what size is the axle nut on yamaha road star warrior 1700

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HARLEY DAVIDSON REAR AXLE-NUT COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REAR AXLE-NUT COVER KIT GENERAL Kit Number 41704-09, 41705-09, 41706-09 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section (English only). Additional Parts Required 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 This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTES The shorter axle-nut cover mounts to the right side of the motorcycle. Axles that have been removed for service, replacement or repair may have been assembled in reverse orientation from their stock design. Axle-nut covers may not fit properly on reversed axles. Refer to the appropriate Service Manual for correct axle orientation. 1. Adjust the position of the exhaust system (if necessary) to provide axle-nut clearance. 2. Position each axle-nut cover over the appropriate axle nut. 3. The skull version nut covers have two set screws per cover. Position the logo and snug up one set screw to hold in place and the other to prevent rotation. 4. Tighten the axle-nut cover set screws to 70 in-lb (7.9 Nm) . NOTE The set screws in this kit are treated with a thread-locking compound. When replacing or re-installing the set screws (2), apply Loctite® 243 (Blue) Threadlocker and Sealant (Harley- Davidson Part Number 99642-97) to the set screw threads. SERVICE PARTS

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Yamaha Road Star EZ-Steer Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Champion Yamaha Road Star EZ-Steer Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamp of your Yamaha Road Star Motorcycle. Much of the OEM hardware is retained and reused. It is assumed that the installer has advanced and/or professional skills in motorcycle servicing. We recommend that you use an OEM service manual and follow the prescribed disassembly, installation and torque specifications for the upper and lower clamp assembly. Recommended Procedures • Remove headlight, windscreen (if so equipped) and brackets from motorcycle. • The wheel and fork assembly can be removed as one complete unit. Disconnect the master cylinder brake line from the tee fitting below the lower triple clamp. The caliper brake lines may be left in place on the tee fitting. • Install supplied extensions to fork tubes the supplied o-rings. Apply lubricant to o-rings and extensions prior to installing to fork tubes. • Install the lower fork tube covers to the lower clamp prior to installation to motorcycle using the longer screws supplied. The two longest screws are used in the outboard holes. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 30 lb. ft. • Slide fork tubes up through bottom of lower clamp approximately 6-8 inches. Install the OEM gaskets, washers and upper fork tube covers. Do not reinstall brake line holders at this time. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of extension is flush with top surface of clamp. • Torque dome nut to 85 lb. ft. • Ensure that fork tube extensions are flush with top of upper clamp. Torque upper and lower clamp bolts to 35lb. ft. • Install handle bars to upper clamp using OEM bolt with supplied flat washers. One washer on top, two on bottom, both sides. • Reinstall brake line holders to the bottom of the lower triple clamp using the supplied M6 NyLoc nuts. • Reinstall all other OEM parts as removed. • Bleed brakes. EZ-Steer Maintenance

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Yamaha Road Star Warrior Fuel Injected Models INSTALLATION INSTRUCTIONS

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

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1. Remove seat and fuel tank. 2. Remove airbox and left airbox cover. We highly recommend you consult the factory service manual for proper removal of airbox. 3. Route wiring harness under frame bracket towards airbox. (Fig 1) 4. Unplug stock black connector for fuel injectors. (Fig 2) 5. Plug Fuelpak 4-pin connectors in-line with the connectors from step 4. 6. Unplug the TPS connector and attach T-tap connector to the center wire (yellow). (Fig 3) 7. Route the Fuelpak violet wire to T-tap. (Fig 4) 8. Reattach the TPS connector. 9. Route black wire to the front of engine and down to the horn. (Fig 5) 10. Disconnect the factory black/white wire from horn. Plug Fuelpak into horn and plug Fuelpak black/white wire to Fuelpak connector. 11. Route black and green wires to battery negative. 12. Attach Fuelpak to Fuelpak harness and mount under seat as shown. (Fig 6) 13. Before reassembling the bike, make sure handlebar switch is in the engine-not-running position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the black wire connection on the horn and that it is connected to the correct wire from the factory harness. 14. Follow the service manual to reinstall the airbox and gas tank. INSTALLATION INSTRUCTIONS FOR P/N 65005 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION FUEL INJECTION MANAGEMENT SYSTEM ROAD STAR WARRIOR NOTICE: Fuelpak is intended for racing or off-highway use only, and is not legal for sale or use in California on pollution-controlled vehicles. PLEASE NOTE: FUELPAK USE REQUIRES A HIGH PERFORMANCE AIR FILTER. HOW IT WORKS ENTERING VALUES 1. Remove Fuelpak clear case cover by removing all four screws, save hardware . 2. Turn on main power with key, but do not start engine. Fuelpak display should light up, if not, turn power off and verify the connectors are fully seated. 3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071. 4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct value as indicated in your Setting Value. After entering your first value, press the mode select button to move to mode 2 and enter the value. Continue until you have entered the value for each of the first 18 mode positions. Each time the value (+) is pressed, the value increases by one number. Each time the value (-) is pressed, the value decreases by one number. (Please refer to the “How It Works” section directly above if you have questions about this step. 5. As the next procedure, after you have entered in your values for the first 18 modes, press the mode select button to move to mode 19. Fully twist open the throttle and return to idle position to calibrate the Fuelpak to your bike. 6. By pressing the mode select button twice, move to mode 21 and verify that it reads “0″ with the throttle closed, “50″ at approximately half-throttle and “99″ when fully opened; if not, repeat step 5. Do not proceed to step 7 until mode 21 is verified. 7. Enter any other mode values as required for your application. 8. Turn off power. 9. Reinstall clear cover, tuck Fuelpak under seat area and reinstall seat. 10. You are now ready to ride.

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HARLEY DAVIDSON SOFTAIL CHROME REAR AXLE ADJUSTER AND COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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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. Block the motorcycle underneath the frame so the weight of the vehicle is off of the rear wheel, but do not raise the rear wheel off the ground. 2. Some models require loosening or removal of the muffler or mufflers in order to remove the rear axle. See the EXHAUST SYSTEM REMOVAL section of the Service Manual. Remove the saddlebags if desired for extra working clearance. See SADDLEBAG REMOVAL in the Service Manual. 3. See Figure 1. Remove the original axle adjustment bolts (1) and jam nuts (2) from both sides of the motorcycle and discard. NOTE On a bike that has been previously serviced, ensure that the axle has not been removed and re-installed from the left side (with the castle nut to the right of the wheel). If it has, the axle MUST be inserted from the right side of the motorcycle. 4. Remove the retaining pin (7), castle nut (5) and washer (4) from the left side of the axle (6). Discard the washer, but save the pin and nut for later re-assembly. 5 7 1 4 6 2 3 is04101 1. Axle adjust bolt 2. Jam nut 3. Axle adjuster collar 4. Washer 5. Castle nut 6. Rear axle 7. Retaining pin Figure 1. Rear Axle Hardware (Left Side Shown) 5. Tap the axle toward the right side of the motorcycle and remove. The belt adjuster collars (3) will fall loose as the axle is removed. The collars can be discarded. The wheel bearing spacers may also fall loose or be dislodged. Be sure to return these to their original position on the vehicle (short spacer on the right side, long spacer on the left). 6. Inspect axle components for damage or excessive wear, and replace as required

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YAMAHA ROAD STAR WARRIOR OIL COOLER KIT INSTALLATION MANUAL

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

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INSTALLATION: 1. See FIG. F: Apply a thin film of oil to O-RING (#9) on OIL COOLER MOUNT ADAPTER (#2). Install the OIL COOLER MOUNT ADAPTER with OIL COOLER SUMP STUD (#6). Note that o-ring on adapter is mounted against oil filter sump. TIP: Only tighten “finger tight” at this point so adapter can move as needed to adjust oil lines. 2. See FIG. G: Install OIL LINES (#3 & #4) to OIL COOLER and OIL COOLER MOUNT ADAPTER as shown. Do not tighten fittings yet. NOTE: The shorter 9-3/4″ OIL LINE will be on the TOP fitting on the ADAPTER. 3. See FIG. H :Install OIL COOLER to frame with the BILLET OIL COOLER CLAMP (#7). Adjust OIL COOLER to desired position and tighten the three 10-24 X 1/2 SOCKET HEAD SCREWS (#8) securely. Rotate the OIL COOLER MOUNT ADAPTER as necessary to align the Oil Lines properly. WARNING: Make sure OIL COOLER is moved outward far enough so that it does not contact the Front Fender when the fender goes through its full range of motion! 5. See FIG. I & J: Tighten the AN fittings on the OIL COOLER MOUNT ADAPTER as shown with an 11/16″ open end wrench. Tighten the AN fittings on the OIL COOLER with an 11/16″ open end wrench. TIP: To prevent the OIL COOLER from turning when the fittings are tightened, place a thin screw driver or long allen wrench between the fittings as shown. NOTE: DO NOT USE ANY SEALANT ON AN FITTINGS! 6. See FIG. K : Tighten OIL COOLER SUMP STUD (#6). Re-install oil filter. Start the engine and check for leaks. Check oil level and top-off as necessary. MAINTENANCE:

YAMAHA ROAD STAR WARRIOR BIG SHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove right side rider and passenger footpeg assemblies. (Save footpegs and bolts for future reassembly. Do not disconnect brake master cylinder plunger rod.) 2. Remove front cylinder exhaust port flange nuts. (Save) 3. Remove rear cylinder exhaust flange bolts. (Save) 4. Remove two bolts connecting muffler mounting bracket to lower frame rail. 5. Remove bolt connecting muffler to upper muffler bracket. Carefully remove complete system from motorcycle. (Assistance is recommended.) Note : Apply tape on crank case area just in front of rear head pipe bend to protect paint during dissassembly and assembly. 6. Remove M6 x 35 button head screws connecting rear brake master cylinder reservoir to stock muffler bracket. (Do notdisconnect hose. Save screws.) 7. Remove stock upper muffler bracket. (Save M10 x 25 button head bolts for reassembly.) VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. 2. Install rear brake master cylinder reservoir bracket (stamped 333) using saved M10 x 25 bolts and supplied M10 lock nuts (Figure 1). 3. Attach rear brake master cylinder reservoir to bracket (stamped 333) using saved M6 x 35 screws and supplied M6 lock nuts (Figure 1). 4. Install and tighten mounting bracket (stamped 336) to frame using supplied M10 x 25 button head allen bolts (Figure 2), If required, M10 flat washers are provided to space bracket away from frame casting ridge. 5. Place heat shields on a non-abrasive surface such as a blanket or carpet. Mark outside surface of front and rear heat shields with location of mounting

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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YAMAHA ROAD STAR WARRIOR PRO PIPE HS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 24-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove right side rider and passenger footpeg assemblies. (Save footpegs and bolts for future reassembly. Do not disconnect brake master cylinder plunger rod.) 2. Remove front cylinder exhaust port flange nuts. (Save) 3. Remove rear cylinder exhaust flange bolts. (Save) 4. Remove two bolts connecting muffler mounting bracket to lower frame rail. 5. Remove bolt connecting muffler to upper muffler bracket. Carefully remove complete system from motorcycle. (Assistance may be required.) Note : Apply tape on crank case area just in front of rear head pipe bend to protect paint during dissassembly and assembly. 6. Remove M6 x 35 button head screws connecting rear brake master cylinder reservoir to stock muffler bracket. (Do not disconnect hose. Save M6 x 35 button head screws.) 7. Remove stock upper muffler bracket. (Save M10 x 25 button head bolts for future reassembly.) VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. 2. Install rear brake master cylinder reservoir bracket (stamped 333) using saved M10 x 25 button head allen bolts and supplied M10 lock nuts. (Refer to Figure 1) 3. Attach rear brake master cylinder reservoir to bracket (stamped 333) using saved M6 x 35 button head screws and supplied M6 lock nuts. (Refer to Figure 2) 4. Install and tighten megaphone mounting bracket (stamped 334) to frame using supplied M10 x 25 button head bolts. (Refer to Figure 3 & 4) If required, M10 flat washers are provided to space bracket away from frame casting ridge. 5. Unscrew all hose clamps (supplied) until they are completely loose. Mark top edge of front, rear, and collector heat shields with the location of mounting clips that are welded to

HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY DAVIDSON SOFTAIL REAR AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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INSTALLATION 1. 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. 2. All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. 3. 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. 4. All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. 5. All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. 1 2 4 3 is04788 1. Axle adjuster screw 2. Jamnut 3. Castle nut 4. Cotter pin (or spring clip) Figure 1. Rear Axle Hardware

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