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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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Suzuki 240 Hayabusa Swingarm Installation Instructions

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Filed Under (Suzuki) by admin on 12-02-2012

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installation Instructions 1.) Stock Component Removal To begin installing this kit it is necessary to raise the rear end of the bike using a suitable hoist. Be sure to keep the bike centered on the front wheel to keep the bike from tipping over. Once you have the bike lifted and properly secured, begin with the removal of the following stock components ( For detailed information on the removal of these parts, please consult your factory manual) : 1.) Muffler or mufflers 2.) Left side and lower body panels 3.) Voltage regulator (08 model only) 4.) Front sprocket cover 5.) Front sprocket 6.) Chain 7.) Rear Axel, wheel and brake assembly 8.) Pivot tube and swingarm
2.) New Swingarm Installation A. Most of the pieces needed are installed on the swing-arm. You’ll need to install the shock mount block with the 4 supplied flat head 5/16″bolts, use red loctite and torque to 25 ft lbs. B. Insert the 2 supplied pivot bushings in the pivot tube. Move your new swingarm into position. Once you have the swingarm in position reinsert the pivot tube to hold it in place. C. On some bikes (07′ and earlier Busa’s) it is necessary to grind approximately 1/8″ off the frame for chain clearance. Not all bikes will require this, but it is best to mock up and test fit before final assembly.

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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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1996-1998 SUZUKI GSXR750 SUPERBIKE LINK KIT Installation Instructions

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Filed Under (Suzuki) by admin on 04-12-2010

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1. Raise the motorcycle and support it to enable the rear suspension to hang free. 2. Remove the stock rear link & struts. 3. Remove the link bearings and sleeves from the stock link with the exception of the bearings and sleeve in the middle of the link. You will be using the bearing & sleeve listed above in the middle position of the new link. This is the same bearing and sleeve that is used at the front of the Link. 4. Press the bearings into the new link making sure that the bearings are centered in the link. 5. Lubricate the bearings with high-pressure synthetic grease. 6. Install the sleeves in the same position as removed using the one listed above in the middle position. 7. Reinstall the link using the new bolt supplied in the kit in the middle position. 8. Torque all the bolts to the factory specifications. Torque the special bolt supplied in the kit to 70Nm, 50Ft-Lb. Blue Locktite is recommended. 9. As a rule of thumb the spring rate should be increased 0.5 kg or 28 lbs. in relation to the spring rate that is currently being used. This is a good starting point. Note: This kit is designed for single rider racing applications. The spring rate and dampening must be tailored for the individual rider weight, style of riding, motorcycle weight and track conditions. An experienced race mechanic using only the appropriate tools for removal and replacement of bearings and other components should only install this kit. Any questions can be directed to Attack Performance at the address and numbers below.

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Suzuki Electronic Jet Kit Installation Instructions

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Filed Under (Suzuki) by admin on 12-02-2012

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at anytime during install or tuning please callus for any and all help, we can’thelpifyoudon’tcall ) 1. Before installing the TFI you must first disconnect the negative lead from the battery. 2. Determinea location for the TFI unit. Suggested locations areas follows: Under the seat, behinda side cover or tail section. 3. The TFIcomeswitha harness with injector connectors that match the factory injector connectors. 4. Locate the factory fuel injectors (see owners manual if you are not sure).** **: Some models are equipped with two sets of injectors (primary and secondary); the unit is designed to interface with the primary injectors. If the TFI harness does not match your injectors do not proceed and call tech support at 877-764-3337. 5. Disconnect the factory injector connectors from the fuel injectors and replace with the TFI injector connectors from the TFI unit, basically unhook the factory injector connector and plug the matching TFI connector (female) to the injector and then connect the factory injector connector to the TFI connector that simulates the injector (male). There is no order to hookup the TFI harness to the factory harness just make sure the original factory connector goes toits’original cylinder. It isa good idea to make sure there is a little slack in the harness to prevent engine vibration from damaging/breakingawireon the connectors. 6. Be sure to check the wires are not indirect contact with any sharp edges, exhaust and/or other objects, which could result in long term wear and/or damage. 7. Connect the TFI ground lead to the negative terminal of the battery along with the factory ground lead. 8. With the rubber plug removed from the TFI, turn the motorcycle key switch to the “ON”position. As the bikes electrical system goes through initial startup mode you may see LED’sflashingonthe TFI.

SUZUKI DR 650SE Oil Filter Guard Installation Instructions

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Before starting make sure you have all the components in the exploded view below. The oil filter guard does not replace the stock oil filter cover but reinforces it with a heavy duty guard. 2. Clean the area around the oil filter housing of any dirt, mud, or grease. 3. Remove the three screws that hold the oil filter cover. 4. Remove the oil filter cover being careful not to loose the cover O-ring and the filter retaining spring. 5. Place the star lock washers over the three screws provided with your new guard. 6. Insert the screws into the mounting holes in the guard. 7. Place the stock oil filter cover over the three screws protruding from the guard. 8. Place the oil filter cover O-ring in the O-ring groove in the stock cover. 9. Place the spring over the boss on the inside of the oil filter cover. 10. Position the entire assembly on the engine and hand tighten the three screws. Be very careful not to loose the O-ring or spring. 11. Check to make sure the O-ring did not get pinched. 12. Tighten the three screws a little at a time with a final torque of 4 ft-lbs (48 in-lb) or 5.5 N-m or 0.55 kg-m. Be careful not to over tighten the screws. Also before inserting screws make sure the threaded holes are free of dirt and grit. Dirt and grit mixed with oil will soon wear away the soft aluminum and cause the threads to fail. DO NOT eliminate the lock washers. The lock washers are there to help prevent the screws from loosening due to engine vibration 13. Getting all the pieces to mount up can be a challenge but with a little practice you should become an expert. If a permanent installation is desired the oil filter cover can be glued to the guard with RTV to aid in installation and give you one less thing to hold together. My best advice is don’t hurry and be thorough. The most costly mistakes are made when you are in a hurry and are not thinking. It might be a good idea just to practice taking the oil filter cover off and putting it back on again so you know how everything fits with the filter, O-rings, and screws. 14. Start the engine and look for leaks or other problems. It is a good idea to inspect your bike before each ride and check your oil level and look for loose bolts or other damage.

SUZUKI GSXR1300R SLIP-ON'S INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 17-12-2010

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1. On the right hand side of the motorcycle, remove the Allen bolt holding the rear of the fairing to gain clearance to the tail pipe clamp (Figure 1). 2. Loosen the two tail pipe clamps, one on each side of the motorcycle. 3. Loosen and carefully remove the muffl er mount bolts and muffl ers. NOTE: Take care not to let the muffl ers drop against the swingarm as they are quite heavy. 4. If gaskets remain on the stock head pipe remove them. As they will not be re-used in this application. 5. Remove the steel inserts and then the rubber grommets from the mount locations on the left and right passenger footpeg hangers. NOTE: Spraying a little contact or brake cleaner on the rubber will soften it up for a few seconds while you push out the inserts and grommets. The steel inserts and rubber grommets will not be re-used and will be replaced by aluminum spacers in this application

2004-2006 Suzuki RM-Z250 Kickstand Installation Instructions

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

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To install your new kickstand: 1. Remove the lower chain roller nut, leave the factory washer installed. Install the included threaded chain roller spacer on the chain roller stud, and tighten. (DO NOT OVER TIGHTEN!) 2. Remove the sub-frame to main-frame mounting bolt. Install the provided subframe bolt spacer into the subframe bolt hole. 3. Install kickstand on the bike using the provided M8X 30mm flat head bolt, in the upper mounting hole. Install the supplied M6X 16mm socket head bolt, in the bottom mounting location. 4. Make sure that you tighten all bolts to the correct torque. 5. Periodically check the kickstand pivot bolt for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride. We recommend using a penetrating lube, such as WD-40. If necessary, you can remove the back cover plate for additional cleaning.

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 DRZ 400E/ S/S M/ Kicker All years and Kawasaki KLX400 All Years CFC Offroad Clutch Cover Installation Instructions

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Filed Under (Tips and Review) by admin on 25-10-2010

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1. Wash engine sidecase to remove any dirt, grease, oil, etc. 2. Clean engine sidecase and the CFC case guard with quick drying solvent such as electrical contact cleaner or brake cleaner 3. Apply an even layer of Permatex 16B silicone adhesive* to the backside of the CFC guard. This can be a messy job and most find the best tool to spread it evenly is your finger. It is suggested that you use a rubber glove to avoid skin contact. Try to get complete coverage free of voids and about 1/16-1/8″ thick 4. Align sidecase Guard with the engine sidecase, keeping the logo horizontal (if the Guard has one). Gently press on the engine sidecase. Once you feel that it is aligned and positioned properly, press with enough evenly distributed pressure to get an equal squeeze out of Permatex all around the perimeter. Don’t worry if you end up with excess. Excess adhesive can be cleaned up with a rag and mineral spirits or brake/contact cleaner. Let dry overnight 5. A couple of strips of masking tape can be carefully applied to assure the guard doesn’t move

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