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KAWASAKI ZX 6R, ZX 6RR AKRAPOVIC RACING AND EVOLUTION EXHAUST SYSTEM Installation instructions

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

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REMOVAL OF STOCK EXHAUST SYSTEM 1. put the motorcycle on a side stand, we recommend a racing stand 2. remove the lower cowling (complete) – unscrew all bolts and remove the plastic bushings (Figure 1, 2, 3, 4) 3. unscrew the bolt for the metal clamp on the link pipe (at the link pipe – collector joint) (Figure 5) 4. unscrew and remove the bolt for the muffler clamp (Figure 6) 5. remove the link pipe together with the muffler (link pipe and muffler are welded together). We recommend spraying the joint with a multi-purpose spray lubricant (WD-40 or equivalent) 6. if you are mounting the optional carbon-fiber muffler bracket, remove the stock muffler bracket 7. unscrew and remove the bolts on the lower radiator brackets and move the radiator out of the way – do not damage the radiator cooling fins (Figure 7, 8) 8. remove the bolts on the flanges (Figure 9) 9. remove the header tubes together with the flanges (Figure 10) INSTALLATION OF THE AKRAPOVIC RACING OR EVOLUTION SYSTEM installing the header tubes: 1. check the position of the radiator – be careful not to damage the fins 2. use the stock gaskets installed in the exhaust port, or place them on the Akrapovic sleeves 3. install the sleeves together with the flanges and tensioning springs – make sure they are correctly oriented and correctly installed, and that the holes for the springs line up with the holes on the tabs on the header tubes (Figure 11 & 12) 4. tighten the flanges 5. mount the header tubes, which come together with the collector (Figure 13) 6. attach the springs (Figure 14) 7. make sure the header tubes are not touching the engine, the radiator, tubes, electrical installations etc. installing the independent link pipe: 1. if installing the EVOLUTION model use ceramic anti-seizing grease 2. slide the link pipe (inlet side) onto the collector (Figure 15) 3. check the orientation of the link pipe – the holes for the springs must line up 4. attach the springs 5. make sure the link pipe is not touching the frame and other parts installing the muffler: 1. install the carbon-fiber muffler bracket, if applicable 2. position the muffler correctly and slide it onto the outlet side of the link pipe; if installing a titanium link pipe use ceramic anti-seizing grease

HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

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Harley-Davidson V-Rod Destroyer Indy Series Exhaust REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 24-10-2010

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STOCK EXHAUST SYSTEM REMOVAL (DESTROYER) 1. Remove both collector bolts. 2. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 3. If the Racepak is installed, remove both O2 and EGT sensors from the front and rear head pipes. 4. Carefully remove complete exhaust from the motorcycle. STOCK EXHAUST SYSTEM REMOVAL (V-ROD) 5. Loosen clamp bolt at front of the collector using a 13mm socket. 6. Remove muffler bracket bolt using a 13mm wrench. 7. Carefully remove muffler and collector assembly from motorcycle. 8. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 9. Carefully remove head pipes from motorcycle. 10. Remove the stock exhaust flanges and circlips from both the front and rear head pipes. If the circlips are bent or twisted they should be replaced, Harley-Davidson part number #65045-01 We also recommend replacing the stock exhaust gaskets, Harley-Davidson part number #65109-01 INDY SERIES EXHAUST SYSTEM INSTALLATION 1. Identify front head pipe #7-8002. Install the stock flange and circlip. Install the exhaust gasket and front header pipe, leaving the flange nuts hand tight. 2. Repeat the above step for the rear head pipe #7-8006. 3. Slip the megaphone/collector assembly onto the head pipes, secure with the four springs supplied using the spring puller tool. 4. Rotate the exhaust so there is adequate clearance in all places. 5. Tighten the cylinder head flange nuts for both the front and rear head pipes. 6. Tighten both the EGT and O2 plugs on the front and rear head pipes. 7. Clean all fingerprints from the exhaust using a contact cleaner (or other non flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. 8. You are now ready to start the motorcycle.

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HARLEY DAVIDSON TOURING OIL COOLER KIT AND CHROME OIL COOLER COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION 1. See Figure 1. Remove the spin-on oil filter (2) and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter adapter. NOTE The oil adapter assembly has two flanges protruding out of the back. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 2. See Figure 2. Install the oil adapter gasket (3) onto the oil filter adapter assembly (1). The oil adapter assembly flanges should be aligned so they are installed into the oil adapter gasket cutout as shown. 1 2 is00602 1. Oil filter adapter 2. Oil filter Figure 1. Oil Filter and Adapter 1 2 3 5 4 is00761a 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket 4. Gasket adhesive side 5. Oil cooler adapter assembly gasket surface Figure 2. Install Oil Adapter

Corolla & Matrix 2005 – 2006 1ZZ-FE ENGINE NO START OR EXTENDED CRANK CONDITION

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Filed Under (Toyota Manuals) by admin on 29-05-2011

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Some 2005 and 2006 model year Corolla and Matrix vehicles equipped with a 1ZZ–FE engine may exhibit a “no start” or “extended crank” condition. This may be caused by insufficient fuel pressure after the vehicle has been parked for a period of time. The fuel pump assembly manufacturing process has been improved to correct this condition. Applicable Vehicles S 2005 – 2006 model year Corolla and Matrix (2WD) vehicles equipped with the
1ZZ–FE engine. Parts Information PREVIOUS PART NUMBER 77020–02180 77144–04010 77169–02050 CURRENT PART NUMBER Same Same Same PART NAME Fuel Suction w/Pump & Gauge Tube Assembly Fuel Pump Gauge etainer
Fuel Suction Tube Set Gasket

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CSS/ CSR Separator, Recovery Tank, Purge Valve, CYC Timer & Pump INSTALLATION & OPERATION MANUAL

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

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1.*The*CSS/CSR*system*skid*should*be*bolted*to*a*flat*&*level*concrete*foundation*with*suitably*sized*and*quantity*of*anchor*bolts.* The entire system (1″-6″) is on a single skid. For systems 8″ and larger, the separator stands alone on its own 3 legs, while the pump/motor, recovery tank (CSR only), and control panel are on an individual skid. It is therefore incumbent upon the installer to insure*that*the*complete*package*is*bolted*to*a*flat*&*level*concrete*foundation,*to*insure*that*the*”piping*assembly”*is*installed* without any undue stress. 2. Inspect and hydrotest all pipe connections for leaks. *All*flanged*connections*must*have*gaskets,*and*all*threaded*connections*must*have*Teflon*tape*or*anti-seize*coating. 4. Flush all new pipe construction before system operation. In the absence of a pump strainer basket, use a y-strainer with 1/4″ perforated*screen.**The*perforated*screen*must*be*at*least*the*same*size*or*one*pipe*size*larger*than*the*pump*suction.**The* perforated screen will block out larger debris such as welding rods, tools, rugs, gloves, etc. ELECTRICAL 1. Voltage supply to the system must be the same as the voltage indicated on the control panel. 2. Follow the pump operating instructions prior to start-up. 3.*Turn*the*motor*”ON”*and*check*rotation.**Rotation*must*turn*in*the*same*direction*as*the*arrow*located*on*the*pump* casing. If pump is rotating in the opposite direction then reverse L1 and L2 on the incoming power to the panel. Recheck rotation. 4. Starting or in-rush current should not exceed 3 seconds, running current should be equal to or less than nameplate full load amps (FLA). 5. Thermal Overload Setting 5a. Select the Operating Voltage 5b. Multiply Motor Service Factor (SF) by the Full Load Amps (FLA) to get the Service Factor Amps (SFA). 5c. Adjust the Thermal Overload Dial to match SFA Note: Some motors come with SFA written on the nameplate. The majority of our motors come with a 1.15 service factor, but very few come with a 1.25 SF. STARTUP 1. Open system inlet valve 100% and outlet valve 50% (supplied by others). 2.*Suction*line*must*be*flooded. 3. Open separator air vent located near the outlet, (standard on 2″ and larger). 4.*Turn*the*system*”ON.” 5. Purge all the air. 6.*For*HH*&*SP*systems,*open*outlet*valve*until*the*gauge*reads*35psi.*For*LH*systems,*open*outlet*valve*until*a*100%* opening*is*achieved.**If*system*begins*to*vibrate,*then*slightly*close*separator*outlet*until*it*stabilizes

2010 Toyota Motorsports/ TRD USA Contingency Award Program

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Filed Under (Toyota Manuals) by admin on 29-09-2011

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To enroll in the program, complete the registration form included in the enclosed material and mail, fax or e-mail it to TRD per the instructions at the bottom of the form. Contact personnel are listed on the attached 2010 Contingency Award Guidelines sheets. These people are available to assist you throughout the year. Parts Ordering: If you are planning to order Toyota parts during 2010 you must supply us with your Visa or Master Card credit card number at the time you register in the program. There is a line on the registration form for this number. See the attached Parts Ordering Guidelines for detailed information on how to order parts. TRD is looking forward to working with each of you, and we wish you a very successful year with your racing program

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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 Sportster Custom Straightshot Exhaust System REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove the nut that mounts the front muffler to the engine, located below the rear brake master cylinder. 4. Remove the bolt that mounts the rear muffler to the mounting bar. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips . INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Vance and Hines recommends you replace your exhaust gaskets with Sceamin’ Eagle gaskets part number 17048-98. 2. Install the circlips and flanges from the stock system on to both of the new head pipes. 3. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of both heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the front head pipe using the stock nuts, do not tighten at this time. 5. Install the rear head pipe using the stock nuts, do not tighten at this time. 6. Install one muffler clamp (supplied) over the inlet (notched end) of each muffler. 7. Identify the front and rear muffler mounting brackets. The front bracket is stamped with the number 305 and the rear muffler bracket is stamped 213 . 8. Install the front muffler mounting bracket to the stud on the engine (where the stock muffler mounted) and fasten using the stock nut (leave loose at this time). The bracket will bend inward towards the center of the motorcycle when installed correctly. Note: You may need to move the wires and hoses on the lower frame rail to decrease the possibility of them chaffing on the bracket bolts. 9. Slip one of the mufflers onto the front head pipe. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the muffler to the mounting bracket using the 5/16″ flange head bolts (supplied) leave them loose at this time. 10. Attach the rear mounting bracket to the rear muffler. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the bracket to the muffler using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note: The single hole in the bracket will point downward and slightly forward when installed correctly

Harley-Davidson DYNA Straightshot Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove both front and rear head pipe clamp bolts. 4. Remove the entire exhaust system and set it aside. 5. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips. 6. Remove the rear head pipe clamp bracket from the transmission cover. Remove any studs and bolts necessary and set aside to use when installing the new muffler mounting bar to the transmission housing. Refer to figure 1. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the mounting bar (supplied) to the transmission housing using the stock hardware. Refer to figure 1 . Note: The mounting bracket should mount flatagainst the transmission housing. Some motorcycles use a stud to mount the stock rear head pipe clamp, be sure to remove the stud from the transmission housing and replace it when mounting the bracket, this will insure that the bracket is flat against the housing. 2. Check condition of stock exhaust gaskets. Replace if worn. Vance & Hines recommends you replace your gaskets with Screamin’ Eagle gaskets, part number 17048-98. 3. Install the circlips and flanges from the stock system onto both new head pipes. 4. Slide one pipe clamp (supplied) onto the front head pipe. Position the clamp in the approximate location on the tube where it mounts to the engine. 5. Slide one pipe clamp (supplied) onto the rear head pipe. Position the clamp in the approximate location on the tube where it mounts to the top hole in the mounting bar bracket. Refer to figure 1. 6. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike