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Kawasaki KLR Lowering Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 01-12-2010

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locate the OEM tie rods (circled in yellow, in the picture below), and the rear shock absorber snubber (circled in red, in the picture below). Notice that there is a tie rod on each side of the motorcycle. These tie rods are secured by two long bolts that pass first through the LH tie rod, then through the suspension, and finally held in place by two 17mm nuts on the RH side. Loosen these two 17mm bolts, and prepare them for removal. It helps to raise the rear tire just slightly with a jack or by a helper, to take the load off of these 17mm bolts. Below is another picture, better exposing the orange rubber snubber on the lower shock absorber rod… This is where the snubber spacers are installed, but don’t do it just yet…there’s more info on this later in the instructions. 3. Remove the 17mm nuts from the tie rods, keep the weight off of the rear wheel, and remove the upper and lower bolts from the tie rods. The rods are easily removed at this point. Take notice that the LH rod has recesses in each end, where the heads of the 17mm securing bolts fit. 4. Replace the tie rods with the new Scootworks tie rods in your kit. Install the tie rod with the recessed bolt holes on the LH side, with the recesses facing outward. Re-install the bolts from the LH side, through the LH tie rod, through the suspension, and through the RH tie rod. Secure them with the original nuts, and torque to 43 ft/lbs. The recessed bolt holes in the LH tie rod are seen in the picture of the Scootworks KLR tie rods below… 5. Do not install the plastic snubber spacers at this time. Lower the rear of the bike and remove the frame from the lift or jack stands. The rear lowering is completed. Sit on the motorcycle and determine if you’ve lowered it to a satisfactory level. If not, proceed to step #6. Your Scootworks KLR Lowering Kit is now installed. The following information is supplied as a supplement, to allow you to complete the job of lowering your bike that you’ve begun by using this Quality Scootworks product. NOTE: Be sure to check the chain tension after installation of the lowering kit, and adjust as necessary. Tips for setup and use of your lowering kit BE SURE to read the FAQ at the end of this document, for tips, warnings, and adjustments for your new lowering kit! Lowering the Front of your KLR-series Motorcycle

2007 KTM 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING INSTALLATION MANUAL

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Filed Under (KTM) by admin on 05-02-2012

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Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button Pushing the black starter button [2] will actuate the E-starter. Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on. ENGLISH 7 2 Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 3 4 5 6 1 OPERATION INSTRUMENTS » ENGLISH 8 TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21″ with production tires). Afterwards the display will return to the previous display mode

2006 KTM 250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING, REPAIR MANUAL

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Filed Under (KTM) by admin on 05-05-2012

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Hot start lever (250 SX-F) If you pull the red hot start lever [1] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean” fuel-air mixture of the type needed for hot starts.
ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXCUSA) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button (EXC) Pushing the black starter button [2] will actuate the E-starter. Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 2 3 4 5 6 Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on

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Victory Lowering Kit INSTALLATION INSTRUCTIONS

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

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This kit was designed for use with stock length shocks ONLY! We do not recommend using shorter than stock length shocks with this kit. We highly recommend that your dealer install this kit. If you do not have access to a stand capable of securely supporting/lifting the motorcycle as well as tools capable of removing/replacing the suspension links, please allow your dealer to assist you. INSTALLATION INSTRUCTIONS 1. Support motorcycle securely so that rear wheel is off the ground. 2. Remove #19, #21, #22, & #23. Refer to Fig.1 Secure & support the swing arm before removal of these parts. 3. Re-install #19, #21, & #22 using our kit in place of #23. 4. Torque fasteners to 35 ft. lbs. 5. Check for proper clearance at fender & belt guard. Please note that excessive load or other riding/road conditions could cause the bike to bottom out and potentially cause the tire to come into contact with the rear wiring harness. Adjust the pre-load of the shock per the owner’s manual or relocate the wiring harness as necessary

Honda Motorcycle Na vigation Kit

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Filed Under (Honda) by admin on 28-11-2010

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Honda Motorcycle Na vigation Kit Honda Motorcycle Navigation Kit G e n e r i c A c c e s s o r i e s 2 0 0 8 For your peace of mind Honda Genuine Accessories are carefully designed, researched and stringently test ed tot he highest standards. And since they’re all Honda approved you’llknowthat they’rejustastoughand well made as your Honda motorcycle. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice. y e a r w a r r a n t y GENUINE ACCESSORIES Honda Motorcycle Navigation Kit Model Part Number Description RRP Remarks NAKED CBF 600 08A 40MER800B CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY CBF 600 08A 40MER800A CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY ON/OFF XL700V 08A 40MFF800 * CONTAINS NA VI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EARPH ONE, MANUAL, 08A 30MFF800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY XL 1000V 08A 40MBT800 CONTAINSNAVI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EAR PH ONE, MANUAL, 08A 30MBT800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY TOURERS/SPORT TOUR ERS DN-01 08A 40MEH800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, AND BATTERY -CONTAINS 08A 30MEW800 ADDITIONALSTE ERIN G HANDLE C LAMPS FORV ISU AL INTE GRAT ION OF THE COMPONENT NT700V 08A 40MEW800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, BATTERY

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HARLEY DAVIDSON SKULL FOOT BOARD INSERT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Kit 50704-04 is an Operator Footboard Insert Kit. •This kit fits all 2004 and later FLHRS/I (Road King® Custom) model motorcycles. •This kitalso fits 1986 and later FLHR/I/CI, FLHT/C/CI/CUI and FLTR/I models equipped with Swept-Wing footboard pans 50683-04 (right) and 50688-04 (left) . Kit 50704-04 contains the following items: QTY DESCRIPTION PART NO. 1Operator footboard insert (right) 50705-04 1Operator footboard insert (left) 50706-04 Kit 50707-04 is a Passenger Footboard Insert Kit. •This kitfits 2004 FLHTCSE models, and all 1986 and later Touring model motorcycles equipped with Swept- Wing Grooved Passenger Footboard Kit 50357-04 . Kit 50707-04 contains the following items: QTY DESCRIPTION PART NO. 1 Passenger footboard insert (right) 50708-04 1 Passenger footboard insert (left) 50709-04 Kit 50710-04 is an Operator Footboard Insert Kit. •This kitfits all 1980 and later Touring models except FLHRS, and 1986 and later FL Softail®model motorcy- cles equipped with footboard pans 50621-79A. Kit 50710-04 contains the following items: QTY DESCRIPTION PART NO. 1Operator footboard insert (right) 50711-04 1Operator footboard insert (left) 50712-04 Kit 50713-04 is a Passenger Footboard Insert Kit. •This kit fits all 1986 and later Touring models . •This kit also fits 1986 and later FL Softail models when equipped with accessory passenger footboard kits (Part Number 50602-89B, 50955-97A, 50955-00 or 50602-00). • This kit iscompatible with Chrome Passenger Footboard Cover Kits (Part Numbers 50782-91, 50193-96, 50194-96 and 50246-00). • This kit is notcompatible with Leather Passenger Footboard Fringe Kits (Part Numbers 50947-98 or 50956-98). Kit 50713-04 contains the following items: QTY DESCRIPTION PART NO. 1 Passenger footboard insert (right) 50714-04 1 Passenger footboard insert (left) 50715-04 Installation, Kit 50704-04 (For Swept-Wing Operator Footboards): Removing Previously Installed Inserts 1. Apply liquid dishwashing soap to the rubber beads protruding through the bottom of the footboard pan. 2. With the operator footboard in the “up” position, use a screwdriver to work the rubber footboard beads out through the top of the footboard. 3. Repeat the above steps for the remaining footboard insert. Installing the New Inserts 4. Apply liquid dishwashing soap to the rubber beads on the new footboard insert. 5. Place the footboard insert into position on the footboard pan. From the underside of the footboard, use a pliers to pull each rubber bead into its mating hole in the footboard pan until the beads protrude through the pan. 6. Repeat the above steps for the remaining footboard insert.

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HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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2007-2008 Kawasaki ER6 and Ninja 650R Lowering Kit Installation Instructions

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

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1) Raise the motorcycle so the rear wheel is off the ground. As an example, you can use a motorcycle lift, two car jacks, or upside-down paint buckets placed under the foot pegs, but anything stable should do. ” Stable ” is the key word. Please take all precautions! 2) Using the 19 mm open wrench and the provided 8 mm hex wrench, loosen the button head bolt and locknut as shown This large washer will not be there on 2007 & 2008 models 3) Next, remove the locknut and the small washer from the back, and remove the button head bolt and the large washer from the front. You can pull out the button head bolt by slightly moving the rear suspension up and down at the same time. 4) 5) Lift the shock absorber and insert the spacer where the shock absorber was installed before. Note: The original bolt and washers (if any were on your bike) are not going to be used, but you should keep them for the future, in case you decide to uninstall the lowering kit. Slide over the main kit body and insert the provided hex head cap screw as shown Next, slide the provided hex head cap screw all the way through

Daytona 675 Motorcycle Race Kit Installation Manual

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Filed Under (Triumph) by admin on 29-10-2010

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Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Fit the chosen race kit cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Caution The use of the following race kit cylinder head gaskets will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. Item Description Qty 1 Head gasket (t = 0.65mm) 1 1 Head gasket (t = 0.60mm) 1 1 * Page 7 of 29 © Triumph Designs Ltd 2007. Cams, Valve Spring & Sprocket Kits Parts Supplied Camshaft Inlet Kit – A9618055 Camshaft Exhaust Kit – A9618056 Valve Spring Kit – A9618058 Camshaft Sprocket Kit – A9618057 Warning The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of the Camshaft, Valve spring & Sprocket race kits detailed below will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. 5 5 4 1 3 2 4 3 Item Description Qty 1 Cam assy, inlet, race 1 Item Description Qty 2 Cam assy, exhaust, race 1 Item Description Qty 3 Valve spring, 14.4id, race12 Item Description Qty 4 Sprocket, camshaft, 34T 2 5 Socket head cap screw, Encapsulated, M6x10 4
Page 8 of 29 © Triumph Designs Ltd 2007. NOTE •The standard inlet cam is 9.25mm max lift and 258.50o duration. The race kit inlet cam is 9.25mm max lift and 268.74o duration. •The standard exhaust cam is 8.5mm max lift and 246o duration. The race kit exhaust cam is 8.5mm max lift and 262.21o duration. •The race kit valve spring must be used in conjunction with the standard spring platforms and retainers. The fitted length of the race springs is the same as the standard spring. 1. The race kit valve springs should be assembled in the same manner as the standard valve springs. Follow the procedure detailed in section 3 of the Daytona 675 service manual. Ensure the springs are installed with the close wound, colour coded end of the springs facing downwards, towards the piston. 2. The race kit camshafts should be assembled in the same manner as the standard camshafts. Follow the procedure detailed in section 3 of the Daytona 675 service manual. 3. The race kit cam sprockets should be mounted and secured to the camshafts using the slotted holes in the sprocket. The slotted holes allow adjustment of the valve timing. The circular holes in the sprockets are for Triumph service tool T3880102 and should not be used to mount the sprockets to the camshafts. NOTE •No timing marks are included on the race sprockets. Race engines will typically have different depths skimmed off the cylinder head and, therefore require specific individual timing. 4. The camshafts should be timed using cam degreeing equipment which typically consists of a degree wheel, pointer, dial indicator and piston stop. Optimum cam timing will depend on the exact specification of the engine, but a recommended starting point is 104o IMOP (Inlet Maximum Opening Point) and 104o EMOP (Exhaust Maximum Opening Point). 5. Always check the inlet and exhaust piston to valve clearance for the timing selected to use, before running the engine. You must ensure both clearances are adequate. As a guide, the standard nominal piston to valve clearance is 1.3mm inlet & 1.5mm exhaust

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HARLEY DAVIDSON HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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