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Kawasaki 900/1100 Billet Head Installation And REMOVAL Instructions

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

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1) Remove stock head and clean the top surface of the cylinder. 2) Remove the stock water fitting from the stock head and install it in the ADA Racing® billet head in the center cylinder location. Install the 1/8″ npt brass plugs in the 2 outer cylinder locations. 3) Install all o’rings in the ADA Racing® billet head, use small amounts of grease to hold them in place, do not use super glue or silicone. 4) Apply a small amount of grease to the small (OR020) o’ring at the top of the dome. This will allow the dome to easily slip into the head shell. Be careful when turning the head upside down to install onto the cylinder, as the domes can slide out of the head shell. 5) Make sure all the o’rings are in place and place the head on top of the cylinder with the water outlet on the intake side. You must be sure that none of the o’rings slip out of their groove, as this will cause an o’ring to get pinched and a water or compression leak could result. 7) Torque all of the nuts to 15ft/lbs, in a center-out criss-cross pattern. Now, torque them again to 18ft/lbs. 8) After the 1st time out riding the head should be re-torqued. 9) The 2 additional 1/8″ npt holes in the ADA Racing® billet head come with brass plugs, but barbed fittings can be installed for custom water routing applications.

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Kawasaki Ultra/ STX-R Billet Head Installation Instructions

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

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1) Remove stock head and clean the top surface of the cylinder. 2) Remove the stock water fittings from the stock head and install them in the ADA head in the same order. 3) Install all o’rings in the ADA billet head, use small amounts of grease to hold them in place, do not use super glue or silicone. 4) Apply a small amount of grease to the small (OR020) o’ring at the top of the dome. This will allow the dome to easily slip into the head shell. Be careful when turning the head upside down to install onto the cylinder, as the domes can slide out of the head shell. 5) Make sure all the o’rings are in place and place the head on top of the cylinder with the water outlets on the top side. You must be sure that none of the o’rings slip out of their groove, as this will cause an o’ring to get pinched and a water or compression leak could result. 6) Use the additional 8mm flat washers on the taller studs, along with the stock wash- ers. 7) Torque all of the nuts to 15ft/lbs, in a center-out criss-cross pattern. Now, torque them again to 18ft/lbs. 8) After the 1st time out riding the head should be re-torqued

YAMAHA VIRAGO 700/ 1100 2 into 2 EXHAUST SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). 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. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8″ x 1″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16″ x 1 1/4″ bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time

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HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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HARLEY DAVIDSON AUTOMATIC COMPRESSION RELEASE TOOLS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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INSTALLATION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) 4 3 6 5 6 1 2 7 is05443 1. Drill, 1.250 inch 2. Drill stop collar, 1.250 inch 3. Drill stop gauge 4. Socket head screw, 5/16 inch 5. Socket head screw, 1/4 inch 6. Dowel pin 7. Top plate Figure 1. Top Plate and Drill Bit Stop Collar Installation 1. Remove valves from cylinder heads. NOTE Do not allow the threaded studs to damage the gasket sealing surface of the cylinder head. 2. See Figure 7 and Table 1. Mount a cylinder head to the tooling plate (1). 3. Place a head bolt spacer (7) over each stock head bolt and lubricate threads and thrust faces, dowels and studs. Tighten head bolts in a crisscross pattern to 10 ft-lbs (13.5 Nm) . 4. See Figure 1. Align the top plate (7) bolt and dowel holes with the head hole pattern, Screamin’ Eagle logo towards the spark plug. This plate will only fit one way for the cylinder head it is being installed on. If the plate does not align with the head, turn it over keeping the logo towards the spark plug and install the cylinder head. 5. Lubricate the two dowel pins (6) and insert in the top plate and into the cylinder head. 6. Apply lubricant to the two socket head screws (4 and 5). Insert into their respective holes in the plate to the cylinder head and tighten to 5 ft-lbs (6.8 Nm)

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Yamaha Road Star 1600/ 1700 Exhaust kit bill of materials Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove left side cover, by removing allen bolt as shown (Fig 1). Once bolt is removed, push cover to motor and push back carefully to your upper body. Figure 1 2. Once left side cover is removed, remove 6mm bolt to opposite side cover as shown (Fig. 2). Also remove allen bolt on right side as shown (Fig 3) and remove carefully . Figure 2 Figure 3 . Remove two allen bolts to the muffler bracket, and also loosen hose clamp to bottom head pipe. (Fig 4 & 5) Figure 4 Figure 5 4. Remove bolt next to rear O/2 sensor bracket as shown (Fig 6), also remove Phillips head bolt from O/2 bracket and slide O/2 sensor off bracket as shown (Fig 7). Once bracket is removed mount just bracket on with Phillips head bolt back on. Figure Figure 7 5. Disconnect O/2 by using a pick on inside switch on opposite side of O/2 bracket. With pick on inside push to you and unplug. (Fig 8 & 9) Figure 8 Figure 9 6. Remove two socket cap nuts from rear head pipe flange as shown (Fig 10). Once removed, remove both mufflers and rear head pipe carefully. Slide muffler back and shift rear head pipe to you. (Fig 11) Figure 10 Figure 11 7. Slide wire off bracket from the front O/2 sensor as shown (Fig 12). Also use pick to remove O/2 sensor, push to you and unplug. Figure 12 Figure 13
8. Remove two allen bolts from foot rest/ brake to give you access to head pipe. (Fig 14) Figure 14 9. Remove two allen socket cap nuts off front head flange and remove head pipe. (Fig 15) Figure 15 10. Remove stock muffler bracket by removing two alien bolts as shown (Fig 16). Also remove bolt that holds stock bracket to the brake line (Fig 17). Once that is done remove brake line from caliper and slide though muffler bracket and re-install. Figure 16 Figure 17
Assembly 11. Remove O/2 sensor from stock pipe and install O/2 sensor in Roadhouse front head pipe and mount front head pipe with stock socket cap nuts on bike as shown. (Fig 18 & 19) Figure 18 Figure 19 12. Mount rear head pipe as shown (Fig 20), including stock socket cap nuts. Also mount y-collector with rear head pipe. Y-collector must slide into front head pipe in one. Install Roadhouse O/2 sensor wire lead from hardware kit into y-collector. (Fig 21) Figure 20 Figure 21

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KAWASAKI VULCAN 700/750 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Place the bike on the center stand. 2. Remove the three clamps attaching the heat shield to the left hand head pipe and set the heat shield aside. 3. Remove the two heat shield clamps attaching the heat shield to the right hand head pipe and set the heat shield aside. 4. Loosen the pinch clamps where the mufflers slip onto the muffler box (the black box in front of the rear tire). Remove the bolt attaching the mufflers to the footrest. 5. Remove the left and right hand mufflers and set them aside. 6. Remove the right hand foot rest and brake pedal assembly from the frame. 7. Loosen the pinch clamps where the head pipes slip into the muffler box. 8. Remove the two nuts that secure the right head pipe to the cylinder head. Repeat this step on the left head pipe and save the nuts for reuse. 9. Remove the left and right hand head pipes. Remove the header flange from each head pipe and save the two flanges for reuse. Set the head pipes aside. 10. Remove the two bolts (one on each side) that mount the muffler box to the frame. Lower the muffler box down and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Remove the two bolts from the charcoal canister mount, the canister is located in front of the rear tire. Using the two 6mm x 16mm bolts (supplied) install the centerstand stop bracket, (stamped 205), by aligning the holes in the bracket with the holes in the canister mount. Be sure the bend closest to the holes in the bracket angles towards the rear of the motorcycle and the tang is pointed to the left hand side. Tighten the two 6mm bolts at this time. 2. 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. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns. 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. Leave them loose at this time. 3. Install a three hole mounting bracket to each muffler as shown in figure 1. Slide one dog bone shaped nut plate under the bracket that is welded to the backside of each muffler. Attach the mounting bracket using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note : The muffler bracket stamped #284 is for the right hand muffler, bracket #285 is for the left hand muffler. 4. Install the rear exhaust assembly, with the heat shield attached, to the rear cylinder using the stock flanges and nuts. Install the stock muffler mounting bolts through the rear footrest brackets, the supplied muffler brackets, and finger tighten the nuts. Leave them loose at this time. 5. Repeat step #4 with the front head pipe

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BMW Motorcycles All R1100 Models- Cylinder Head Gasket

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Filed Under (BMW) by admin on 16-11-2010

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Situation: All R1100 models produced from calendar week 18 (April 28, 1997) onwards will be equipped with head gaskets of Multi-Layered Steel (MLS) technology. Service Information: The MLS cylinder head gasket can be used in place of all earlier gaskets, on all R1100 models, without any modifications. Part Number: MSL cylinder head gasket for all R1100 models. P/N: 11 12 1 341 173 Note: The MLS cylinder-head gasket is applicable to R1100 models only. If it becomes necessary to replace cylinder-head gaskets on R850 R models, the conventional gasket, P/N 11 12 1 342 082, must be used. Warranty Processing: If your retail center has any quantity of the conventional head gasket for the R 1100 models, P/N: 11 12 1 342 127, in stock, please file a warranty claim using the information below. If your retail center has the engine gasket set, P/N: 11 00 1 341 901 in stock , please make sure that the new style MLS gaskets are used in place of the conventional head gasket supplied in this set. All current BMW NA inventory of P/N 11 00 1 341 901 will have the MLS head gasket included. Defect Code: 00 11 01 00 00 Frame Number: 4990150 Warranty Type: 2 Warranty Stage: 1 Very truly yours,

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2008 FLT Police Models Service Manual Supplement

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ITEM SERVICED 14-21 ft-lbs (19.0-28.5 Nm) Drain plug torque Engine oil and filter 4 qt. (3.8 L) Oil capacity Hand tighten 1/2-3/4 turn after gasket contact Filter 63798-99A Chrome filter part number 63731-99A Black filter part number FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity Primary chain lubricant Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml) 14-21 ft-lbs (19.0-28.5 Nm) Primary chaincase drain plug torque 1/2-1 turn Adjuster screw free play Clutch adjustment 72-120 in-lbs (8.1-13.6 Nm) Adjuster screw locknut torque 1/16-1/8 in. (1.6-3.2 mm) Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm) Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads. Lubricant level Transmission lubricant FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity 32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm) Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm) Transmission filler plug/dipstick torque Front: 36 psi (248 kPA) Pressure: solo rider Tire pressure and wear Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread pattern Wear 55 in-lbs (6.2 Nm) minimum Spoke nipple torque Wheel spokes 99953-99A (12 oz.) D.O.T. 4 hydraulic brake fluid part number Brake fluid level Front: 0.20 in. (5.0 mm) Fluid level (from top of master cylinder reservoir) Rear: 0.26 in. (6.5 mm) Front: 7-10 in-lbs (0.8-1.1 Nm) Master cylinder reservoir cover screw torque Rear: 12-15 in-lbs (1.4-1.7 Nm) 0.016 in. (0.4 mm) Minimum brake pad thickness Brake pads and discs 75-102 in-lbs (8.5.-11.5 Nm) Brake caliper pad pin torque Front: 0.18 in. (4.5 mm) Minimum brake disc thickness Rear: 0.25 in. (6.3 mm) 0.008 in. (0.2 mm) Maximum brake disc lateral runout (warpage) 10 lb. (4.5 kg) Upward force applied at midpoint of bottom belt strand Drive belt deflection 3/8-7/16 in. (9.5-11.1 mm) FLHTP 1/4-5/16 in. (6.4-7.9 mm) FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm) Air cleaner cover bracket screw torque Air cleaner 36-60 in-lbs (4.1-6.8 Nm) Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER 243 (BLUE) Air cleaner cover screw Threadlocker Part No. 99642-97 (6 ml) LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.) Lubricant part number Clutch cable 35-45 in-lbs (4.0-5.1 Nm) Handlebar switch housing screw torque

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2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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