Kawasaki ZX-9R Ninja TiForce exhaust system Installation Instructions

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Filed Under (Kawasaki) by admin on 07-05-2012

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1. Remove the lower fairing. Remove thelower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1 (blue), 2 (red), 3 (yellow), and 4 (green) by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. 2000 through 2002 models ONLY!!! Place a billet aluminum exhaust port centering flange Z on each TiForce headpipe -see figure 3 for details. 6. Attachthe assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the headpipes fit flush and snug in the ports and centering flanges Z before tightening (’00-’02 ONLY). 7. Install the S-Bend to the front section of the headpipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications -make sure the headpipes and flanges Z are centered in each port (’00-’02 ONLY!!! ) . 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. See figure 1. 11. Place the bands approximately 108 mm from the edge of the end can. See figure 2. 12. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 15. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 /figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTIONWHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN.

Yamaha 1999-2002 YZF-R6 TiForce exhaust system Installation Instructions (full system)

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Filed Under (Yamaha) by admin on 12-01-2012

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1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide more access to the exhaust nuts (flange nuts). 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the mounting bolt and nut for the end can to the passenger footpeg for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1, 2, 3 , and 4 by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remainingsteps. Reuse the flange nuts saved from step 3 above. Make sure the ends of the headpipes fit flush and snug in the ports before tightening. 6. Install the S-Bend to the front section of the headpipes and two Y-pipes. 7. Go back and retighten the head pipe flange nuts per factory specifications. 8. Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stayarm / hanger G to the end can using the supplied 6mm hardware H. (See figure 1) . 9. Place the bands approximately 195mmfrom the edge of the end can. (See figure 2) . 10. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 11. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can. 12. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance

Honda CBR-929RR/ 954RR – Installation Instructions (slip on system)

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Filed Under (Honda) by admin on 03-11-2011

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Remove the lower fairing. Remove the rear turn signals. Remove the existing exhaust system from the HTEV valve rearward, save the mounting bolts for reuse. Save the stock exhaust can mounting bolt and nut for the end can to the passenger footpeg for reuse as well. Install the supplied HTEV joint plate to the rear of HTEV valve (see photo 1) using the stock mounting bolts. Tighten per factory specifications. Install the 2 Y-pipes to the joint plate, but do not install the supplied springs at this time. Install the S-Bend to the two Y-pipes, but do not install the supplied springs at this time. If you plan to keep the passenger footpegs, follow this step, otherwise, skip to step 8. Reassemble the right
passenger footpeg assembly in this order (from the subframe outwards): Spacer A, Stay Arm F, Spacer B, passenger footpeg assembly (from step 7 above). Use the supplied 8x110mm bolts D (2x) to fasten to the subframe (reuse nuts). See figure 3 for details. Proceed to step 8. If you plan to remove the passenger footpeg assemblies, follow this step and ignore step 6 above. Use: Spacer A and place the Stay Arm F against it. Use the supplied 8x50mm bolts E (2x) to fasten to the subframe (reuse nuts). See figure 3 for details, but use only the hardware specified in this step.
Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. See figure 1 for details. Place the bands approximately 120mm from the edge of the end can. See figure 2 for details.

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TOYOTA 4RUNNER SR5 SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 31-05-2011

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FRONT OF 4RUNNER/FJ CRUISER 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel.
3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Before lifting vehicle, remove rear shock absorbers and discard. 5. Jack up the vehicle from the lift point in Figure A. 6. Support the vehicle with jack stands from the points in Figure A. 7. Remove the front wheels. 8. Remove sway bar end links from spindle using 17mm socket (both sides). See Figure B. 9. Remove front skid plate using 12mm socket. 10. Remove sway bar from frame using 14mm socket. See Figure C. 11. Using 19mm socket, remove lower bolt and nut from the bottom of the strut (both sides). 12. Remove cotter key and 19mm nut from outer tie rod end, rack &
pinion utilizing a tie rod end puller (or pickle fork). 13. Remove the three nuts (14mm) from the top of the strut. See Figure D. 14. Remove the struts from the vehicle, making sure that they are marked driver and passenger side respectively for reinstallation.

HARLEY DAVIDSON SOFTAIL SWINGARM PIVOT COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. Use rubbing alcohol to clean the swingarm surface, pivot bolt, and nut. 2. Place the larger left-side pivot cover (3) over the pivot nut. Position the set screw (4) at the bottom of the cover. Tighten set screw to 16 in-lbs (1.8 Nm) . 3. Remove adhesive backing from and apply the left-side trimplate to the swingarm. Apply pressure to the trimplate on the swingarm for one minute. 4. Remove adhesive backing from and apply an emblem to the center of the pivot cover. Apply pressure to the emblem for one minute. 5. Repeat Steps 1-4 for the right side of the swingarm. 6. Allow adhesive to cure for 24 hours before operating the vehicle. SERVICE PARTS 4 2 5 3 1 5 6 3 is01811 Figure 1. Service Parts: Swingarm Pivot Cover Kit Table 1. Service Parts: Swingarm Pivot Cover Kit Part Number Description (Quantity) Item Not Sold Separately Right-side trimplate and adhe- sive 1 Not Sold Separately Left-side trimplate and adhesive 2 Not Sold Separately Adhesive emblem (2) 3 Not Sold Separately Left-side pivot cover 4 3231B Set screw (2) 5 Not Sold Separately

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SUZUKI SV1000/ S SERVICE MANUAL Supplimentary

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Filed Under (Suzuki) by admin on 26-02-2011

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CHASSIS BOLT AND NUT Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to below and page 2-29 of SV1000S Service manual for the locations of the following nuts and bolts on the motorcycle.) CHASSIS FRONT FORK REMOUNTING Align the upper surface A of the inner tube with the upper surface B of the steering stem upper bracket. Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. ITEM N·m kgf-m lb-ft 1 Handlebar clamp bolt 23 2.3 16.5 2 Handlebar holder set nut 45 4.5 32.5 SV1000K3 5 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are eight grooves on the spring adjuster. Position 1 provides the maximum spring pre-load and position 8 provides the minimum spring pre-load. STD position: 7 DAMPING FORCE ADJUSTMENT Rebound damping force Fully turn the damping force adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position. STD position: 1 and 1/4 turns out from stiffest position Compression damping force Fully turn the damping force adjuster 2 clockwise. It is at stiffest position and turn it out to standard setting position. STD position: 1 turn out from stiffest position STANDARD FRONT SUSPENSION SETTING ! FRONT Spring pre-load adjuster Damping force adjuster Rebound Compression Solo and dual riding 7 1 and 1/4 turns out from stiffest position 1 turn out from stiffest position Be sure to adjust the spring pre-load and damping force on both front fork legs equally. 6 SV1000K3 HANDLEBARS REMOVAL AND DISASSEMBLY Remove the handlebar balancer 1. NOTE: Do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. Remove the rear view mirror 2. Disconnect the front brake light switch coupler 3. Remove the front brake master cylinder. Remove the right handlebar switch 4 and throttle grip 5. Disconnect the clutch switch lead wires 6. Remove the left handlebar switch 7. Remove the rear view mirror 8. Remove the clutch master cylinder. Remove the handlebar clamp caps

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PASSENGER FLOORBOARD RELOCATION ARMS FOR TRIUMPH AMERICA AND SPEEDMASTER

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Filed Under (Triumph) by admin on 25-12-2010

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1. If you are installing the relocation arms at the same time as floorboards install the floorboards first per their instructions. When installing the relocation arms with floorboards already installed proceed as follows. 2. Starting on the left side, fold the floorboard up. Remove the socket head bolt and nut which secures the floorboard to the motorcycles stock peg support and remove the floorboard taking notice of which holes the dowel pins are located in. 3. Install one of the 5/16″x1 Ω” hex bolts supplied thru the stock peg support from the backside (The threads of the bolt will face out towards you.) Place the two dowel pins into the holes at one o’clock and seven o’clock on the stock peg mount. Place the spacer blocks backside (stamped with an “L”) onto the bolt and align the hole with the pins. 4. Locate the relocation arm that has an “L” stamped on the backside of it. Place two of the supplied dowel pins into one of the two sets of the holes in the arm that are directly across from one another (180 degrees apart). Place the arm onto the spacer bock aligning the pins in the arm with the holes closest to six and twelve o’clock. Depending on which of the two sets of holes on the arm you chose the arm would, either be down at about seven o’clock or just below nine o’clock. These are the initial height settings and you may select which ever set is most comfortable for the passenger. Install one of the acorn nuts supplied onto the bolt and make finger tight. 5. Place the floorboard with its two dowel pins into the set of holes at the other end of the relocation arm that allows the floorboard to be horizontal or parallel to the ground. Use one of the 5/16″x3/4″ socket head bolts supplied to bolt the floorboard to the relocation arm and make finger tight. 6. Install the right side in the same manner, place the dowel pins in the holes at eleven o’clock and at five o’clock on the stock peg mount, then the spacer blocks backside (stamped “R”) onto the pins followed by the relocation arm with two dowel pins in one set of holes (180 degrees apart). Check to see that the right arm is at the same height or position as the left then install the acorn nut finger tight. Bolt the floorboard the other end of the arm using the remaining dowel pins and socket head bolt. Tighten the two bolts with the acorn nuts and the two socket head bolts securely

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Kawasaki ZX-9R Ninja Installation Instructions

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Filed Under (Kawasaki) by admin on 05-11-2010

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1. Remove the lower fairing. Remove thelower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1 (blue), 2 (red), 3 (yellow), and 4 (green) by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. 2000 through 2002 models ONLY!!! Place a billet aluminum exhaust port centering flange Z on each TiForce headpipe -see figure 3 for details. 6. Attachthe assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the headpipes fit flush and snug in the ports and centering flanges Z before tightening (’00-’02 ONLY). 7. Install the S-Bend to the front section of the headpipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications -make sure the headpipes and flanges Z are centered in each port (’00-’02 ONLY!!! ) . 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. See figure 1. 11. Place the bands approximately 108 mm from the edge of the end can. See figure 2. 12. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 15. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 /figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTIONWHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 16. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 17. Go back and reinstall the radiator and oil cooler as per factory specifications. Verify fluid levels as needed. 18. Checkthat all hardware is properly tightened, then start the motor and check for exhaust leaks. 19. Reinstall the fairing and tighten any fasteners per factory specification

Ridley TRANSMISSION BELT REMOVAL AND INSTALLATION

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Filed Under (Ridley) by admin on 01-11-2010

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1.Remove the transmission cover and inspect the belt for wear, damage, or breaks. 2.Fraying on sides of belt is considered normal. 3.To replace the belt, remove the clutches and remove the old belt. Install new belt onto clutches and simultaneously install the clutches. Refer to “Clutches” for more detailed information. CLUTCHES: Tools Needed for Service: Transmission Removal A1.) Remove the bolts holding on the transmission cover with a 6mm Allen Wrench and remove the cover away from the motorcycle. Refer to bolt #11 in Figure 3. •6mm Allen Wrench •Torque Wrench •5/16 Allen Wrench •1-1/8″ Socket Wrench •Chisel •Hammer Figure 3
A2.) Bend the tab on the driven washer with a chisel. Remove both the bolt and nut holding the clutches onto the transmission as well as the washers. Refer to numbers 5,6,8 and 9 in Figure 3. Number 9 is for the drive and number 6 is for the driven. Use a 5/16 Allen for the bolt and a 1-1/8 socket wrench for the nut. A3.) Remove the drive and driven at the same time. Remove the belt from the clutches. Refer to number 3 in Figure 3. Drive Clutch Service B1.) Remove the clutch cover by bending down the tabs and removing the bolts. Refer to Figure 4. B2.) Remove the snap ring using a pair of snap-ring pliers. See Figure 5. *NOTE: Make sure to use caution when removing the snap ring. The snap ring can “spring” off during removal and can cause damage to the eyes if not careful.

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Kawasaki 2000- ZX-12R Ninja exhaust system Installation Instructions

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

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1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1, 2, 3, and 4 by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. Place a billet aluminum Mouthpiece ring Z on each TiForce head pipe. (see figure 3 for details) . 6. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the head pipes fit flush and snug in the ports and Mouthpiece ring Z before tightening. 7. Install the S-Bend to the front section of the head pipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes and Mouthpiece ring Z are centered in each port. 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. (See figure 1) . 11. Place the bands approximately 118 mm from the edge of the end can. (See figure 2) . 12. Using the stock provided mounting point on the passenger foot peg, and using the stock-mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance