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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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HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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2008 Suzuki GSXR 600-750 Super bike Kit INSTALLATION INSTRUCTIONS

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

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Step 1: Identify the key components that complete our SUPERBIKE brake line kit: You should have two (2) hoses, one (1) double banjo bolt, and two (2) male adapters with two 1.55mm thick washers. There are also a total of (7) washers. five (5) will be used, and two (2) are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. 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 with the two thick crush washers provided into the calipers with one washer, and torque at 12 to 13 ft pounds. 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 is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 90 degree banjo from left line, washer, 90 banjo from right line, washer and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. (For positioning see picture A) Make sure that the 90-degree fittings on each caliper are pointing away from the bike just a little bit (see picture B) . Thread each female 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 (GALFER’S C-CLIP) to bring the lines together about the same level as the lower triple clamp.

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 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.)

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2007 SUZUKI SV650 CUP RULES

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Filed Under (Suzuki) by admin on 22-02-2012

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suzuki SV650 Cup motorcycles must meet the requirements of Lightweight Sportbike Equipment except as noted: a) The exhaust system may be replaced with commercially available aftermarket exhaust systems meeting mandatory track noise limits. b) The rear shock may be replaced with an after-market shock. c) Front forks must remain stock. Internal springs, valving, and oil may be changed with any aftermarket components. d) All riders must race on the same brand of tires. For 2007 the spec tire will be Pirelli . The Pirelli SuperCorsa Pro 120/70-17 SC1 (Super Soft) front and the Pirelli SuperCorsa Pro 160/60-17 SC2 (Soft) rear for dry weather and the Diablo Rain 120/70-17 SCR1 (Super Soft) front, 160/60-17 SCR1 (Super Soft) rear for wet weather conditions. e) Steel braided brake lines may be used to replace stock lines. Calipers and rotors must remain stock. (After market brake pads are acceptable.) f) Horsepower limit: 75hp measured at the rear wheel (Sanctioning body to enforce if required). g) Suzuki SV Cup Machines must weigh no less than 365 pounds in the same condition in which they finish the race, including all fluids such as oil, water and fuel. Weights will be checked immediately following races, and no fluid may be added prior to the determination of weight or before the post race horsepower check on the dyno.

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2003 SUZUKI SV 1000 Service Manual

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Filed Under (Suzuki) by admin on 26-02-2011

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections . 2. The section titles are listed in the GROUP INDEX . 3 . Holding the manual as shown at the right will allow you to find the first page of the section easily . 4. The contents are listed on the first page of each section to help you find the item and page you need . COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view . Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided . Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40 . If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart . BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result . Do not use any brake fluid taken from old or used or unsealed containers . Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil . GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only . WATER FOR MIXING Use distilled water only . Water other than distilled water can corrode and clog the aluminum radiator . ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze . Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator . LIQUID AMOUNT OF WATER/ENGINE COOLANT

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SUZUKI M109 1800 cc FRONT/REAR EXHAUST / HEATSHIELD INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set collar and grommet aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve actuator solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System

SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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DUCATI TITANIUM EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Ducati) by admin on 26-10-2010

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BILLET BRAKE RADIAL MOUNTS Moto Corse brake radial mounts are crafted by precision machine tools as shown, the caliper mount is “box” type precision tooled from single ERGAL 7075 solid piece. The result: performance, reduced weight, quality and beauty unmatched by none used extensively in moto gp as standard technology Moto Corse delivers moto gp technology for the ultimate performance. The kit is available for caliper with bolt distance 108mm or 100mm and includes all the parts to assemble it on the bike. 102143002 102143003 102143005 102143006 102143008 102143009 102143011 raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM Ducati 999s/999r/749r Ducati 748r/996sps/996r/998r/998 eF Ducati 748r/996sps/996r/998r/998 eF Ducati 999s/999r/749/r Ducati 749/749s/999 748/998 – MOnster 1000/s4/s2r Ducati MultistraDa 1000D

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