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Triumph Bonneville America And Speedmaster The Freak Installation Instructions and Parts List

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

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INSTALLATION In order to install The Freak, the factory air-box must be removed. Because of it’s design, the factory air-box is not an item that is easily removed. There are several parts that must be removed in order to get the air-box out of the bike in one piece. We recommend using the following method to remove your air box without having to cut it into smaller pieces in order to get it out of the frame. 1. PARTS REMOVAL In order to gain access to the air-box, it is necessary to remove certain parts of the motorcycle to gain access to the air-box area of the frame. Removing the following parts should be the first steps you take. A. Seats – Remove both seats starting with the passenger pillion, if applicable. B. Side cover and grommets – Remove the plastic side cover on the right side (throttle side) of your motorcycle. This is the faux oil-tank cover that has the name of your bike on it. Underneath the side cover there are three rubber grommets (1 on the frame tab, and two on the air-box) that support the side cover. Remove the two that are on the air-box and leave the one on the frame. You will attach the two that you removed to the right side bracket in Section 4C . C. Faux air filter covers – On the right side of the bike, remove the chrome faux air filter covers, by removing the one allen head screw that holds it onto the air-box. On the left hand side (clutch side) remove the faux air filter cover in the same manner, you removed the one on the right. D. Plastic shrouds – on the left side, remove the black plastic air-box shroud, by removing the two allen head screws holding it in place. Then remove the plastic shroud covering your fuse box (this is the piece that surrounds your ignition terminal next to the battery). E. Battery – Remove the battery by unscrewing the torx-head bolt that holds the chrome bracket in place. Remove the chrome bracket and the black plastic cap. Tilt the battery out of the box with the top towards you. Disconnect both battery terminal connectors, negative (-) terminal first. Remove the battery. F. Battery box – Remove the two bolts that hold the battery box to the frame. Pull the battery box out as far as you can, then remove the the ignition terminal from the battery box, by removing the two allen screws that hold it in place from the back. Next, remove the fuse box from the battery box, by pushing it out from the back. It is not necessary to disconnect any of the wiring going to the fuse box, or the ignition terminal. G. Rear fender – Remove the rear fender, by first disconnecting the taillight wires. Follow the wires from the tail light assembly on the inside of the rear fender (left side) towards the front of the bike until you come to the box connector. Disconnect the tail light wires at this connector, being careful not to break it. Once the wiring is disconnected, remove the 6 bolts that hold it to the struts. Have someone hold the fender for you while you are removing all of the bolts so that it does not drop once the bolts are removed. Slide the fender out the rear of the bike. 2. PREPARE THE MOTORCYCLE FOR AIR-BOX REMOVAL To remove the factory air-box without damaging it, it is necessary to lift the bike. We recommend the use of a multi-position ATV/motorcycle jack with a minimum lift height of 10″. A. Setting up the lift – Place the lift under your bike and secure your bike to the lift according to the lift manufacturer’s instructions. B. Raise slightly – Lift the motorcycle to the point where the rear springs are without tension, but NOT to where the rear tire is off the ground. C. Remove the rear springs – Take off each of the rear springs by removing the the two bolts on each spring. Once all the bolts are removed gently pull the springs out off of the studs. If they do not pull off easily, you can raise or lower the bike slightly with the lift to ease tension on the spring. Remember, you should not have the rear tire off the ground at this point. The bike should only be raised enough to relax the tension in the springs. D. Remove the mufflers – Remove the mufflers by loosening the clamp at the exhaust header, and by removing the rear foot peg hangers. If the mufflers are not removed, they can become damaged by the axles in Section 2H . E. Disconnect the carburetors – With a small flathead screwdriver, pull the retainer springs out of the channel of the carburetor intake tubes (the two large black tubes coming from the air box into the back of each carburetor), and simply push them towards the air box off of the carbs

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2009 Kawasaki ULTRA 250X/ 260X FUEL INJECTION CONTROLLERS And REGULATORS INSTALLATION MANUAL

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

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The R&D high performance Air Filter Kit will improve acceleration and top speed performance by increasing air flow and reducing air temperatures that enter directly into the Ultra 250X’s air plenum box area. The O.E.M. air plenum box on the Ultra 250X is a great design that will flow plenty of air. However, the air that feeds the plenum box is heated by the engine. R&D has created an easy to install “flat filter” that installs directly in place of the large center access inspection cover located directly under the main glove box. The R&D Flat Air Filter insert will allow unrestricted fresh and cool air to enter the air plenum box area which will add power you can feel and a nice high performance tone. The R&D Performance Filter Kit also features two filters, one for each of the surge and blowoff protections valves. The O.E.M. surge valve recycles compressed hot air back into the air box plenum at idle and under deceleration conditions. The R&D surge and blowoff valve filter kit removes the air recycling hoses which will keep the hot air from entering the air plenum box reducing the engines intake air temperatures. The R&D Ultra 250X Air Filter Kit offers great performance tips on how to remove the restrictive air vent hoses which will further reduce the under seat ambient air temperatures. The R&D Filter system does not remove or alter the O.E.M. plenum box in any way, therefore there are no questions to be answered regarding water ingestion

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Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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Air Shock Installation Instructions

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Filed Under (Tips and Review) by admin on 24-11-2010

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Air HoseInstallation. Choose the most convenient loca- tiononyour motorcycle for the air fill valve. Drilla 5/16″hole and install the air fill valve as shown in Figure 3orsecure air fill valve to frame tube. 2. Keep hose ends clean during installation because dirt can cause air leaks. 3. Install hose connector, tube clamp and two O-rings onto one end of the air hose (See Figures4&5) Apply rubber lubricant (soap solution, not oil) to the O-rings to ease installation on the air hose& into the shock absorber inlet. Plastic connector should just bottom on fitting. Do not overtighten! The function of the nut is to hold everything together in place, the O- rings do the sealing. Fin- gertightenonly (10 in/lb maximum). 4. After routing the air hose, trim the length to fit air fill valve. Install hose connector, tube clamp, and twoO-rings onto end of hose (See figures 4&5). Lubricate as above and assemble to air fill valve. Use the same procedure formating hose. Important —leaveasmall amount of slack in hose near shock absorber to allow for the slight move- mentofthe shock. Caution! Do not install hose near ex- haustsystem, battery or any other sharp edges or seat movement. Keep hoses clear of moving parts such as wheels or suspension components. Do not allow hoses to have excess slack and sag below the motorcycle. The hoses could catch on road surfaces or debris and could be damaged while the motorcycle is in motion. 5. If necessary the air hose can be secured along the motorcycle’swiringharness with tie-wraps. 6. Testing: Inflate system to 50 psi. Apply soapy water solution to all connections and check for air leaks. If there are any leaks, disconnect the suspected fitting and check for dirt or damage to the air line or the O-rings. Remove any dirt or foreign matter, re-lubricate the O-rings and reinstall. If unable to locate the leak, remove rubber boot from shocks and submerge pressurized components under water (in- cludingT-Valve) and check for leaks. If you cannot solve the air leak problem, please contact our technical staff for assistance

Toyota Celica GT 2000- 2003 5 speed and automatic REMOVAL and INSTALLATION

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Filed Under (Toyota Manuals) by admin on 23-09-2011

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Remove the OBD canister, vacuum switching valve and air temperature control sensor from the air box
without removing any vacuum lines. Once all sensors have been removed take out the remaining air box
and air duct leading to the throttle body. Remove the two-piece air duct leading into the black ECU box.
We recommend you remove the front bumper to make the installation easier. The vacuum switching
valve used to control the valves or by-pass flaps in the box will no longer be used. These flaps control the
amount of air taken in when the engine is running. A 3mm cap will cap-off the port at the engine block.
2 Slip the 2 3/4” straight hose over the throttle body and use two clamps. Tighten the clamp on the throttle
body at this point. (See fig. 2) 3 Remove the black relay fuse box from the bracket bolted to the car frame. (See figs. 1) Remove the stock m6 bolt holding the bracket in place and set the OBD canister on top of the bracket. Screw
the stock bolt tight in place securing the OBD canister to the bracket. Take the vibra-mount and screw
it into the tapped hole right above the OBD canister. (See fig. 6) 4 Once the bumper has been removed cut an opening in the lower section of the plastic wheel well as seen in figure 3. A razor or any cutting device will work to make the opening

KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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TOYOTA TUNDRA 2007 COLD AIR INTAKE REMOVAL And Installation

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Filed Under (Toyota Manuals) by admin on 26-09-2011

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Removal Procedure: 4.7L V8 OE Air Inlet System (a) Remove the two 10 mm cap nuts and throttle body cover (Fig. 4-1). (b) Remove air cleaner hose assembly. (1) Disconnect the vacuum hose and No. 2 ventilation hose (Fig. 4-2).
(2) Loosen the two 10 mm hose clamps and remove the air cleaner hose (Fig. 4-2). 5. Removal Procedure: 5.7L and 4.7L V8 OE Air Inlet System (a) Remove the air cleaner lid. (1) Disconnect the MAF sensor connector (Fig. 5-1).
(2) Using a clip remover, detach the wire harness clamp (Fig. 5-1). (3) Unfasten the 4 hook clamps and then
remove the air cleaner lid (Fig. 5-1). (b) Remove OE air filter and save. (c) Remove the two 10 mm bolts and air cleaner
case (Fig. 5-2)

TOYOTA All Models AIR CONDITIONING EVAPORATOR ODOR

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Filed Under (Toyota Manuals) by admin on 09-10-2011

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A musty odor may be emitted from the air conditioning system of some vehicles which are usually operated in areas with high temperature and humidity. It is most noticeable when the air conditioner is first turned “ON” after the vehicle has been parked for several hours. The odor could result from one or more of the following conditions: 1. Blockage of the evaporator housing drain pipe, resulting in the build up of condensate. 2. Microbial growth in the evaporator, arising from dampness in the evaporator housing where the cooling air flow is dehumidified. To address excessive air conditioning evaporator odor, check the evaporator housing drain pipe for blockage. If no problems are found, the evaporator and housing should be cleaned and disinfected using the general procedure given on page 2, and the model specific procedure on the pages indicated in the Table of Contents at the bottom of this page. Affected While this procedure may be used on any Toyota vehicle, this bulletin gives details Vehicles specifically for the AE100 Corolla, SXV/VCV10 Camry, MCX10 Avalon, MX83 Cressida, AT 180/200 Celica, ST184/204 Celica, JZA80 Supra, EL42/44/53 Tercel/ Paseo, TCR10/20 Previa, FZJ80 Land Cruiser series as well as recent production Truck, Tacoma, T100, 4Runner and MR2 models.

HARLEY DAVIDSON LOCKING GLOVE BOX DOOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. Unsnap the original equipment (O.E.) left-side glove box door, and unfasten the tether by bringing the aglet end (see Figure 1, B) out through the retaining hole. Always wear proper eye protection when drilling or grinding. Flying debris could cause serious eye injury. (00402e) 2. Using an 3/16 inch (5 mm) bit positioned in the center of each snap, drill out the four plastic snaps surrounding the glove box opening. NOTE The glove box door, hinge and frame assemblies are side- specific. The assemblies install so that the tether retaining hole (C) in the door frame is to the inboard side. 3. Obtain the new left-side glove box door, hinge and frame assembly (1), a lock (2) and a tether assembly (8) from the kit. Remove the nut (3) from the lock. 4. Insert the lock through the hole in the glove box door as shown. Assemble the tether over the lock threads with the tab (A) on the inboard side of the lock, same as the retaining hole in the door frame. Tighten securely. 5. Open the left-side door, and position the door assembly at the glove box opening, lining up the holes. 6. Insert a screw (9) through each of the holes in the door frame and glove box. Install a hex nut with washer (10) onto the threads of each screw. Tighten finger-tight. NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the gaskets to the glove box door frame. 7. Clean the glove box door frame with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. NOTE The glove box gaskets are side-specific. With the paper backing facing the door frame, the oblong hole at the top of the gasket is to the outboard side. 8. Obtain the left-side gasket (6) and a hinge gasket (7) from the kit. Install the gaskets to the glove box door frame. a. The gasket liner on the large gasket is split to aid alignment. Peel one half of the liner from the adhesive backing of the left-side gasket. b. Using the frame edges and screw heads as a guide, carefully position the gasket to the glove box door frame and press firmly into place. c. Peel the remaining half of the liner from the gasket backing, and carefully position the rest of the gasket to the door frame. Press firmly into place. d. Apply steady pressure for a few seconds at all areas of the gasket to verify proper adhesion. e. Peel the liner from the hinge gasket. f. Carefully position the gasket to the door frame above the hinge, and press firmly into place.

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Kawasaki Prairie 650 Snorkel REMOVAL AND INSTALLATION

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

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Remove plastic from around air filter housing. Remove air filter housing lid and air filter. Remove 8 small screws from bottom of air box. Next, remove bolt from front and rear of air box. Remove the air box. Remove old snorkel from air box. Remove hose clamp and rubber drain tube from old snorkel. Reinstall on new snorkel. Install new snorkel vertical with the air box. Reinstall air box making certain all vacuum hoses are reinstalled. Check for clearance around new snorkel. Make sure all wires and steering stem do not come into contact with the snorkel. Adjust as necessary Reinstall filter and filter cover. Jetting depends on your elevation. A good starting point for 1000 feet and under is to remove the main jet #142 from the rear carburetor. Install it in the front carburetor. Purchase and install a #145 main jet in the rear carburetor. This works well with an aftermarket air filter and exhaust. For a very reasonable price, HMF Exhaust offers a jet kit with their exhaust that we recommend. Let them know Diamond G Racing sent you.

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