HONDA 2005 CRF 50 F AKRAPOVIC RACING EXHAUST SYSTEM INSTALLATION

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Filed Under (Honda) by admin on 03-12-2011

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put the motorcycle on a side standn 2. unscrew and remove the bolts from the rear and front part of the motorcycle cowling (Figure 1, 2, 3, 4) m3. remove complete cowling together with the seat (Figure 5) 4. unscrew the bolt from the metal bracket for the muffler (Figure 6) 5. unscrew and remove the bolts on the flange of the header tube (Figure 7) 6. remove the stock exhaust system (Figure 8) 7. remove the stock heat shield (Figure 9) INSTALLATION OF THE AKRAPOVIC RACING EXHAUST SYSTEM installing the header tube: 1. attach the stock heat shield onto the Akrapovic header tube (Figure 10, 11) 2. set up the Akrapovic header tube and hand tighten the flange; use stock gasket; (Figure 12, 13) 3. make sure the header tube is not touching the engine or frame installing the muffler:
1. correctly position the muffler and slide it onto the header tube (Figure 14) 2. attach the spring at the muffler – header tube joint igure 15) 3. attach the muffler to the chassis hanging bracket – use the bolt, washer and spacers supplied in the Akrapovic kit. Do not
fully tighten. Make sure the additional parts from the Akrapovic kit are correctly installed. (Figure 16, 17) 4. make sure the header tube is not touching the engine or frame final installation: 1. tighten fully the bolts of the muffler metal bracket and header tube flange (Figure 18, 19) 2. reattach the complete cowling (Figure 20, 21, 22, 23, 24) 3. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. stainless steel header tube: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 4. position of the correctly installed Akrapovic RACING system (Figure 25)
5. Check the operation of the brakes and suspension. Make sure all the bolts are sufficiently tightened. In case the exhaust system touches the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer

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HONDA HT1500 GOLD WING CONVERSION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 25-11-2011

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Cut-off the saddlebag support tubes where the vertical tube meets the angled tube in the front and back. All you want left is the tour pack support. Loosen tour pack support at bottom bolts, remove top bolts, and then lift up a little. This allows the body to go under the support. If you have the fuel tank: Secure the two black control boxes, facing each other, one on top of the other. Secure to frame using the green ground wire hole at center of frame. Use the 2 ¼”
spacer tube and long screw provided to hold them together. If no fuel tank: leave rear half of fender in place Install machined studs in the swing arm pivot hole with some blue Locktite on them. This provides a 5/8” stud on the side of the frame for the suspension side plates. Screw in until flush with frame. Remove the 6mm bolts from the exhaust heat shield on the outside of the frame rail. nInstall the shock replacement bars on the top shock stud and re-install bolts, leave bars hanging loose for now. Install air-compressor relocation bracket (1 ½” x 4″ w/ 3 holes) and remount compressor. After
mounting, secure the compressor to the bracket with a wire tie.

BUSHTEC GL1800 STANDARD & DELUXE VERTICAL RECEIVER HITCH SYSTEM Trailer Hitch Installation Instructions

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Filed Under (Honda) by admin on 24-11-2011

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Place the motorcycle on its centerstand on level ground. Remove the four bolts in the seat handles with a 6mm Allen head socket and remove the seat. NOTE: The rubber bushingsinside the seat may fall out during removal; Make sure they are in place upon reassembly.2. Remove both side covers.3. Remove the (5) five bolts in the rear fender (license plate panel, between saddlebags)with a 5mm Allen head socket. Remove the rear fender. NOTE: The fifth bolt is behindthe license plate.4. Remove the (3) three bolts in the passenger floorboard holder cover with a 5mm Allenhead socket. Remove the cover and repeat for other side.5. Remove the (2) bolts in the rear saddlebag guard with a 12mm socket. Remove thesaddlebag guard and repeat for other side 6. Remove the bolt in the muffler hanger using a 12mm socket. Repeat for other side.7. Loosen, but do not remove, the muffler clamps using a 6mm Allen head socket. Rotatethe mufflers down slightly to allow the hitch hoop to slide between the mufflers and the saddlebag

Honda RC-51 / VTR-1000 SP1 – Installation Instructions

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Filed Under (Honda) by admin on 23-11-2011

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Remove the lower fairing. Remove the existing exhaust system from the mid pipes rearward. Save the exhaust clamps for reuse Save the stock exhaust can mounting bolts and nut for the end can to the passenger footpegs for reuse as well. Inspect the original exhaust gaskets. Replace as necessary. Slide the tail pipes into place. Do not tighten the clamps at this point. Slide the TiForce end cans into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to each end can using the supplied 6mm hardware H. See figure 1 for details. 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
(see figure 1). Attach the supplied springs to all the joints (from the tail pipes to the TiForce end cans). Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can, then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO
BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN(s).

HONDA XL 1000 V VARADERO 2005 AKRAPOVIC SLIP- ON SP SERIES EXHAUST SYSTEM

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Filed Under (Honda) by admin on 21-11-2011

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coat the bolt and interior side of the metal clamp with Akrapovic anti-seize lead-free copper paste (black tube)
2. correctly position and install the graphite inner sleeve and metal clamp 3. slide the link pipe onto the stock collector 4. hand tighten the bolt of the link pipe bracket 5. make sure the link pipes are not touching the frame and other parts 6.
perform the process on both sides of the motorcycle installing the muffler: 1. position the muffler correctly and slide it onto the outlet side of the link pipe (Figure 17) 2. attach the springs at the muffler – link pipe joint (Figure 18) 3. correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp for the right muffler and the right offset for the left muffler viewed from the rear. WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! (Figure 19) 4. hand tighten the carbon-fiber clamp onto the stock chassis hanging bracket – use the bolts, washer and spacers supplied in the Akrapovic kit. Do not fully tighten. Make sure the additional parts from the Akrapovic kit are correctly installed. (Figure 20, 21, 22) 5. make sure the muffler is not touching other parts of the motorcycle 6. perform the process on both sides of the motorcycle final installation: 1. tighten the bolt of the link pipe bracket (Figure 23) 2. tighten the carbon-fiber clamp (Figure 24) 3. tighten the metal clamp at the Akrapovic link pipe – stock collector joint (Figure 25) 4. perform the process on both sides of the motorcycle 5. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. muffler – carbon-fiber outer sleeve: use a soft dry cloth c. stainless steel link pipe: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 6. reattach side panels (Figure 26) 7. reconnect the electric connectors for turn signal lamps (Figure 27) 8. reattach the cable for locking / unlocking the seat (Figure 28) 9. reattach the passenger handlebars and top case plate (Figure 29, 30, 31, 32) 10. reattach both seats (Figure 33) 11. position of the installed Akrapovic Slip-on SP series system (Figure 34)

CR500R/ 500 AF Hi Power Digital Ignition & Light Coil Installation Instructions

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Filed Under (Honda) by admin on 19-11-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI.b6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator. 10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on
the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 bkg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012”. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012”. Use a good/no good
technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap

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2007 Honda CBR600RR Power Commander Installation Instructions

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Filed Under (Honda) by admin on 16-11-2011

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Remove the bolt that holds the ground wires and bracket for the alternator connectors to the frame on the left hand side of the bike. This allows access to the Throttle Position Sensor connector. Unplug the stock wiring harness from the Throttle Position Sensor (Fig. F).Remove the main seat and the passenger seat. Remove the fuel tank cover. Remove the left hand fairing. Prop the fuel tank up. Lay the PCIII in the tail section temporarily and route the harness underneath the tail sec- tion (Fig. A). Removing the 4 bolts that hold the tail sectionb in place will make this easier Route the harness towards the throttle bodies (Fig. B) Attach the ground wire from the PCIII to the negative side of the battery.

2008 CBR1000RR replace the clutch inner

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Filed Under (Honda) by admin on 06-11-2011

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Clamping Centerstand to Frame. Notice the centerstand is shipped with (2) white plastic washers. Note: See photo #2-A These are in place to overcome the spring tension or lock the stand in place and allow you to pivot the lower stand down partially to make installation easier. Pivot the upper stand about half way from the retracted to the extended (down) position. Note: This will require some force. If the stand will not stay in the position you can further tighten the two 9/16” pivot nuts. Remove the bolts from the four band clamps. Wrap the (2) small clamps around the small upper frame tube and start the bolts so that the bolt will be at the bottom of the tube and the wrench head facing towards the rear of the motorcycle. Note: See photo #2. Center the stand on the frame from side to side so as to gain even clearance between the feet on the centerstand and the rear tire when the stand is in the retracted position. Holding the larger cradle up against the frame, tighten the (2) small clamps enough to hold the centerstand in place. Install one of the large clamps as shown in photo #3-A. Install the 2 nd large clamp as shown in photo #2-C. Again retract the stand and check that the feet have even amounts of space from the side of the rear tire. Tighten the flour clamps securely 5-7 ft. lbs. Next remove the (2) 9/16” pivot nuts and the white plastic washers as shown in photo #2-A. Re-install and tighten the 9/16” pivot nuts securely 8-12 ft lbs. With the stand in the retracted position-adjust the stop bolt and lock nut, see photo #3-B, so that the stand is parallel with the ground and does not come incontact with any parts of the motorcycle

1997-2003 HONDA CBR1100 XX Black Bird Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 05-11-2011

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identify the key components that complete our brake line kit: You should have eleven (11) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) Installation CD. There are also a total of Thirty Six (36) washers and two (2) “olive” conic inversors two (2) c-clips. Thirty Two (32) washers will be used, and two olives. The rest are spares. Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G, H, K, I are installed on the front of the motorcycle, while brake hoses (J and K) are installed on the rear. Each label will reference a different drawing, which will show you the location of each brake line. Step 3: To ensure no paint damage from brake fluid, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a
couple pictures, in case you need to re-install. Step 4: Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G,H,K,I. Locate lline A. this hose will run from the master cylinder down to the Galfer t-block
joining line B to the right caliper upper mounting point. Line C will travel across the fender down to the left caliper upper mounting point. Line D will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE). This O.E.M tubing travels to the rear master cylinder. Line E Travels from the lower delay valve down to the right caliper lower mounting point. Line F will run from the (SECONDARY MASTER CYLINDER) up through the C-CLIP to the left upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE).This tubing travels tothe rear delay vale

Toyota Power Steering Conversion Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 04-10-2011

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Remove the stock steering box and column. Be sure to clear the area of all wiring, brake lines and fuel lines. 2. Bolt the Toyota box to the mounting bracket so that the long arm of the bracket points in the same direction as the steering column input shaft (small shaft.) To mount the bracket and box correctly, the longer end should be towards the rear of the vehicle. It may be necessary to grind on the power steering box where the two flanges protrude above the bracket. For technical help call Classic Performance Products Monday thru Friday 8:30am to 5:00pm at (714) 522-2000. Rev. 8/17/2009 3. Locate the box/bracket assembly into the frame by centering the Toyota sector shaft through the original hole in the frame. This hole will need to be elongated approximately 3/8″ to allow the sector shaft to clear the frame. Bolt the bracket directly into the mounting holes for the original steering box. 4. With the first bolt in, check the fit by reattaching the steering box. Make sure the splined shaft goes through the frame without interference. Torque down the mounting bolts to 45 lbs. 5. Attach the pitman arm to the steering box. Before this is done the steering sector must be centered. Turn the input shaft clockwise as far as it can go. Make a reference mark. Now turn the shaft counter clockwise as far it can go and be sure to count the turns. Turn the shaft back half the distance and now the box is centered. Be sure to double and triple check this procedure. Attach the pitman arm to the output shaft with the output shaft nut. Torque the bolt down to 110ft/lbs. Reconnect the stock drag link and you are on your way

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