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HARLEY DAVIDSON SOFTAIL LEFT SIDE LEATHER TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Installation While handling and installing tool box, be careful not to scratch surface. 1. See Service Parts Illustration. Install tool box (1) to mounting bracket (6) using button head screws (2) and washers (5). Screws (2) should be inserted through mounting holes on inside of tool box (1) and then inserted through bracket (6) holes and threaded into weld nuts attached to bracket. 2. Remove and save the two screws that secure left rear fender support to motorcycle frame. 3. Remove two bolts, nuts, and washers that secure debris deflector to motorcycle frame. This will allow you to move debris deflector out of the way when installing new passenger footpeg support bolt. Save hardware for reinstallation. 4. For 1990 to 1999 Softails: If tool box is being installed with passenger footpeg, remove the hex head bolt and left passenger footpeg. Retain footpeg and lockwasher for reinstallation. Discard bolt . If tool box is being installed without passenger footpeg, remove hex head bolt and left passenger footpeg. Discard footpeg. Retain bolt and lockwasher. For 2000 and later Softails: See page 3 . Remove footrest from clevis. Remove clevis from frame by removing cap screw from center of clevis. If tool box is installed with footpegs, keep all hardware. If toolbox is to be installed with footboards, discard hardware. 5. Slide top of mounting bracket (6) between rear fender support and frame. Align top holes in bracket with fender support holes. Align lower bracket hole with footpeg mounting hole in frame. Install the two screws, removed in Step 2, in fender support. Do not tighten screws at this time. 6. For 1990 to 1999 Softails: Place lockwasher retained in step 4 on footpeg support hex head bolt (3) from kit. CAUTION 1 of 3 For 2000 and later Softails with footpegs: Install kit 49352-00 according to instructions included in this kit. Footpeg must fold up at a 45°angle (from vertical) toward rear of motorcycle. This angle allows footpeg to fold up if, by accident, it strikes the ground surface when making a sharp turn. Failure to set footpeg to the proper fold-up angle could result in death or serious injury. 7. For 1990 to 1999 Softails: Position footpeg so it folds up and back at a 45°angle. Install bolt (3) from kit through frame, tool box bracket (6), and spacer (4), into footpeg, as shown. NOTE If vehicle is equipped with saddlebag support bracket, Part No. 90346-90 or 90346-94, position saddlebag support bracket between tool box bracket and spacer.

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HARLEY DAVIDSON PUSHROD COVER RETAINER INSTALLATION AND REMOVAL TOOL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Figure 1. Pushrod Cover Retainer Installation and Removal Tool There are no Service Parts available with this kit. REMOVAL 1. See Figure 2. Insert the pin of the pushrod cover retainer tool into the retainer loop with the back of the tool towards the cylinder fins. Rotate the tool towards the cylinder to remove the pushrod cover retainer. INSTALLATION 2. See Figure 3. Load the pushrod cover retainer into the tool as shown in figure 3. Place the top edge of pushrod cover against top edge of push rod. 3. See Figure 4. Place the tool on top of the spring cover. Pivot the tool upward to install the pushrod cover retainer is05892a Figure 2. Removing Pushrod Cover Retainer is05895a Figure 3. Loading Pushrod Cover Retainer in Tool is05893a Figure 4. Pushrod Cover Retainer Installation

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RACE TECH SUSPENSION SERVICE TOOLS

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Filed Under (Tips and Review) by admin on 01-12-2010

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SHOCK SEAL BULLET TOOL “Bullet Tools” make seal head installation onto shafts quick and easy. 35-8677 TSSB12512.5 x 10mm Shock Seal Bullet 35-8678 TSSB1414 x 12mm Shock Seal Bullet 35-8679 TSSB1616 x 12mm Shock Seal Bullet FORK CAP WRENCH 46/50MM Black Oxidized steel construction for superior strength. Multiple applications (46/50mm): Honda CR250 (97-00), Suzuki RM125/250 (96-00), and removes compression adjuster assembly on Suzuki RM125/250 (98-00). Sold each. 35-8670 TFCW4650 Fork Cap Wrench SHAFT HOLDING TOOL Holds fork damping rods, cartridges, shock shafts, etc. while servicing. (aluminum) 35-8672 TFSH10 Shaft Holding Tool 10, 12, 12.5, & 14mm (Dampning Rods) 35-8673 TFSH14 Shaft Holding Tool 14, 16, & 18mm (Shock Shafts) 35-8674 TFSH20 Shaft Holding Tool 20, 24, & 29mm (20 & 25mm Fork Cartridges) 35-8675 TFSH32 Shaft Holding Tool 32 & 35mm (28 & 32mm Fork Cartridges) ULTRA SLICK SEAL GREASE Race Tech Ultra-Slick Grease provides maximum lubrication and minimum friction for all seal and bushing needs. Available in 1 oz. container. 35-8682 Ultra Slick Seal Grease SHOCK SEAL HEAD SETTING TOOL Allows easy removal and installation of all 40 – 46mm integral shock seal head assemblies. 35-8676 TFSH32 Shock Seal Head Setting Tool SAG MASTER™ The Sag Master is a tool that makes measuring “Race Sag”a snap because you read it directly. No more subtracting! Also useful in determining proper spring rates and monitoring linkage and seal drag. Comes with complete instructions and, doubles as a tape measure. 35-8681 TSSM01 Sag Master Race Sag Setting Tool FORK SPRING COMPRESSOR TOOL This unique fork spring compressor is designed to work on most current sport bikes and road racers. It allows the spring to be compressed while the fork cap is removed from the rod. It can be used on or off the bike on most models. 35-8680 TFSC01 Fork Spring Compressor Tool

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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How to Replacing Rear Main Seal 1

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

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The next day I woke up early and drank lots of coffee before going out to the garage. I knew I had two distinct problems confronting me. First, I would have to purchase an impact tool in order to loosen the six bolts holding the clutch together. Also, I would have to purchase at least three 8mm by 50mm bolts and nuts in order to prevent the clutch from exploding when the six bolts were unscrewed. For the third time in two days, I went to Sears and asked the salesman, (who I now I knew as Art,) where I could find an impact tool. He did not know what it was I was looking for, but he asked another employee and soon I had the tool as well as a 6mm Allen socket. Unfortunately, the Allen socket only came in 3/8″ drive, and the impact tool only came in 1/2″ drive. Thinking quickly, I purchased a 1/2″ to 3/8″ adapter, as well as a 3lb. dead- blow hammer. On the way home, I stopped at a Chief Auto Parts to buy the bolts I would need. The closest size they had were 8mm by 40mm, which was nearly 10mm too short. I was unsure whether the clutch cover bolts were coarse thread or fine thread, so I bought three of each, along with corresponding nuts. Finally, around 11 o’clock in the morning, I was back at the garage ready to work. I prepared the impact tool and placed the adapter and the Allen socket on it. I began to hammer on the end of the tool, trying to loosen each of the six bolts. None of them seemed to move, even though it seemed the impact tool was turning. Finally, I put the Allen socket on the breaker bar and found that all of the bolts had actually come loose. The tension from the clutch spring made it nearly impossible to see, however. I removed three of the bolts in a triangular pattern. Into these empty holes I threaded the fine- thread 40mm bolts with nuts attached and tightened them evenly. I was now able to remove the remaining Allen bolts. By slowly turning and loosening the nuts evenly on the 40mm bolts, I relieved the pressure from the clutch spring until the cover plate was free. I removed the cover plate, the clutch, the pressure plate, and finally the clutch spring. I had already marked each of the elements with Whiteout to insure that they would fit together the same way on installation. Apparently, this is essential as the flywheel could be rendered out-of-balance if the clutch components are not installed correctly. The flywheel itself was now exposed. I could see the five bolts that attached it to the crankshaft. I now used a tool I had fabricated. Although the manual describes two possible tools that can be fabricated, I found a piece of metal that resembled the tool and decided to use it. Unfortunately it was not strong enough and broke. I turned and looked at my workbench, and noticed a bracket which I had previously fabricated for mounting a mirror on my Vespa. The piece of steel was extremely strong and was already pre-drilled with correct-sized holes. It fit perfectly, so I placed it over the exposed bolt which protruded from the case, and placed the other end on one of the 40mm bolts, which I then bolted into the flywheel itself. I used the breaker bar again and removed the five bolts. The flywheel came loose after inserting two more 40mm bolts and tugging on them evenly

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Kawasaki FI Calibration Tool Instruction Manual

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Filed Under (Kawasaki) by admin on 08-02-2011

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System Function Kawasaki FI Calibration Tool (FI Tool) is developed to modify the mapping of the racing machine to gain operating conditions suitable for the course and the rider’s skill. The following are the available setting functions. Table 1 FI Tool Function Model Name Functions Available Setting Range ’04 ZX-10R ’05 ZX-6RR ’05 ZX-10R ’06 ZX-10R ’07 ZX-6R 1) Adjust the injected fuel rate at acceleration -30 % ~ +30 % 〇 〇 〇 〇 〇 2) Adjust the injected fuel rate of No.1 and No.4 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 3) Adjust the injected fuel rate of No.2 and No.3 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 4) Adjust the injected fuel rate of primary and secondary injector * -30 % ~ +30 % -10 % ~ +10 % — – — 〇 — – — – — 〇 5) Adjust the ignition timing -15°CA~ +5°CA 〇 〇 〇 〇 〇 6) Adjust the sub-throttle opening angle -50 % ~ +50 % -45 % ~ +45 % 〇 — – 〇 〇 — 〇 — – 〇 7) Adjust the exhaust device opening angle -50 % ~ +50 % 〇 — 〇 〇 — 8) Adjust the all injected fuel rates of all cylinders and operating are a simultaneously -30 % ~ +30 % 〇 〇 〇 〇 〇 9) Adjust the value of engine over revolution limiter 0 ~ +300 rpm -1000 ~ +700rpm -1000 ~+1200rpm — – — 〇 — – — 〇 — – — 〇 〇 — – 10) Set the fuel cut or not at deceleration Use or Not Use 〇 〇 〇 〇 〇 11) Set the sub throttle controlled or not Controlled or Full Open Fixed 〇 — – — – 12) Set the exhaust device controlled or not Controlled or Full Open Fixed 〇 〇 〇 〇 〇 13) Set the Auto Shifter Ignition Cut Length Controlled or not, set Ig. Cut Time by gear range — – 〇 〇 〇 14) Set the Pit Road RPM Limit Controlled or not, set Upper Limit RPM by gear range

1988-1989 ENGINES Toyota 1.6L 16- Valve 4 – Cylinder REMOVAL & INSTALLATION

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Filed Under (Toyota Manuals) by admin on 25-09-2011

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Removal 1) Mark and remove hood. Remove battery. Remove engine under cover (splash) shields. Drain coolant, engine oil and transaxle fluid. Mark and disconnect vacuum hoses and electrical connectors. 2) Remove air cleaner assembly. Disconnect coolant hoses. Mark and disconnect throttle, cruise, and kickdown cables (ifequipped). Mark and disconnect fuel inlet and return hoses. 3) Remove fuel tank protectors. Remove airflow meter assembly. Remove transaxle protector (if equipped). Remove accessory drive belts. Remove alternator. 4) Disconnect oil cooler hoses (if equipped). Disconnect power steering pump and A/C compressor and set aside (if equipped). Disconnect speedometer cable from transaxle. Remove clutch slave cylinder (if equipped). Mark and remove shift control cable(s). 5) Remove cruise control actuator assembly (if equipped). Raise vehicle and disconnect exhaust pipe from exhaust manifold.

Harley-Davidson Motorcycles Specialty Tools

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Filed Under (Harley Davidson) by admin on 31-10-2010

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Crankshaft Bearing Endplay Setup Tool The tool consists of a large precision machined bolt & nut. The outer bearing races are pressed into the crankcase. Then the inner races & shims are assembled in the crankcase using the HD437. End play is measured with a dial indicator. Repeat with different shims if necessary to reach desired endplay. Fast Shim Changes/Setup Times. The diameter of the bolt is slightly smaller than the crankshaft diameter allowing the inner bearing races to be installed & removed without pressing in place. Applications: Big Twins HD444 Steering Stem Bearing Endplay Setup Tool for Springer® Forks The tool is a 3-prong offset spanner wrench with a hole in the center allowing a threaded shaft to pass through. Benefits. •Offset handle provides clearance for the fuel tank & other items. •Triple prong engagement allows precise stem bearing end play adjustment. HD485 Camshaft Gear Alignment Tool The tool is a block with two round pins & an centered triangular pin for gear tooth alignment and a diameter with a key for radial alignment. Reduced Installation Time. The tool locks the radial position of the gear & camshaft together allowing the gear to be easily & accurately pressed on the camshaft Applications: Evolution HD5530 Intake Manifold Wrench Reversible ratcheting box wrench with 1/4″ ball end hex bit. Quickly & easily install/remove intake manifold socket head cap screws. •Plastic grip for comfort & control •Reversible •Ball end hex bit for flexibility in the tight area next to the intake runners Applications: Big Twins

SUSPENSION SERVICE TOOLS/ FORK DAMPER ROD BLEED TOOL

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Filed Under (Tips and Review) by admin on 30-11-2010

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33 SHOP EQUIPMENT & TOOLS SUSPENSION SERVICE TOOLS K&L FORK TUBE U-BLOCKS Precision machined from billet aluminum, these quality three piece sets are a handy, accurate and safe way to straighten and check fork tubes. 35-9411 36mm (for 33 thru 36mm tubes) 35-9412 40mm (for 37 thru 40mm tubes) 35-9413 43mm (for 41 thru 43mm tubes) 35-9414 46mm (for 44 thru 46mm tubes) 35-1964 35-8579 35-7995 DAMPER ROD HOLDERS Holds damper rod when disassembling forks. 35-8578 Yamaha front forks, 43mm Kayaba YZ125/250 (1988) YZ490 (88-90) 35-8579 Yamaha YZ125/250 with UD(upside down) forks FORK DAMPER ROD TOOLS Sold each. 35-7995 Combination Fork Damper Tool Designed to hold the damper rod during assembly & disassembly of Honda XR400′s or Suzuki DR-Z400S. One end features spanner type prongs for the XR400 and the other a 27mm hex for Suzuki. 35-1964 Combination Damper Rod Fork Tool Designed for assembly and disassembly of most inverted Kayaba and Showa 41mm, 43mm, 46, and 47mm forks. Use one end for Kayaba forks and the other for Showa forks. (not required for 91-92 Honda CR models) ROD HOLDER Double sided damper rod holder. Works on Kayaba U.D (upside down) 41mm forks. 35-8580 Yamaha YZ125/250Amodels (89-90) FRONT FORK CAP SOCKET Designed to remove and install Yamaha front fork caps with female hex head. Sold each. 35-8571 14mm female socket 35-8573 19mm female socket FORK DAMPER ROD HOLDERS Holds damper rod when disassembling and assembling front forks. 35-8576 Use for Yamaha 43mm Kayaba forks, 30mm hex YZ125 (84-87), YZ250 (81-87) IT250 (1983) YZ490 (82-87) 35-8577 Use for Yamaha 38mm Kayaba forks, 24mm hex YZ125 (81-83), IT175 (82-83), IT250 (81-82) YZ250 (77-80), YZ400 (77-79), IT465 (81-82) FORK CAP WRENCH Designed to remove the front fork caps on late model Honda CR’s and Suzuki RM’s. Can also be used for adjusting compression. One end of wrench is 49mm, the other is 50mm. Sold each. 35-7803 Fork Cap Wrench 35-8576 35-8577 35-8571 35-8573 6 Point Hex 35-8578

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1993-1999 Honda CBR900RR Frame Slider Installation Instructions

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Filed Under (Honda) by admin on 27-10-2010

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1. Some photos in this section are used for illustration examples only. It is up to you how you decide to cut your motorcycles bodywork to accept the frame slider there are many different ways customers go through this process. Shogun is not responsible for any part of your motorcycle for any reason. Precisely measure location of cut and if in doubt at any point please call us before the install process has begun. Professional installation is recommended. Always use proper safety measures during the install of this product. Do not try to install this product without proper tools, recently calibrated torque wrench, correct torque specifications from factory service manual, safety goggles and gloves. 2. Body Prep. Use masking tape to completely mask off the area on the body where you will be working. We usually will tape off approximately 6 to 8 inches around the though hole area and any other edges that could get bumped or scratched while working. Tip: In some locations you may want to double up the thickness of the masking take to give extra protection. 3. Locating and cutting the body. This is a simple illustration of how most of us install the product here. It takes a bit longer but our end results have been more consistent with a better overall fit and finish. We start with (99-SPOT-1012560) Shogun Spot tool. It’s nothing special just a 10mm socket cap bolt with a 1.25 pitch that we cut the head off of and sharpen to a point. You can purchase the tool for $12.99 or go to your local hardware store and make your own. Keep in mind Metric 10 or 12mm X 1.25 pitch bolts (most common sportbike engine studs) are fairly hard to find. Make sure you know the size and that the bolt you’re buying is a 1.25 pitch bolt. With the body removed, thread in by hand your spot tool. Make sure you have the spot tool screwed in enough to clear the body on the inside. 4. Loosely mount your bodywork and adjust the spot tool out to lightly touch the inside of the body. Make sure you have at least 15mm of thread engagement, without that the spot tool will tend to sag down giving you a false location. With the body mounted in the correct location use a soft micro fiber cloth over the spot tool location and softly tap to leave a spot mark on the inside of the body. Be careful not to scratch or chip the body

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