tool to set toe on kawasaki mule alignment

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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

Kawasaki Mule Lift Kit Installation Manual

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Filed Under (Kawasaki) by admin on 04-05-2012

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Front Lift Installation 1. Ensuring that the parking brake is set, place jack under center of the Mule front end and lift until front wheels clear the ground. Be careful to support Mule properly so that it is secure, but so that the A-arms and struts can droop to full extension. 2. Remove front wheels. 3. If applicable, remove the heater to allow access to the strut mount behind the heater coil. Heater 4. Starting with the left side (driver side), remove the cotter pin and castle nut that secures the strut to the strut mount. Castle Nut & Pen 5. Push bolt through the bolthole, taking care not to damage the brake line that is attached to the bolt. If you are having difficulty removing the bolt, you may have to remove the brake lines that are attached to the front brakes. In this case refer to owners manual for removing brake lines. Screwdriver NOTE: Keep in mind that if you remove the brake lines you must bleed your brakes according to operator’s manual. 6. Once the bottom of the strut has been loosened, then unbolt the top of the strut. The nuts securing the top strut can be located in the dash of the Mule on the left and right sides. In most cases these nuts are easily accessible, but you may have to remove the glove box or heater coils, depending on the model and options purchased with the Mule.

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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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TRIUMPH ROCKET III HEEL / TOE SHIFTER INSTALLATION INSTRUCTIONS

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

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1. Loosen the 10mm nuts at the ends of the shifter linkage rod (notice one end is a left hand thread). Remove the 10mm nut from the shifter arm & disengage the linkage. Remove the shifter pivot bolt using a 8mm hex key wrench. Remove the washer on the threaded side of the shifter pivot bolt. 2. Place one of the wave washers supplied onto the pivot bolt. Place a small amount of grease on the shifter pivot bolt shank and the Heel / Toe shifter pivot hole, insert the pivot bolt into the pivot hole of the toe heel shifter. Use a drop of blue loctite on the shifter pivot bolt threads and install the Heel / Toe shifter, tighten the pivot bolt securely. Check to see that the shifter pivots freely. If the side play is excessive (this is a result of variances in manufacturing tolerances of the stock and supplied components) remove the pivot bolt and install the second wave washer supplied. 3. Unscrew the linkage rod and replace it with the longer rod supplied (NOTE the rod has a left hand thread on one end and right hand threads on the other). Insert the shifter linkage stud into the desired hole in the new shifter being sure the flats on the stud engage the slot on the backside of the bolthole. Install the nut and finger-tighten only at this time. 4. While seated on the motorcycle first find the height setting you prefer for the toe shifter. Using one of the three boltholes for the linkage can set this. You can also gain some adjustment by exposing more or less threads of the new longer shifter linkage rod; however be sue that you have a minimum of 4-5 threads still engaged in the linkage ends. After setting the height, tighten all three 10mm nuts (the two at the ends of the linkage rod and the one which attaches the linkage to the toe/heel shifter) securely. After you have the toe shifter adjusted to your liking you can select the heel shifter height by moving the button head cap screw that secures the toe shifter to the heel shifter (Using a 5/32″ hex key wrench) next to the 10mm linkage nut to any of its three holes

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Kawasaki MULE 600 / 610 SNOW PLOW INSTALLATION INSTRUCTIONS

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

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1. PRELIMINARY: 1.1 Remove the six 6 mm. screws and plastic skid / splash shield from the bottom front of the vehicle frame. (These bolts and plastic skid / splash shield will not be reused snow plow mounting frame installed onto the vehicle.) 1.2 If the vehicle has the Kawasaki optional brush guard installed, it will have to be removed and then reinstalled after the snow plow mounting frame is installed. (The brush guard will fit with the snow plow mounting frame installed first.) 2. VEHICLE MOUNTING FRAME 2.1 Position the vehicle mounting frame (13) under the front of the vehicle so that the six holes (with pipe spacers) line up with the six 6 mm. threaded holes that the plastic skid / splash shield was attached with and the upper plate is through the large oval hole in the vehicle plastic fascia. Fasten loosely using 6mm. x 1.0mm. x 30mm. bolts (33) , 6mm. lock washers (35) and 6mm. flat washers (34). 2.2 Place a 5/16″-18 “U” bolt (36) around the front cross tube behind the plastic fascia and through each set of holes in the flange of the upper plate of the vehicle mounting frame (total of two “U” bolts). Fasten loosely using 5/16″flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.3 Install a 5/16″-18 “U” bolt (36) around the lower frame tubes and through each set of slotted holes in the lower plate of the vehicle mounting frame (total of four “U” bolts). Fasten loosely using 5/16″ flat washers (41), 5/16″ lock washers (40), and 5/16″-18 nuts (42). 2.4 Tighten all the fasteners holding the vehicle mounting frame to the vehicle starting with the 6mm. bolts

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HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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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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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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Filed Under (Kawasaki) by admin on 30-11-2010

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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KAWASAKI TERYX 750 CLUTCH KIT INSTALLATION INSTRUCTIONS

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

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1. Remove both seats from the vehicle. Next, remove the passenger side lower body panel. There is a mixture of Philips head screws and also plastic push pin fasteners that have to be removed. 2. With the side panel off, the next item to remove is the plastic housing over the engine. These are all “push in” style plastic clips that hold it in place. Once all the pins are out, you can slide the housing off and set it aside. 3. Now the lower long plastic panel under the seat has to be removed (again mainly plastic push clips to remove) . Once they are all out, carefully remove and set aside. 4. Next, remove the fuel tank. Remove the two lines on the top of the tank. There are two straps that hold the tank in place. Remove the bolt from each strap, remove the straps, and lift the fuel tank out. 5. Now the bracket that holds the fuel pump on has to be removed. There are two bolts here to take out. Once this is done, mark the two wires to the coil and disconnect them. Set the bracket out of the way . 6. Next, the clutch cover bolts can be removed and the norkel on the housing can be loosened and i Teryx 750 Clutch Kit Instructions 5/1/09 removed. Take the clutch cove off and set out of the way. 7. With the clutch visible, you can remove the secondary clutch with a large impact wrench and metric socket . 8. Remove the bolt from the primary clutch. This is a left hand thread on the bolt. Next you will need a Kawasaki drive clutch puller (part #352251) to pop the clutch loose. If you do not have a puller, the spring cap can be removed on the vehicle and the weights can be changed out in there as well. 9. With the clutches sitting on the bench, remove the bolts that hold on the spring cover. Remove the stock spring and the stock weights 10. After reading the directions on the new weights, add the correct amount of weight to each clutch weight and install them in the clutch. Place the weight to the left side in the clutch pocket and then install the aluminum spacer. Repeat this process for the other three weights. 11. Install the new spring supplied in the kit and install the spring cover, paying close attention to the arrows on the cover. 12. Next, remove the stock spring from the secondary. It is recommended that you use the TEAM Compression tool (part # 930001) for this. With the clutch on the compression tool, compress the spring retainer down far enough to remove the snap ring with the needle-nose pliers . Slowly back off the t-handle and remove the tool.

HONDA GL1800 DRIVER BOARDS WITH HEEL/ TOE SHIFT INSTALLATION INSTRUCTIONS

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

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1. Place the motorcycle on its centerstand. Remove the stock foot pegs and mounts (four 6mm wrench size allen screws) 2. Beginning on the left or shift side remove the rubber cover from the shift pedal. (Some WD-40 or armor all will make it much easier). Using a hacksaw cut the retaining knob off the end of the shift pedal as shown in photo #1A. Don’t worry should you ever remove the floorboards you can replace the rubber and glue it in place. 3. Install the left floorboard assembly being sure the fork in the toe-heel shifter goes over the shift pedal. Install the two original bolts and snug them. 4. Locate the black plastic shift bushing (see photo #2A) notice the set screw on the side of the bushing slide the bushing onto the shift pedal with the small diameter going on first and engaging the fork on the toe-heel shifter. The shoulder of the bushing should be touching but not putting a side force on the fork. Rotate the bushing so that the set screw is at 9 o’clock tighten the set screw. Locate the rubber cap provided and install it over the end of the stock shift pedal. (See photo #2B). 5. Next rock or pivot the floorboard assembly up and down noting the play between the bolts and bolt holes. Position the floorboard half way between these two extremes then tighten the bolts securely. Check for clearance between the bottom of the toe shifter and the floorboard (min. 1/8″) by pushing the toe shifter down until it stops while rotating the rear wheel (see photo 2C). If there is not sufficient clearance loosen the two mounting screws and pivot the floorboard to obtain the1/8″ clearance and retighten the screws. If installing the heel shifter into one of the two optional forward mounting holes check for the 1/8″ clearance while rotating the rear wheel and up shifting. 6. On the right side remove the 12mm brake pedal mounting bolt, notice the punch mark on the pedal shaft that aligns with the slot in the pedal. The pedal MUST be re-installed in the same position. Pull the pedal outward and off the shaft. 7. See photo (3). On the bottom side of the footpad make a mark ¾” from the rear and outside edge as shown. Drill a ¼” hole thru the pedal at the mark. See photo (4) lay the brake pedal extension upside down on a bench and place the stock pedal into the opening as shown, while holding the two pieces firmly together and using the hole drilled earlier as a guide drill a ¼” hole thru the bottom of the pedal extension. Turn the two pieces over, using a needle nose pliers insert the ¼” bolt provided from the top down thru both pieces, install the lock nut provided and tighten securely. Carefully align the punch mark with the slot on the pedal and re-install the brake pedal (should the shaft slide inward you will need to remove the chrome side cover and hold the shaft outward using your finger as shown in photo (5A). Install the original 12mm bolt and tighten securely