KAWASAKI VULCAN 900 SLASH CUT STAGGEREDS INSTALLATION MANUAL

0

Filed Under (Kawasaki) by admin on 02-05-2012

download
1. Attach mounting bracket 440-P to frame using two stock fl ange head bolts used on stock upper bracket (Figures 1 and 2). 2. Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through (Figure 3). 3. Lay front header, and rear header into their head heat shields and muffl er body heat shields. 4. Install #20 hose clamps (supplied) on heat shields and #36 (supplied) on muffl er body heat shields by feeding tail end of clamps into heat shield clips (fi gure 3). Take note of clamp screw head direction (Figure 4). Screw heads must be accessible when system is installed on motorcycle for adjustment purposes. NOTE: Do not tighten at this time. 5. Using stock fl ange nuts, carefully install head pipes into exhaust ports. Assistance may be required. NOTE: Do not tighten at this time. 6. Slide nut plates inside bracket that is welded to backside of muffl er bodies (Figure 5). While holding nut plates in place, attach muffl er bodies to mounting bracket 440-P using two 5/16″x 5/8″ fl ange head bolts (supplied). Leave them loose at this time. 7. Align muffl er bodies so they are level and parallel when viewing from the right side of the bike. Tighten cylinder port exhaust fl ange nuts on front and rear cylinders. 8. Tighten the fl ange bolts on both muffl ers. 9. Tighten all heat shield clamps. 10. Check for adequate clearance of all exhaust system components and motorcycle accessories prone to heat damage. NOTE: For models with fl oorboards, two Spacer washers are supplied to space out the fl oorboard bracket enough to allow the fl oorboard to fold up without hitting the heat shield. 11. Be sure to tighten all hardware before starting your motorcycle. 12. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up

Incoming search terms:

HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 13-04-2011

download
REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

HARLEY DAVIDSON SOFTAIL DETACHABLE WINDSHIELD INSTALLATION INSTRUCTIONS

0

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

download
INSTALLATION NOTES To prevent scratches, cover the headlamp and the front of the fuel tank with a clean cloth and be sure the windshield assembly does not contact chrome or painted parts when removing or installing it. 1. Remove the original equipment windshield, if equipped. Discard the windshield and attaching hardware. 2. See Figure 1. Remove and discard screws and washers securing trim strip (6) to the front and rear trim pieces. 3. Peel protective cover from adhesive side of clear tape. Center tape over front panel trim piece, attach tape to trim piece, wrap tape edges around trim piece and attach to back of trim piece. Leave the protective tape on the trim pieces after kit installation. 4. Install a flat washer (2), bushing (3) and thick washer (4) onto mushroom screw (1), then install the screw into the upper hole of the trim strip (6) and front and rear trim pieces. Do not tighten screw. 6 1 4 2 3 5 4 2 3 is02411a 1. Mushroom head screw (2) 2. Flat washer from kit (4) 3. Docking point bushing (4) 4. Washer, thick (4) 5. Button head screw (2) 6. Front panel trim strip Figure 1. Front Panel Trim Strip and Windshield Dock Installation 5. Install a flat washer (2), bushing (3) and thick washer (4) onto button screw (5), then install the screw into the lower hole of the trim strip (6) and front and rear trim pieces. Tighten screws to 96 in-lbs (10.8 Nm) . 6. Repeat procedures 2 – 5 on the opposite side. 7. Lock the bottom windshield assembly jaws into the grooves of the lower rubber docking bushings on each side of the front fork assembly. 8. Hook the top windshield assembly jaws into the grooves of the upper rubber docking bushings. 9. Firmly press the windshield into place until it is seated on the docking bushings. 10. Tighten the upper screws to 96 in-lbs (10.8 Nm) . Improper installation of accessories or loading of cargo can affect motorcycle stability and handling, which could result in death or serious injury. (00455b) Failure to provide adequate clearance between stationary and moving parts can cause loss of control, which could result in death or serious injury. (00378a)

HARLEY DAVIDSON FLHR/ FLHP WINDSHIELD KITS INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 09-02-2011

download
INSTALLATION 1. Remove stock windshield. 2. Remove all hardware that secures the mounting brackets to the windshield. The nine screws that must be removed require a T-27 TORX® screwdriver. Save all hardware and brackets for installing the new windshield. 3. Remove all old tape from the brackets. Apply tape from kit to areas of the new windshield that had tape on the stock windshield. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets and tighten all screws and acorn nuts to 23-27 in-lbs (2.6-3.0 Nm) . 5. Install windshield on motorcycle. Improper installation of accessories or loading of cargo can affect motorcycle stability and handling, which could result in death or serious injury. (00455b) Failure to provide adequate clearance between stationary and moving parts can cause loss of control, which could result in death or serious injury. (00378a) NOTE Inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. NOTE Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of components. CARE AND CLEANING NOTE Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections

HARLEY DAVIDSON CHROME SADDLEBAG LID TRIM KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 08-02-2011

download
INSTALLATION 1. Remove all articles from inside, then thoroughly wash and dry the saddlebag lid. 2. Close the saddlebag lid. Cut a piece of masking tape at least 10 inches (25 cm) long and lay it lengthwise down the center of the top outer surface of the lid starting at the front. Mark a line lengthwise down the tape, measuring an equal distance from each side so the line is centered on the lid. 3. Obtain the template (7) from the kit, and position it on the line, with the short leg held against the front surface of the lid. Carefully mark the tape at the two arrows, then remove the template and set it aside. 4. At each of the marks made in Step 3, carefully drill a 1/8 inch (3 mm) diameter pilot hole. 5. Using the pilot holes drilled in Step 4, use a 9/32 inch (7 mm) diameter bit to finish drilling the holes for the trim piece. NOTES Before installing the lid trim, test fit to ensure adequate clearance of both mounting pads through the drilled holes in the saddlebag lid. The trim pieces are side-specific; the front legs are angled to match the lid front. If the pads do not fit loosely in the holes, it may be necessary to slightly enlarge the holes to provide clearance and maintain proper alignment of the trim on the lid. Clean the saddlebag lid inside and out, and the inside of the saddlebag with a soft cloth, making sure to remove any shavings left from drilling. 6. Obtain the correct saddlebag lid trim (1 or 2) and a trim gasket (3) from the kit. Peel the liner from the adhesive backing of the gasket. 7. Position the gasket onto the bottom surface of the trim, making sure the gasket remains inside the outer edges of the trim, and smooth it into place. 8. Obtain a pan head screw (6) from the kit. 9. Using a T25 TORX® drive head, start the screw part way into one of the holes on the underside of the trim, to form a few threads in the hole, then back the screw out of the hole. Repeat for the second hole. 10. Install the trim piece onto the lid, fitting the mounting pads into the holes drilled in Step 5. 11. Place a flat washer (5) from the kit onto the threads of the screw (6), followed by a rubber washer (4). Place two drops of Loctite® 243 (blue) onto the screw threads. 12. While supporting the lid trim in place, open the saddlebag lid and install the washers and screw through the lid into one of the trim mounting pads, finger tight. Repeat for the remaining trim mounting pad, with another screw, flat washer and rubber washer. 13. Apply a small amount of pressure to the trim piece above each screw and continue to tighten both screws to 25-28 in-lbs (2.8-3.2 Nm) . 14. Repeat steps 1 through 13 for the opposite saddlebag lid

Incoming search terms:

HARLEY DAVIDSON STAINLESS STEEL SPLASHGUARD INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 30-01-2011

1. Refer to the appropriate Service Manual and remove the Maxi® fuse. 2. Refer to the applicable Service Manual and remove the rear wheel. 3. See Figure 1. Remove one screw (1) and stock splash- guard (2) from swingarm (3). 4. Remove the protective film from the new splashguard. 5. See Figure 4. Using two screws (4) and nuts (2), loosely install the H-clips to the back of the splash guard vertically as shown. 2 1 3 is04881 1. P-clamp 2. Splashguard 3. Raised bar of swingarm Figure 2. Install Splashguard -J04271 1 of 2 1 3 2 4 5 is04892 1. H-clip 2. Swingarm 3. Splashguard 4. Screw 5. Nut Figure 3. H-Clips Installed on Swingarm 6. See Figure 2. Slide two P-clamps (1) around the upper bar of the rear fork. The straight side of the clamp will face rearward, as shown in Figure 4. 7. See Figure 4. Orient the splashguard with the polished side facing the rear wheel. Align the upper two holes with the P-clamp holes. Secure splashguard to the P-clips with two screws (4) and locknuts (2). Do not tighten at this time. 8. See Figure 3. Turn H-clips (1) horizontal on the splash- guard. Press splashguard (3) into place. When the splashguard is in place, rotate the H-clips down over the raise bar of the swingarm (2). Tighten the screw (4) and nut (5) to secure the H-clips. NOTE If adequate clearance does not exist between the splashguard and rear brake line and drive belt, adjust fender extension by loosening hardware and centering the splashguard. 9. See Figure 4. Ensure the splashguard does not touch the drive belt on the left side and the rear brake line on the right side, then tighten P-clip mounting screws (4) and nuts (2) securely. 10. Refer to the applicable Service Manual and install the rear wheel. 11. Refer to the appropriate Service Manual and install the Maxi fuse

HONDA VTX1300, VTX1800 R, C & S MODEL HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

0

Filed Under (Honda) by admin on 27-12-2010

download
1 .Lay a blanket folded several times over the fuel tank to protect it. 2. Notice on the 1800 models that there is a small punch mark on the handlebars located on the right hand, front side of the handlebars where the risers meet the top clamp/speedometer housing. This is to reference the handlebar position when re-assembling. On the 1300 models there is a punch mark on the forward facing side of the clamp, these must be installed the same way. 3. Loosen the two 19mm nuts holding the risers to the upper triple clamp (steering head). 4. Pry out the four chrome caps covering the handlebar bolts. Remove the four handlebar clamp bolts. (6mm allen wrench). While sitting on the motorcycle, pull the handlebars and upper clamp off of the risers. They may be slightly stuck and require some force to get free. Lay the handlebar and/or upper clamp/gauge assembly carefully on the blanket. 5. Remove the 19mm nuts and the risers from the triple clamp. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Place the thin flat washers provided into the recess at the top of the riser bolt holes on the triple clamp. Assemble the lock washers provided and then the original flat washers onto the bolts provided. Install the new risers onto the triple clamp and snug the bolts. 6. Re-install the handlebars and upper clamp/gauge assembly. ( Remember the punch marks) Tighten the front bolts first closing the gap at the front, and then tighten the rear bolts. Tighten the two 19mm riser-mounting bolts securely. Check for adequate clearance and proper routing of cables and hoses.

HONDA VTX1300 "C" MODEL HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

0

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

download
1. Lay a blanket folded several times over the fuel tank to protect it. 2. Remove from underneath, the two hex nuts holding the handlebars to the upper triple clamp. (Steering head) Remove handlebars & carefully set on blanket. 3. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Assemble the supplied lock washers and flat washers onto the supplied bolts. Install the new risers onto the triple clamp and finger-tighten the bolts. 4. Re-install the handlebars onto the risers & finger tighten the nuts. Align handlebars & risers to be parallel & centered. Tighten the two riser-mounting bolts securely. Tighten the handlebar mounting nuts securely. Check for adequate clearance and proper routing of cables and hoses

Honda VTX1800F Left/ Right Floor Board Assembly Installation Manual

0

Filed Under (Honda) by admin on 14-11-2010

download
1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

Honda VTX1800C/ J Left/ Ringht Floor Board Assembly Instruction Manual

0

Filed Under (Honda) by admin on 14-11-2010

download
Left Side 1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

Incoming search terms: