle is in a turn, causing loss of control or startling the rider, resulting in possible personal injury. If pegs do not fold up and back at a 45°angle, remove pegs and turn them over so the flat surface is facing forward.

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KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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HARLEY DAVIDSON ANGLED HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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INSTALLATION Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a) Mount the footpegs so they will not strike the ground during cornering. Foopegs striking the ground during cornering can cause loss of control, resulting in death or serious injury. (00458b) 1. Determine what height on the engine guard you prefer for the final mounting of the footpeg mounts. Mark location, if desired. 2. See Figure 2. Obtain the mounting clamp (11) from kit. Position the clamp halves around the engine guard at the desired height and install with hinge pin head facing upward. The “cogged” face of the clamp should face the extension arm. 3. Obtain the washer (5), screw (8) and one of the angled arms (11) (long or short depending on kit number) from kit. Using the screw, align and install the angled arm with washer (5) positioned between the clamp “ears”. 4. See Figure 1. Position the angled arm such that footpeg will pivot upward and toward the rear of the motorcycle. Do not tighten completely at this time. 2 3 4 1 is 02264 1. Clamp 2. Extension arm 3. Screw 4. Hinge pin Figure 1. Engine Guard Footpeg Mounting (Shown Installed with Footpeg) NOTE The footpeg will be a tight fit if the D-spring washer is installed correctly. 5. Refer to Figure 1 and Figure 2. Obtain the footpeg (sold separately), D-spring washer (10) and screw (7) from kit. Install the D-spring washer so it is positioned inside the footpeg mount (arm) with the square “D” edge towards the inside of the mount. Hold the washer in place and slide the footpeg into position. Install the screw and tighten footpeg screw to 19 ft-lbs (26 Nm). 6. Note the two small tapped holes on the back side of the footpeg mount clevis area. Install the setscrew to the lower of the two holes. The angle of the footpeg is adjusted by running the set screw in and out. Repeat Steps 1 through 6 for the opposite side. 7. Position the footpeg assemblies so they are at equal heights and symmetrical. Securely tighten each assembly until it cannot be rotated on the engine guard with reasonable foot pressure but do not exceed 55-60 ft-lbs (75-81 Nm) on item 8

Yamaha Road Star Forward Control Kit Installation Instructions

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

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Before starting to assemble this forward kit on your motorcycle check the packing list to make sure that the kit you received is the correct one for your model motorcycle and that the foot pegs are the style you ordered (billet or ISO). Next check the contents hardware kit P.N.0109-1000 against the packing list for completeness. Installing The Shift Control Photo 1 Remove wires from horn. Remove the two hex head bolts (Save for later installation) that mount the OEM shift controls to your motorcycle. Unthread stock shift rod at trans shift arm, leaving OEM rod end connected to stock shift arm. Using Original Metric hardware, place a drop of Loctite #242 (blue) to the bolt threads and mount the shift control plate to the motorcycle frame, Photo 2. FORWARD CONTROL KIT PM SHIFT CONTROL ASSEMBLY Note Before torquing the shift control mounting bolts down, tighten them snug and look behind the shift control mounting plate to where it contacts the mounting lug on the frame. Make sure it fits squarely to the lug before proceeding further. Torque the two shift control mounting bolts down to 25 ft-lb. Using a 3/8″ x 1″ hex head bolt with a lock and flat washer put a drop of Loctite #242 (blue) on the threads and insert the bolt through the rear of the control mounting plate and attach the foot-peg pivot to it. Tighten the bolt while holding the footpeg pivot so that its hinge is lined up in a 45˚ rear facing angle. Thread supplied shift rod coupler to stock shift rod end at trans arm. Mount the shift pedal to the other end of the shift ro d using a 5/16″ x 1″ socket head screw and Nylocnut . Adjust the transmission shift linkage so that the shift arm on the forward controls and the shift arm on the transmission are parallel. Secure it with the jam nuts. Apply a drop of Loctite #242 (blue) to the threads under the jam nut before tightening see Photo 3 After you have assembled the shift control onto your motorcycle you must align the footpeg. The folding footpeg assembly uses a blind stud to attach the footpeg to the footpeg pivot. Shim washers (3/8″ x .015″) are used on the stud between the footpeg and the pivot, see Photo 4, so that the top surface of the footpeg is correctly aligned for your foot when it is tightened down on the pivot. This is done by setting a couple of shim washers on the footpeg mounting stud “A” and then screwing the footpeg onto the mounting stud, if the footpeg is rotated to far forward then add another shim washer, if not far enough then remove a shim washer. After you have the selected the correct number of shims for your footpeg, disassemble the footpeg and put a drop of Loctite #271 (red) on both ends of the stud and reassemble the footpeg. This will also need to be done on the brake control footpeg. Setting Up the Master Cylinder The master cylinder pushrod return spring and pushrod boot must be installed on the master cylinder before it is assembled onto the forward control mount. The parts are shown in Photo 5: pushrod boot (A), pushrod return spring (B), spring seat washer (C), and master cylinder (D). Place the return spring seat washer into bore of master cylinder so that is sits on top of the piston retaining snap ring. Next set the pushrod return spring on the seat washer and slide the pushrod boot over the return spring now slip the big end of the boot over the flange on the master cylinder so that the ridge on the inside of the boot fits into groove “A” that is machined into the end of the master cylinder flange, see Photo 6. Installing The Brake Control Unplug stock brake light switch at master cylinder. Remove brake line from rear caliper. Remove the existing brake controls from your motorcycle down to the control mounting lug that is welded on to the frame’s right side, see Photo 8. Save Metric hardware for later use. A Shim Washer PHOTO 4 A B C D PHOTO 5 A PHOTO 6 PHOTO 7 Note For complete brake system removal instructions and precau – tions refer to the appropriate service manual for your year and model motorcycle

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SUZUKI M109 ADJUSTABLE HIGHWAY PEG MOUNTS Installation Instructions

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

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1. Starting on the left side of the motorcycle remove the two 14mm bolts that attach the left foot peg and shifter mounting bracket to the frame. Locate the longer two of the (4) supplied mounting bolts supplied, place a lock washer first and then a washer on each. Locate the left curved main mount (it will have its polished chrome side and the circle of dowel pin holes facing outward when installed on the left side). Place the bolts thru the bolts thru the holes in the mount the slide a spacer (supplied) over each bolt. Place the mount with the bolts and spacers thru the holes of the foot peg and shifter mounting bracket removed earlier and thread the bots into the frame then tighten securely 2. Repeat this procedure on the right side using the remaining shorter bolts, lock washers, washers, mount and spacers and again tighten securely. 3. Again starting on the left side install one of the dowel pins supplied into any of the holes in the mount, place one of the remaining mounting arms (they are the same left and right) onto the dowel pin that is closest to the position you want the arm to be in. Place one of the washers onto the large allen screws then thru the finished side of the arm and thread it into the center hole of the mount. 4. Repeat this procedure on the right side. Loosely install the foot peg set you have selected onto the arms. Sit on the motorcycle to see if you are comfortable with the position you have chosen. You can adjust the position of the arms in Ω” increments forward or back as follows. Remove the arm while leaving the pin in its hole, now move the pin to the next hole forward to rotate the arm back towards the rider Ω” or into the next hole back to rotate the arm forward Ω” and re-install the arm into the corresponding hole that is in the direction you want the arm to go. 5. Adjust the angle of the foot pegs so that they are both comfortable to your feet and will fold up and to the rear when not in use. Set the peg pivot bolts tight enough to hold the in the folded position but loose enough so that you can fold them down with your foot when you need them. Recheck all fasteners for tightness.

Kawasaki Nerf Bar / Heel Guard INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 24-10-2010

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Set/Lock rear parking brake on bike and turn gas petcock to ‘Off’ position. Make sure vehicle is secure while installing the Nerf Bar. b) Remove and discard Foot Peg Bolts 3. Install Webbing: a) Install Web Straps on Welded Tabs: see fig #1 Note: see drawing for correct orientation of the web strap assembly to the nerf bar tabs. From the top, slip each web strap down and through the (2) nearest tab slots against the nerf tube. From the bottom, pull the web strap up and out through the middle slot until snug and in-line with tabs. 4). Install Nerf Bar / Heel Guards: Right Side: “Loosely” install following hardware. see fig #2 a) Install (1) Item #10 Foot Peg Weldment to Frame using (2) Item #2 Bolts, (2) Item #12 Washers, and (1) Item #6 Spacer. b) Slide Rear of Nerf Tube over (1) Item #9 Steel Foot Peg Mount Tube and position Front Nerf Bar Tube into ATV frame. c) Attach Rear Nerf Tube Hanger Bracket to OEM Foot Peg using (1) Item #4 Bolt, (1) Item #10 Washer, and (1) Item #5 Nut Left Side: “Loosely” install following hardware. a) Install (1) Item #10 Foot Peg Weldment to Frame using (2) Item #2 Bolts, (2) Item #12 Washers, and (1) Item #6 Spacer. b) Slide Rear of Nerf Tube over (1) Item #9 Steel Foot Peg Mount Tube and slide Front Nerf Bar Tube into Right Nerf Tube. c) Attach Rear Nerf Tube Hanger Bracket to OEM Foot Peg using (1) Item #4 Bolt, (1) Item #10 Washer, and (1) Item #5 Nut Front Side: With the Front Left Nerf Bar Tube inserted into the Front Right Nerf Tube attach (2) Item #3 Bolts and (2) Item #11 Washers. (both sides)

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