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HONDA VTX, VTX RETRO AND VALKYRIE DRIVE SHAFT COVER INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Place the cover over the drive shaft housing. 2. Hook one end of the springs provided into the lower holes. Wrap the springs around the backside of the drive shaft housing. Using a needle nose pliers stretch the springs and hook them into the upper holes. 3. Note; if springs are too long, shorten and reform end to be able to hook spring in place.

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HONDA VTX 1800R AND VTX 1300R SOLO RACK INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Remove the stock passenger seat. And “U” shaped mounting bracket from the rear fender. 2. Install the 2 “L” brackets provided (NOTE: there is a left and a right) onto the rear fender using the bolts from the stock bracket. Snug the bolts just enough to still allow them to slide. 3. Using the 3 knobs provided re-install the stock seat using the knob with the long stud in the rear hole. Center the slot in the seat and tighten the knob. Install the 2 knobs with the short threaded studs through the front seat mounting holes and into the new brackets. Center the bracket holes to the seat holes and snug the knobs. This will align the forward brackets. Carefully remove all three knobs and the seat. Tighten the forward bracket securely. 4. Install the solo rack starting with the 2 short knobs at the front then the long knob at the rear with the black spacer between the rack and the fender. Tighten all 3 knobs securely, as tight as you can by hand. Lost knobs are not a warrantable item. Now you can switch from your new cool solo rack look back to your stock passenger seat in seconds without any tools. NOTE: when using the stock seat, place the black spacer on the long rear knob and install them over the stock rear seat bracket. This keeps the long stud from extending below the inside of the fender and possibly contacting the rear tire if the rear shocks should bottom out

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Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

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2007 KTM EXC LED Taillight and Turn Signal Kit Installation Instructions

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Filed Under (KTM) by admin on 31-01-2012

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Remove the seat & fuel tank. Photo 1 Unplug 2. Unplug the two three-pin connectors that mate the taillight & turn signal power leads to the stock wiring harness on top of the airbox. See Photo 1. 3. Unbolt and remove the stock taillight & rear turn signal assembly from the rear fender. The wires & connectors will pull through the gap in the fender/airbox plastic with a little finesse. 4. Unplug the two small white plastic connectors near the upper edge of the stock taillight lens and separate the wire extension from the taillight. See Photo 2. Photo 2 Unplug these two connectors and remove wire extension Photo 3 Remove 5. Using a sharp blade or cut-off wheel, remove the two molded mounting bosses on the bottom of the fender. See Photo 3. 6. Attach the new LED taillight to the fender as shown using the provided countersunk mounting hardware. Use the two longer bolts for the front mounts. The LED cluster should not protrude beyond the edge of the fender

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Honda XR 400 Removal and Installation Manual

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Filed Under (Honda) by admin on 09-12-2011

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Turn Signal Switch Installation Front Wiring Connections Field Effect Transistor Installation Taillight Installation: Install the Acerbis DOT taillight over the empty well left in the stock fender using the two 5 x 20 mm bolts and 6 x 16 mm bolt found in the parts bag. Position the taillight over the previous taillight mounting well and transfer the hole locations for the top mounting holes onto the fender with a felt pen or snap punch (Photo 3) so that they are 3/8 of an inch above the edge of the taillight opening as shown in Photo 3. Drill two 3/16 inch holes for the top mounts. Attach the taillight using the top mounting screws, then pull the license plate holder down toward the bottom of the fender so that the taillight is pulled as horizontal as possible. Transfer drill a 1/4” hole at the bottom mounting location with the taillight in this position. When installing the bottom license plate mount bolt, make sure to install the 6 x 16 mm bolt from the bottom up to minimize the opportunity for the tire to grab it. Run the taillight
wires along the left frame rail using the stock wire clamps to support it. 8. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean,
durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5, 3-3/4 inches back from the front edge (pointed tip of fender where it meets the side panel) and 2-3/4 “ up from the bottom edge Brake Light Switch Installation

Suzuki DRZ400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 23-11-2010

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3.

Kawasaki KLX450R Dual Sport Kit Installation And Removal Manual

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

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1. Remove the seat, fuel tank, and side panels. 2. Unplug and remove the stock headlight. 3. Taillight Installation: The Baja Designs taillight will run in conjunction with the stock taillight for this installation. Start by removing the first wire guide that the stock taillight wires pass through near the end of the fender. Once removed, trim off the remaining molded mounting boss as shown in Photo 1. Drill three ¼” holes in the fender and use the provided countersunk mounting hardware to attach the Baja Designs taillight as shown in Photo 2. The rear edge of the LED cluster should line up with the rear edge of the fender. Route the wires forward between the plastics to the left of the front mounting bolt. We’ll attach them in a later step. Photo 1 Molded mounting boss removed Stock taillight Photo 2
4. Turn Signal Installation: Drill a 7/16″ hole in each side of the fender plastic in the locations shown in Photo 3. Install the rear turn signals and route the wires forward as shown in Photo 4. Photo 3 Photo 4 Zip-tie BD taillight wires to fender here Route left signal wires through fender with stock taillight wires 5. Brakelight Switch: The KLX uses a hydraulic operated switch to activate the brakelight. Installation of this switch requires bleeding the rear brake system. If you do not feel competent performing this task please refer it to a qualified mechanic. An improperly bled brake can lead to rear brake failure. Caliper Guard Modification: The hydraulic brakeswitch replaces the banjo-bolt that attaches the rear brake hose to the caliper. Because of its larger size, the plastic caliper guard must be relieved slightly to provide clearance. Remove the caliper guard and modify as shown in Photo 5.

Honda VTX 1800 Motorcycles EZ-Steer Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Honda VTX 1800 EZ-Steer Instruction Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Honda VTX 1800 Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Recommended Procedures • Disconnect all wiring to headlight and remove headlight, windscreen (if so equipped) and brackets from motorcycle. • Remove handle bars from top clamp. • Remove brake caliper and brackets; disconnect all mounting points on brake lines. Secure calipers to frame being careful not to damage brake lines. • The wheel and fork tube assembly can be removed as one complete unit. • Remove steering lock fromOEM bottom clamp and install on Champion’s bottom clamp. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion’s lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 35 lb. ft.. • Install covers to bottom forks if supplied with OEM motorcycle. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of forks are flush with top surface of clamp. • Torque dome nut to 75 lb. ft.. • Ensure that fork tube extensions are flush with top of upper clamp. Torque lower 8mm bolts to 20 lb.ft. and upper 10 mm clamp bolts to 30 lb. ft.. • Install handle bars to upper clamp using OEM nut and flat washers. • Reinstall brake line holders to the lower triple clamp. • Reinstall all other OEM parts as removed. • Bleed brakes. • OEM windshield # 08R80-MCH-100 can be used on this kit

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HONDA VTX DESTINATIONS FUEL SYSTEM INSTALLATION

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Filed Under (Honda) by admin on 10-02-2012

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WHY CHOOSE A VTX? Riders have always chosen Hondas because they want to ride. Really ride. They like the performance. The reliability. The build quality. They know that a Honda is a bike you can rely on for decades, and thousands of miles. Our 2008 Honda VTX® cruisers still offer all that. But along the way, we’ve added another feature: drop-dead-gorgeous good looks. It used to be you had to choose between performance and style. Between reliability and looks. But with a Honda VTX, you can have it all. Maybe you’re content to trailer your bike places, or to just ride it ten minutes at a time and then get off and pose. Hey, whatever turns your crank—it’s your life. But when you want to actually ride, well, then there’s only one choice

Suzuki DRZ 400K Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 11-02-2012

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DRZ 400 (Kick Start) Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight from the stock wiring and remove. 4. Unplug the kill button from the stock wiring and remove (Photo 2). The connector is a gray two-conductor connector located under the fuel tank. Release detent on connector to separate. Kill switch connector Photo 2 5. Unplug the stock taillight and remove. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. ¼” Photo 3 Countersunk screw and bezel, 4 Places 6. Taillight Installation Position the taillight assembly so that the edge of the red taillight extends past the edge of the fender about 1/4″ as shown in Photo 3. With the taillight positioned as shown Photos 3 & 4 , transfer the four mounting hole locations into the bottom of the fender. Drill the mounting holes at 1/4″ diameter. Use the 6 x 16 mm counter-sunk fasteners and bezels for mounting the taillight

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