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KAWASAKI VULCAN 800 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install the heat shield to the front head pipe using the three 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 front head pipe into the heat shield, 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. 3. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 4. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bracket and into the frame. Leave them loose at this time. 5. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time.

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Kawasaki Vulcan 400/ 800 Preload Improvement Kit Installation Instructions

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

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1. Begin by removing both side compartment covers. The RH compartment cover requires the use of the ignition key for removal; the LH compartment cover is secured by a large Phillips screw. Once you’ve removed the LH cover, place the Phillips screw back into the hole in the frame (so you don’t misplace it) and set both covers aside. In many applications, you must remove the upper exhaust pipe (from the rear cylinder), and loosen the other pipe, to remove the inner parts of the RH side compartment cover (see below). Before attempting step #2 below, try step #3 first… depending on the brand of exhaust pipes you have, you may be able to avoid removal in step #2, if you are successful with step #3 first. Some brands of exhaust pipes provide access to the fasteners securing the RH side covers, eliminating the requirement to remove pipes for rear suspension access. 2. Remove the rear cylinder’s exhaust pipe. To do so, remove the two Allen nuts on the exhaust header, where it attaches to the engine, using an 8mm Allen wrench. Most often, this goes much more smoothly if you first spray the inside of the allen nut with a penetrating lubricant like WD-40. Remove the black acorn nut from the discharge end of the exhaust pipe (under the upper exhaust pipe, near the discharge end of the pipe) using a 12mm open-end wrench or socket. You’ll find a black metal spacer, through which the bolt goes, that is pressed through the rubber grommet. To avoid the potential of having it fall out unnoticed, remove it and place it aside with the nut. Remove the black bolt from the pipe just aft (to the rear) of where the pipe enlarges and above the pipe. This is actually a bracket that holds the two pipes together at a joint. Loosen the bolt using a 12mm socket, then slide it back onto the pipe you’re removing. Once you have the pipe off of the bike, the clamp will be loose. Be sure to keep it with the pipe, along with the rest of the removed parts. Loosen the pipe from the front cylinder BEFORE trying to remove the pipe from the rear cylinder. By loosening the header nuts on the pipe from the front cylinder, and removing the two black Allen bolts (6mm Allen wrench) under the forward pipe that attach it to the frame, you will be able to remove the rear pipe. There are more spacers in grommets where the 6mm Allen bolts secure the lower pipe to the frame (like those used in the rearmost connection o

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KAWASAKI VULCAN 800 STRAIGHT SHOT EXHAUST SYSTEM INSTALATION MANUAL

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install a chrome header flange onto the front and rear head pipes. 3. Install the heat shield to the front head pipe using the two 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 front head pipe into the heat shield, 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. 4. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 5. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 6. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. 8. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Do this to each muffler but leave the clamp loose at this time. 9. Install one muffler to the four hole bracket welded to the V&H mounting bar using the two 5/16″ flange bolts (supplied) and leave them loose. (See figure 1) 10. Slip the muffler and mounting bar assembly onto the front head pipe while aligning the grommet holes in the mounting bar with the holes in the frame.

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Yamaha WR motorcycle ProEFX 12V Hot Start Installation

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Filed Under (Yamaha) by admin on 06-01-2012

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1. Remove seat, tank and shrouds. Remove existing hot start lever, cable and valve from the carburetor. 2. Tip: Clean all dirt from hot start bore and mating surfaces on the carburetor body with gas and a q-tip. 3. Tip: Use a small amount of Teflon tape (one wrap) on the threads of the aluminum mounting nut to ensure a water tight seal. 4. Install the Pro EFX hot start valve in the hot start bore (as shown in picture), with return spring, impact washer and delrin plunger in place. • Tip: Installation of the solenoid valve may require temporary rotation of the carburetor away from the top engine mount bracket. • Install with the solenoid valve assembly disconnected from wiring harness. • Screw in by hand and finish tightening with needle nose pliers. Do not over-tighten. Solenoid valve assembly: 5. Mount activation switch on preferred handle bar location. Pictured on clutch side, in place of the stock kill switch.
6. Route wiring harness around steering column and down frame backbone. Insert battery leads through slot in rubber protective boot. (follow existing wiring to battery) 7. Connect positive (red) and negative (black) leads to motorcycle battery. 8. Connect male and female terminals to wiring harness on previously installed solenoid valve assembly. 9. Depress activation button and listen for valve actuation. Plunger should freely “snap” between open and closed position in hot start bore, as activation button is depressed and released. If you don’t hear the valve “snap” open and closed, follow the trouble shooting guidelines or call /email for support. 10. Maintenance: Periodically ensure proper tightness of solenoid valve in carburetor body as part of standard motorcycle maintenance. Keep the battery terminal connections free from corrosion.

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BMW Motorcycle F 650 GS/ F 800 GS Accessories

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Filed Under (BMW) by admin on 20-11-2010

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Stowage-equipment line Vario case, black, left 71 60 7 696 299 £184 / G Vario case, black, right 71 60 7 696 300 £185 / G (+) Case carrier for Vario case, including fasteners 71 60 7 696 301 £144 / G (+) Lock barrel, complete, for 2 cases 51 25 7 688 566 £20.80 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 2x) 51 25 7 681 199 £33.59 (o) Lock-barrel set 51 25 7 698 202 £15.20 / I Liner for Vario case, left 71 60 7 687 610 £67 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Vario topcase, black 71 60 7 696 302 £225 / I (+) Luggage rack, large, for Vario topcase (including adapter plate) 71 60 7 696 303 £64 / I (+) Lock barrel for topcase 51 25 7 688 568 £12.50 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 1x) 51 25 7 681 199 £33.60 / I (o) Lock barrels for 2 cases and topcase 51 25 7 688 567 £29.10 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Backrest pad for topcase 71 60 7 688 877 £45 / I Luggage carrier, small 71 60 7 701 810 £42.90 / G Tank rucksack, waterproof 71 60 7 711 240 £130 / I Enduro rear softbag 71 60 7 711 245 £35.90 / I Sport softbag, small, 19 l 71 60 7 694 117 £102 / I Sport softbag, large, 51 l 71 60 7 693 567 £139 / I Stuffbag, waterproof, 53 l 72 60 7 653 818 £90 / I Luggage strap with pull-tight buckle 72 60 2 304 808 £6.30 / E Bungee-cord spider 72 60 9 057 579 £3.95 / E Design line Spray-guard extension, rear 71 60 7 695 031 £24.20 / I Sound components Akrapović sports silencer 71 60 7 713 339 *1 £475 / G Ergonomics and comfort line Windscreen, large, tinted 71 60 7 713 834 *1 £138 / I Windscreen, large, clear (standard for F 800 GS) 71 60 7 713 833 £127 / I Windscreen, small, clear (standard for F 650 GS) 71 60 7 713 296 £87 / I Centre stand (F 650 GS) 46 52 7 700 864 *2 £83 / I Centre stand (F 800 GS) 46 52 7 700 049 *2 £91.50 / I (+) Fasteners for centre stand (F 650 GS + F 800 GS) 71 60 7 706 738 £24.90 / I Seat, low, black, 790 mm (F 650 GS), 850 mm ( F 800 GS) 52 53 7 695 013 £174 / I Heated handlebar grips and switches (see electronic parts catalogue) Navigation and communication components BMW Motorrad Navigator III plus 2008 72 60 7 716 116 *1 £650 / I (+) Holder for BMW Motorrad Navigator 71 60 7 697 785 £45.80 / E (+) Securing screw (order 4 of) 32 71 7 652 161 £4.55 / I Connecting cable for BMW Motorrad Navigator 71 60 7 686 670 £55 / E TMC module for BMW Motorrad Navigator 72 60 7 702 687 *1/3 £111 / E Car kit for BMW Motorrad Navigator 72 60 7 703 996 *3 £60.50 / E Navigator carry-bag function 71 60 7 683 161 £49 / I Safety line Hand-protector bar 71 60 7 716 043 £57 / I (+) Countersunk-head screw (order 2 of) 32 71 7 712 836 £3.34 / E Hand protector, small 71 60 7 705 963 £19.50 / I Hand protector, large 71 60 7 715 135 £23.10 / I Protector-mounted spoiler for hand protector, large 71 60 7 705 964 £15.20 / I Crash bar, left 71 60 7 699 437 £104 / I Crash bar, right 71 60 7 699 438 £104 / I (+) Fasteners for crash bar 71 60 7 702 395

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2004 Honda CRF450R OWNER'S MANUAL

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Filed Under (Honda) by admin on 21-11-2010

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motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick- starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever 1. Shift the transmission into neutral. 2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting the engine excessively charged with fuel by throttle blipping or other reasons: 1. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine. 3. Pull the hot start lever and kick-start the engine (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. Stopping The Engine 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle 2 – 3 times, and then close it. 4. Depress and hold the engine stop button until the engine stops completely. NOTE: • Failure to close the fuel valve may cause the carburetor to overflow. (1) THROTTLE GRIP (2) ENGINE STOP BUTTON Break-In Procedure Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: • Piston is replaced • Rings are replaced • Cylinder is replaced • Crankshaft or crank bearing are replaced

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CHANGING OIL IN THE KAWASAKI VULCAN VN 2000

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Filed Under (Kawasaki) by admin on 16-12-2010

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CHANGING OIL IN THE KAWASAKI VULCAN VN2000 ( based on a 2005 model) by tensm an1 Preparing the motorcycle: 1. To start, level the motorcycle – my preference is to put a spacer blocks under the kickstand on the left side of the motorcycle and under the frame on the right side of the bike just under the frame member. These blocks are made from scrap lumber. I find it is easier to set the right side block first as shown and tilt the motorcycle until the frame contacts the block, then, holding the handlebars, kick the left side block under the kickstand. 6″ NOTE: This dimension may not be correct for 2004 models as the 2005 models have a different kickstand – the 2004 model will likely be thicker. To be sure your blocks are the correct thickness the first time, lay a level across the luggage rack as shown. You may need to shim them slightly to hold the bike dead level. 2 7/8″”
Or, in the absence of a luggage rack, the seat will do: 2. Get the necessary tools ready: Oil filter wrench – I like the band type shown, but a metal strap type will work. 14 mm box wrench

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KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 23-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove right side frame cover. 2. If motorcycle is oxygen sensor equipped, remove passenger seat. Remove two bolts securing operator seat and set seat aside. Locate and unplug oxygen sensor connector from wiring harness (Figure 1).(Note wire routing for reassembly). 3. Remove right side floorboard assembly held in place by two bolts (Figure 2). 4. Remove exhaust port flange nuts. 5. Remove flange bolts securing rear muffler to exhaust system mounting bracket. 6. Remove complete exhaust system. Start by removing front head pipe from exhaust port (assistance may be required). Page 1of 4 K400IN Rev. 1.1 KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM Part #18311 Tools required for installations 6mm Allen wrench 8mm 12mm 14mm sockets 3/8″ Ratchet & Extensions 19mm Wrench 9/16 Wrench Brake bleeder & fluid
7. Check condition of stock exhaust gaskets. Replace if damaged or worn. 8. Remove plastic hose clamp securing rear brake hose to swingarm.Save for re-use. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loops in swingarm. 11. Remove three bolts holding stock exhaust mounting bracket and slide bracket off end of brake hose. 12. Slide brake hose through loop on new bracket (stamped 357-P) and install to the original mounting bracket location, using three 8mm x 16mm Allen bolts (supplied) (Figure 3). 13. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 14. Slide brake hose through loops on swingarm and reconnect brake hose to caliper. 15. Reinstall plastic clip onto swingarm. 16. Brake system must be bled or brake will not operate correctly.

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SUZUKI 1400/ 800 INTRUDER TURN SIGNAL RELOCATION INSTALLATION AND CLEANING INSTRUCTIONS

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Filed Under (Suzuki) by admin on 09-11-2010

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1. Refer to Figure 1. 2. Remove seat. Safety: disconnect battery prior to all wiring modifications LeatherLyke 510 5/1/2009 3. Disconnect wires to turn signals. 4. Remove turn signals and retain hardware for reinstallation. Observe and mark “left” and “right” for reinstallation. Information: Do not remove license plate bracket . 5. Remove license plate. Turn signal bracket must be oriented with flange (side with only 2 holes) on top. 6. Install turn signal bracket behind license plate bracket and license plate using 6 x 35mm pan phil machine screws for the 800 or 6 x 20mm pan phil machine screws for the 1400, 1/4″ flat washers, and 6mm locknuts. Insert black spacer spool between license plate bracket and turn signal bracket. 7. Mount turn signals directly to turn signal bracket using 6 x 10mm hex cap screws and star lock washer. Information: Observe all color-coding of wires and splice one wire at a time. 8. Cut each turn signal wires three inches from end and splice 10 inches of supplied wire. Secure wires to inner fender clips. 9. Follow route of tail light wires and connect wires into harness. 10. Secure wires together behind license plate bracket with tie wrap. 11. Connect battery and test turn signals for function. 12. Install seat. Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. WARNING: States may have minimum width requirements on motorcycle turn- signals, so check your local laws. LeatherLyke 510 5/1/2009 SADDLEBAG INSTALLATION 13. Refer to Figure 2. Information: Cover plates are pressed into strut. 14. Remove round cover plate at end of fender mount strut on right side. 15. Remove nut on right rear and replace with 1.2″ hex adapter. If hex adapter is less than flush with the outside of both fender struts, add a 5/16″ flat washer. 16. Assemble 5 x 30mm flathead screw and 5mm mounting spool with chamfer on spool under head of screw. Insert assembly thru 1 1/4″ fender washer for the 1400 or 1″ for the 800. 17. Install spool assembly into previously installed 1.2” hex adapter. Information: Do not remove washer on shock absorber. Hex adapter will protrude 1/4″ beyond fender strut. 18. Remove round cover plate over right rear shock, remove shock absorber nut and install .75″ hex adapter. 19. Assemble 5 x 30mm flathead screw, mounting spool and cup washer with chamfer on spool under head of screw. 20. Install spool assembly into previously installed hex adapter. 21. Insert 5/8” finishing plug into old turn signal hole on right side. 22. Repeat procedures on opposite side

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HARLEY DAVIDSON V-Series California Engine Owner's Manual

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Filed Under (Harley Davidson) by admin on 28-11-2010

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During Break-In At 50 Miles (80 Kilometers): 1- Change engine oil and filter. 2- Inspect for fuel and oil leaks. 3- Inspect air cleaner element and service as required. 4- Check tightness of exterior fasteners, except head bolts. Engine Maintenance at 500 Miles (800 Kilometers): 1- Change engine oil and filter. 2- Inspect for fuel and oil leaks. 3- Inspect air cleaner element and service as required. 4- Check tightness of exterior fasteners, except head bolts. 5- Check operation of enrichment device and throttle controls. 6- Check engine idle speed. 7- Check tightness of engine mounts. Regular Service Intervals Regular lubrication and maintenance will help keep your new S&S engine operating at peak performance. The following table presents the required service schedule for normal operating conditions. Failure to complete the required engine maintenance can result in engine damage and an increase in emissions. Please refer to the motorcycle owner’s manual for any additional required chassis maintenance. Engine Service Intervals Item Interval Engine Oil & Filter Change at 50, 500, 2,500 miles (80, 800, 4,000 kilometers), every 2,500 miles (4,000 kilometers) thereafter1 Air Cleaner Element Inspect at 50 and 500 miles (80 and 800 kilometers), every 2,500 miles (4,000 kilometers) thereafter2 Tappet Oil Screen Inspect every 2,500 miles (4,000 kilometers). Replace every 5,000 miles (8,000 kilometers). Petcock, Lines, & Fittings, Vacuum Lines Inspect at 50 and 500 miles (80 and 800 kilometers), every 2,500 miles (4,000 kilometers) thereafter. Fuel Tank Filter Screen & In-Line Fuel Filter (If used) Inspect every 5,000 miles (8,000 kilometers). Engine Idle Speed Adjust as required. Operation of Throttle & Enrichment Device ControlsInspect at 500 miles (800 kilometers) and every 2,500 miles (4,000 kilometers) thereafter. Spark Plugs Inspect every 5,000 miles (8,000 kilometers). Replace every 10,000 miles (16,000 kilometers) or as needed. Ignition Timing Inspect every 5,000 miles (8,000 kilometers). Engine Mounts Inspect at 500 miles (800 kilometers) and every 5,000 miles (8,000 kilometers) thereafter. External Fasteners Except Engine Head Bolts Re-torque at 500 miles (800 kilometers) and every 5,000 miles (8,000 kilometers) thereafter. 1- S&S recommends that petroleum-based oil not specifically formulated for motorcycles should be changed every 1,000 miles (1,600 kilometers) after the break-in period. 2- Replace more frequently if required or if engine is operated in a dusty environment.

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