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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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2003-2007 Victory Motorcycles Installation Instructions for S&S Freedom Performance Tuner

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Filed Under (Victory) by admin on 31-10-2010

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Once the download of S&S Freedom Performance Tuner has been installed on your PC, double click the icon on your desk top. Picture 3 illustrates the S&S Freedom Performance Tuner icon. 2- Enter in your Username and Password and click the login button. Your Username and Password for logging in will be the same as your login for Picture 1 Picture 2 Picture 3 3 3 – Once you’re logged onto S&S® Freedom® Performance Tuner, click on the Year and Model of the bike you’re performing the work on in the middle of the page as illustrated in Picture 4. 4 – Click on the Select Vehicle tab at the bottom of the page as illustrated in Picture 5. The tabs on the left side of the page will now be illuminated. Picture 4 Picture 5 4 5- Click on the ECU Reprogramming tab on the left side of the screen as illustrated in Picture 6. 6- In the center of the screen you will now be prompted to enter in customer information, VIN number of the motorcycle you are performing calibration download on, and calibration card number. Select a re-flash file from the drop down list that you want to download into the motorcycle. All the fields must be filled out for you to continue with the download. Picture 7 illustrates the information screen with required fields filled out. Picture 6 Picture 7 5 Note: Due to the limited description space available in the drop down list in S&S® Freedom® Performance Tuner, a detailed list of available calibrations and part numbers can be viewed on the S&S dealer web. Go to ® Calibrations on the left side of the home page. Here you will find a detailed list of calibrations and part numbers for reference only. Picture 8 illustrates the home page and location for the S&S/Victory Calibrations. Picture 9 illustrates the calibrations for reference

S&S Super E and G Series "Shorty" Carburetors REMOVAL, Installation and Jetting Instructions

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Filed Under (S&S) by admin on 29-10-2010

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Remove Old Carburetor WARNINGS ● Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a health and fire hazard. ● If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation. ● Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in inadvertent engagement of starter and personal injury. A. Shut off fuel petcock and disconnect battery. B. Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting hardware NOTE – Removing and tightening hard to reach Allen bolts such as carb-manifold mounting bolts and V2 manifold flange bolts can be greatly simplified by the use of Allen ball-end drivers. These tools are available at most automotive and tool supply houses. See Picture 9. Additionally, Performance Plus of Evansville, Indiana, produces a hex wrench specially modified for accessibility of V 2 manifold bolts. Call 812-963-8854 for further information. As alternative, standard hex wrench can be shortened for convenience. NOTE – Some Buell motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be taken off engine. Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with pliers and snap off, then remove fitting. CAUTION – Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S recommends packing breather fitting with gease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for containment of chips and other debris. Picture 2 Picture 4 Picture 3
5 2. Prepare Air Cleaner Backplate NOTE – Fast idle lever screws, part #11-2384, must not be overtightened. Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose. CAUTION – Overtightening fast idle screws may damage backplate. A. All engines except V2s 1. Knuckles & Pans, 1936 to 1965 – Press plugs, part #50-8312, into holes in air cleaner backplate. See Picture 2 . 2. Shovels, 1966 to 1979, and Ironhead (IH) XLs, 1957 to 1979 – Press plug, part #50-8312, into hole in air cleaner backplate. See Picture 3 . 3. Shovels 1980 to 1984 and IH XLs 1980 to 1985 – Screw crankcase breather vent elbow fitting, part #50-8110, into hole in air cleaner backplate and angle downward as shown in Picture 4 . On 1983 and 1984 Shovels press plug, part #50-8312, into other hole on left. 4. Assemble fast idle mechanism as shown in Figure A . B. FL V2s 1984 to 1992 1. Press plug, part #50-8312, into hole on left in air cleaner backplate as shown in Picture 5 . 2. Screw vent hose elbow fitting, part #50-8110, into remaining hole at right. See Picture 5 . 3. Assemble fast idle mechanism as shown in Figure A . C. XL V2s 1986 to 1990 1. Press plug, part #50-8312, into hole on right in air cleaner backplate as shown in Picture 6 . 2. Screw vent hose nipple fitting, part #50-8111, into remaining hole at left. See Picture 6 . Elbow fitting, part #50-8110, supplied in kit may also be used in this location if required. 3. Assemble fast idle mechanism as shown in Figure A . D. FL V2s 1993 and up and XL V2s 1991 and up 1. Press plugs, part #50-8312, into both holes in air cleaner backplate as shown in Picture 7 . 2. Assemble fast idle mechanism as shown in Figure A . E. Buell motorcycles, 1994 and up 1. Assemble fast idle mechanism as shown in Figure A. 3. Throttle Preparation NOTE – Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when released. Cable routing must be free of tight bends to minimize friction between cable and housing

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Installation Instructions S&S Billet Air Cleaner Kit for Victory Motorcycles

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Filed Under (S&S) by admin on 29-10-2010

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory motorcycle following your Victory service manual for the specifi c model you are performing the work on. Picture 1 WARNING 3 Key Switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. Picture 2 illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. Picture 3 points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and Throttle Position Sensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. Picture 4 points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. Picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. Picture 4 points out the IAC rear delivery hose

HONDA GL1800 BACKREST (INSERT) INSTALLATION MANUAL

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Filed Under (Honda) by admin on 04-03-2011

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1. Place motorcycle on center stand. 2. Remove the two passenger handles and seat. 3. Install the base mount between the seat mounts (picture 1) and mark the two holes on seat base. 4. Drill two 9/32″ holes in the seat base. 5. In the middle of the two seams and in the center of the seat, install the boot (picture 2). 6. With a long serrated knife cut a hole in the seat inside the boot opening. You must clear a path in the foam from the cut to the two 9/32″ holes. 7. Insert the long bar through the hole into the seat from the outside with the hole tube facing forward (picture 3). 8. Bolt the base mount to the long bar using bolts and lock washers. 9. Attach the chrome pad mount to the long bar protruding through seat (picture 4). 10. Attach the pad to the pad mount with the mounting bracket (picture 5). 11. Reinstall the seat and adjust the pad angle (picture 6). Reattach passenger handles

2008 Kawasaki ZG1400 Concours ABS Front 3-Line Kit and FK003D625R Single Line Rear INSTALLATION INSTRUCTIONS

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

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Step 1: Identify the key components that complete our front brake line kit: You should have three (3) hoses, one (1) double banjo bolt, and two (2) single banjo bolts There are also a total of nine (9) washers and (3) brass conic inversors. Seven (7) washers and two (2) inversors will be used; the rest are spares. If you have purchased a rear kit as well, locate the following additional pieces: One (1) hose with bracket and c-clip attached, one (1) single banjo bolt, two (2) brass inversors and three (3) washers. You will use one (1) “olive” conic inversor and two (2) washers, the rest are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. On the front brake line kit, we are replacing three hoses and their respective blocks (see pictures 1-2 for blocks) . For the rear, we are replacing one hose from the master cylinder to the ABS hard line. Take note of how the stock system was routed, in case you need to reinstall it. Step 4: Locate Line A – This will travel from the master cylinder to the ABS Junction. (See picture 3) You will use a single banjo bolt and two washers at the master cylinder, and an “olive” inversor to thread female end to hard pipe for incoming ABS (right side). * We have replaced the block at the upper triple clamp with a c-clip; please use your stock bolt to thread this in. (See picture 4) Locate Line B – This will travel from the ABS Junction to the right caliper. First, thread the female end to the hard pipe for outgoing ABS (left side). There will be a bolt from the OEM blocks at ABS Junction; please use this to thread c-clips into frame as shown in picture 5 . There is another bolt/OEM block located at the lower triple clamp; please use this to thread the c-clip in as seen in picture 6. Locate Line C – This will cross over the front fender using OEM holders, from right caliper to left caliper. Thread caliper banjos from Line B and C using the following sequence: double banjo hex, washer, 40- degree banjo from Line C, washer, 20-degree banjo from Line B, washer, caliper. Please see pictures 7 and 8 for reference. Thread single banjo bolt into left caliper, using two washers and 40-degree banjo. If applicable, locate rear Line D – this will travel from the rear master cylinder to the hard line for ABS. Thread the hard pipe into female end using a “olive” inversor, and attach bracket to swingarm as seen in picture 9 . Use the bolt from the holder for ABS hose, and sit our bracket on top of the OEM holder. Using the bolt from the OEM ABS hose holder in location shown in picture 10 , attach the c-clip on top of holder and tighten. Finally, thread 30-degree banjo in caliper using the following sequence: single banjo hex, washer, banjo, washer, caliper

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Victory Motorcycles Lloydz Motorworkz Billet Air Cleaner Kit Installation Instructions

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Filed Under (Victory) by admin on 31-10-2010

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory® motorcycle following your Victory service manual for the specific model you are performing the work on. Key switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. picture 2 below illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. picture 3 below points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and throttle position s ensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. picture 4 next page points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. picture 4 points out the IAC rear delivery hose

Balancing Honda GL1500 Carburetor Manual

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Filed Under (Honda) by admin on 08-04-2011

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First pry off the plastic clip covering the screw as in the first picture. Note the type of screw used, as shown in the third picture. You must put this one back in the right place. Tip; When refitting this clip later on, a bit of Blutack or similar will stop it falling off and getting lost. Pull the L piece trim away, taking care not to break the tab shown in the fifth picture Now pry off the small black plastic cover at the rear of the running light. Blutack will be a good idea here as well when refitting the cover. The owner of this GL1500 didn’t use it and the cover on each side of the Goldwing got lost, which is why you can’t see them in the pictures. Note the type of screw used here as well, same as the one mentioned earlier. The third picture shows the two normal Phillips screws at the front of the running light, remove them. Remove the running light and pull the lower fairing panel away Remove the rubber plug from the right side fan. The adjuster screw for balancing the carbs is about 6″ behind and up, and hard to see. I removed the fan so I could get the camera in and the second picture shows the adjuster screw

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2006-2008 Yamaha R6 FK002D512GP ( GP Kit ) INSTALLATION INSTRUCTIONS

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

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Step 1: Identify the key components that complete our GP kit: You should have 3-line (front kit), 3 SINGLE banjo bolt and 1 C-CLIP. There are also a total of 8 washers. 6 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines, all other installations VOID warranty. Inspect your brake system after every race. Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the GALFER GP 3-Line starting with the master cylinder line (top line). Torque level is 12 to 13 ft pounds. (See picture A2) Step 5: Install the C-CLIP provided to the lower triple tee top line needs to be held by c-clip [see picture A4&A5] . Lower lines will travel in front of the forks to the calipers; two single banjo bolt (see picture A1) are included for master cylinder to each caliper. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, forty-degree banjo (Top line), and washer. Single banjo bolt torque level is 12 FT Pounds. ( See picture A2 for positioning) Make sure that the [ CALIPER fittings ] on each caliper are positioned [ positioning ] (see picture A6- A7) . Thread banjo bolt into the caliper, and torque bolt to 12 to 13 Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and are clear of any obstructions. Once the lines have been checked for clearance. Proceed to step #6 Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with GALFER DOT 4-brake fluid is recommended.

2007-2008 KAWASAKI ZX-6RR GP Kit INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 05-01-2011

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Step 1: Identify the key components that complete our GP kit: You should have 3-line (front kit) , 3 SINGLE banjo bolt and 1 C-CLIP. There are also a total of 8 washers. 6 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines, all other installations will VOID the warranty . Inspect your brake system after every race. Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the GALFER GP 3-Line starting with the master cylinder line (top line). Torque level is 12 to 13 ft pounds. (See picture A2) Step 5: Install the C-CLIP provided to the lower triple tee left line needs to be held by c-clip [see picture A4] . Lower lines will travel in front of the forks to the calipers; three single banjo bolt (see picture A1) are included for master cylinder to each caliper. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 40-degree banjo (Top line), and washer. Single banjo bolt torque level is 12 FT Pounds. ( See picture A2 for positioning) Make sure that the [ CALIPER fittings ] on each caliper are positioned [ positioning ] (see picture A5- A6) . Thread banjo bolt into the caliper, and torque bolt to 12 to 13 Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and are clear of any obstructions. Once the lines have been checked for clearance.

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