HARLEY DAVIDSON SPORTSTER BLACK EXHAUST HEAT SHIELDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION Remove Original Equipment (OE) Heat Shields Avoid contact with exhaust system and wear protective clothing that completely covers legs while riding. Exhaust pipes and mufflers get very hot when engine is running and remain too hot to touch, even after engine is turned off. Failure to wear protective clothing could result in burns or other serious injury. (00009a) 1. Allow the motorcycle to cool. 2. Identify the position of the OE clamp screws securing the black heat shields to the exhaust pipes. NOTE The clamp screws are positioned on either side of the exhaust pipe for clearance. 3. See Figure 1. Open the heat shield clamps (1) and spread the bands to remove front and rear heat shields (2) from the exhausts. Retain the heat shield clamps Install Black Heat Shields 1. See Figure 2. Matching the OE position of the heat shield clamps, open the clamps bands and thread the bands through the brackets of the front (1) and rear (2) black heat shields. 2. Spread the band around the exhaust pipes and push the end of the bands to engage the clamp screws. Tighten to hold the heat shields in place. 3. Adjust the shields and heat shield clamps to access clamp screws and to avoid contact with other components. 4. Tighten the heat shield clamp screws

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HARLEY DAVIDSON CHROME PASSENGER FOOTBOARD SUPPORT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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Removing Passenger Footpegs 1. Remove and discard the socket screw and lock washer attaching the existing footpeg bracket to the rear swing arm bracket. Proceed to Step 5. Removing Passenger Footboard Supports 1. For standard footboard 50613-91: See the Service Parts illustration. Tilt the footboard to the “up” position. Remove the underside chrome footboard covers if so equipped. From the bottom of the footboard, use a small flat-blade screwdriver to push the rubber beads on the pad up through the holes in the footboard pan. Remove the pad. For swept-wing (FLHRS- and FLHTCSE-style) footboards: With the passenger footboard in the “down” position, carefully raise an outside “corner” of the stock footboard insert off the footboard pan with a suitable flat-bladed tool, taking care to avoid scratching the chrome footboard pan. Continue around the edge of the footboard, using a second flat-bladed tool if necessary to pry up and remove the old insert. 2. Using a brass drift and rubber mallet, tap one pivot pin (6) out of the pivot hole into the center pocket of the footboard pan, remove the pin and set it aside. Repeat for the second pin. 3. Remove the footboard from the support bracket (1). Remove and discard the steel ball (5) and spring (4) from the hole in the bracket. 4. Remove and discard the socket head screw (2) and lock washer (3) attaching the footboard support bracket to the rear swing arm bracket. Proceed to Step 5. Installing the New Footboard Supports NOTE Three holes are available in the rear fork brackets for footboard support mounting. Depending on model and year, the footboards can be installed in any of two or three positions for passenger comfort. A plastic plug, inserted in the upper hole at the factory, can be removed. 5. See the Service Parts illustration. Position a new chrome footboard support (1) against the swing arm bracket at the desired height. The left and right supports are identical. With the locating peg on the footboard support in the next lower hole, fasten the support with a hex socket screw (2) and lockwasher (3) from the kit. Tighten the screw to 15-18 ft-lbs (20-24 Nm). 6. Place the new spring (4) into the retaining hole in the footboard support. Rest the detent ball (5) on top of the spring

HARLEY DAVIDSON DYNA SLIP-ON ACCESSORY MUFFLERS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 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) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. -J04263 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HARLEY DAVIDSON PASSENGER FOOTPEG MOUNTING KIT INSTALLATION INSTRUCTIONS

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

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This passenger footpeg mounting kit fits 1993 and later FLT, FLHT, FLHS, and FLHR model motorcycles. See Service Parts illustration below for items contained in this kit.Installation 1. On each side of the motorcycle, remove the socket head capscrew and lockwasher that attaches each footboard bracket and footboard to motorcycle. Remove both footboard brackets along with their footboards. 2. See Service Parts illustration. Place each footpeg support (2-right side, 3-left side) in position (the supports can be installed in one of two different height positions to suit passenger preference) and securely fasten to motorcycle with lockwasher and capscrew removed in step 1. 3. Install footpegs (sold separately) on each footpeg support using capscrews (1), spring washers (4), and locknuts (5). The spring washer goes between the jaws of the footpeg supports along with the mounting end of the footpeg. Tighten hardware securely. NOTE If footpeg supports are properly installed, footpegs will point 45˚ (from vertical) toward rear of motorcycle. Footpegs must fold up at a 45˚ angle (from vertical) toward rear of motorcycle. This angle allows footpegs to fold up if they accidentally strike the ground when making a sharp turn. Failure to install footpegs with the proper fold-up angle could result in death or serious injury.

HARLEY DAVIDSON SPORSTER, DYNA AND SOFTAIL LICENSE / TURN SIGNAL RELOCATOR INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Remove the license plate. Remove the license plate mounting bracket from the fender. Remove the two screws from the tail light lens and pull the light outward, unplug the wire connector and set aside. Unplug the turn signal wire connectors from the tail light base and push them out thru the hole in the fender. Looking up underneath the rear fender remove the wires from the clips that secure them to the bottom side of the fender. Cut the wires 2″ from the plugs as shown in photo 1. 2. Unscrew the signal housings from their mounting stems while rotating the wires on the inside of the fender so as not to twist them off while unscrewing the signal from the stem. Remove the signals pushing the wires thru from the inside while pulling the signal outward. Remove the nuts from the backside of the fender that secure the stems and remove the stems. 3. Assemble the license/turn signal bracket, turn signals. Place the smaller reinforcing bracket inside the license plate bracket. Locate the two supplied 5/16″ X 1″ bolts with holes drilled thru the center and the two supplied 5/16″ long spacers. Place the bolts thru the brackets from the inside, threads facing outward followed by the spacers. Thread the wires of the signals thru the bolts and thread the bolts into the signals and snug the bolts. 4. Mounting the LED lights a. Locate the supplied LED tail/brake lights. NOTE: this license plate holder is designed for the new U.S. standardized 7″ wide license plate. If you have an old style wider plate call us at the phone number below and we will send you a separate set of chrome brackets to work with your larger plate at no charge. b. Install the lights as shown in photos 2 & 3. Thread the wires of the LED lights thru the lower holes in the license bracket, peel the adhesive backing and press them firmly in place. Cut the wires off at about 18″ long. c. Install the license plate bracket with signals and LED lights onto the rear fender as shown in photos 2 & 3. Place the two supplied 1/4″ X 1″ flat head screws thru the license plate mounting block. Notice that the thicker half of the mounting block goes toward the top of the fender. d. Next route all the wires from the right turn signal and LED into the slot or notch on the backside of the mounting block followed by the rubber mounting gasket. Install the two nuts from the underside of the fender (Removed from the original license bracket.) onto the two flat head screws and snug them being sure the wires are all in the slot of the mounting block. Run all of the signal and LED wires thru the hole in the fender to the left of the mounting block. e. Install the license plate assembly onto the mounting block using the two supplied 1/4″ X 1/2″ flat head screws. Check the slack from all the wires and again be sure the wires are not pinched between the mounting block and the fender. Tighten all four flat head screws securely. Align the turn signals and tighten their mounting bolts securely.

HARLEY DAVIDSON RIDER BACKREST MOUNTING HARDWARE KIT INSTALLATION INTSRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION 1. Remove seat according to the instructions in the service manual. 2. Remove the ECM caddy/battery cover by removing two screws. 3. See Figure 1 and Figure 2 for the mounting locations of the brackets. NOTE Some seats may limit the fore/aft mounting location of the backrest bracket. 4. See Figure 3 and Table 1. Remove plastic protective cap and locknut from stud. Leave the small plastic washer in place or the stud plate will fall out. With the backrest mounting bracket tab facing forward, attach the backrest mounting bracket (1) to stud plate with stock locknuts from the stud plate. 5. Tighten locknuts to 5-8 ft-lbs (6.8-10.8 Nm) . 6. Attach the front mounting bracket (6) to the frame cross- member using using two flange screws (8) and flange nuts (7). Tighten screws to 72 in-lbs (8.1 Nm) . 7. Attach the bracket support (2) to the front mounting bracket (6) with screw (8) and nut (7). 8. Install screw (5) and nut (9) to bracket support and backrest tab and tighten to 15 ft-lbs (20.3 Nm) . 1 2 is05475 1. Backrest mounting bracket 2. Front mounting bracket Figure 1. Bracket Mounting Locations 3 2 1 is05476 1. Backrest mounting bracket 2. Front mounting bracket 3. Bracket support Figure 2. Backrest mounted After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) -J04733 1 of 2
9. Install the ECM caddy/battery cover using two screws previously removed and tighten to 6-8 ft-lbs (8.1-10.8 Nm) . 10. Install seat according to service manual instructions. 11. Hold slit between rider and passenger seat open. On rider backrest, compress backrest rods and spring. Insert rods into backrest mounting bracket. Backrest Pad Adjustment 1. Adjust fore/aft position of backrest pad. Use 3/16 inch hex wrench to adjust set screw that is accessible through eyelet opening on rear of pad. If possible, do not remove set screw because it is difficult to install.

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HONDA VTX1300 FRONT FENDER BUMPER INSTALLATION INSTRUCTIONS

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

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1. Carefully slide the bumper up into position (it will be necessary to flex the bumper inward to get the brackets over the fender mounting bolts. 2. Remove the 2 front bolts and replace them with the longer bolts supplied and next replace the 2 rear bolts. Tighten all 4 securely. 3. Install the 4 nuts supplied, before tightening peel the backing from the clear bumper supplied and stick it to the fender behind the center of the lower chrome front bumper rail, center the bumper left to right while keeping it down against the rubber bumper on the fender and tighten the 4 nuts securely.

HONDA VTX 1300 FRONT FENDER BUMPER INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-12-2010

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1. Carefully slide the bumper up into position (it will be necessary to flex the bumper inward to get the brackets over the fender mounting bolts. 2. Remove the 2 front bolts and replace them with the longer bolts supplied and next replace the 2 rear bolts. Tighten all 4 securely. 3. Install the 4 nuts supplied, before tightening peel the backing from the clear bumper supplied and stick it to the fender behind the center of the lower chrome front bumper rail, center the bumper left to right while keeping it down against the rubber bumper on the fender and tighten the 4 nuts securely.

BMW R1200RT Sport/ Touring 1100X Kit Installation Manual

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Filed Under (BMW) by admin on 17-12-2010

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Step 1 — Locate ‘mold circle’ indentation on each side fairing panel (Pic 1). With panel mounted on bike, this indentation is center, at rear inside panel edge, and faces inside. Temporarily install bracket as shown in (Pic 2), align bottom bracket hole over indentation and mark for hole. Remove brackets at this time. Step 2 — Remove fairing body side panels. Four screws per side required for removal, see owners manual. Drill a 3/8″ hole at mark. If harness kit has not been installed, do not re-install left side panel until finished unless you remove tank to install harness. Removal of the tank is the best option to route harness from battery area to front of the bike. Step 3 — As required, re-install fairing body side panels. Do not re-install the top factory inner panel Torx Screw yet, as you will re-use this screw to secure the top light bracket mounting hole to the fairing panel. Step 4 — Using 10/32×1/2 screws and black shoulder washers from Hardware package, secure lights to PIAA Ezy-Mount® brackets (See Pics 3 & 4). Right side bracket is stamped ‘EZY-MOUNT’. See note below for Powersports lights. Due to close proximity of the light body to fairing side panel, access to the vertical adjustment screw on the panel side of the light will not be possible after installation. To prepare for this; before installing bracket/light assembly to panel, make sure this screw is tightened so that you can barely move the light body. After bracket is installed, final vertical adjustment can be secured with the inside screw. Torque on this screw is adequate to hold vertical adjustment, and the screw that faces the panel will not come loose. NOTE: WHEN INSTALLING POWERSPORTS LIGHTS, YOU MUST INSERT THE SHOULDER ADAPTER WASHER INTO THE LIGHT FOOT, BEFORE INSERTING SCREW TO SECURE LIGHT FOOT TO BRACKET. THIS ADAPTER CENTERS LIGHT FOOT OVER PEMNUT (TIGHTEN THIS SCREW SECURELY). Step 5 — Insert well nut into previously drilled 3/8″ hole. Place bracket assembly against fairing, aligning top hole with the top fairing mounting position; re-install the factory Torx screw at this location. Adjust as necessary and install the second supplied SS 10/32 x 5/8 Torx screw thru the lower bracket mounting hole to the well nut. With constant pressure on the screw, tighten securely. Constant pressure ensures that the rear expandable section of the well nut captures the back of the plastic inner panel as you tighten the screw. Future removal of fairing panels is now possible with light assembly installed (utilizing the bottom bracket mounting screw), thus re-alignment of lights is not required after normal maintenance.

1500cc Honda Goldwing Installation Manual

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Filed Under (Honda) by admin on 02-12-2010

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Review entire installation manual Loosen saddle bags and remove rear fender cover Modify rear fender cover Install receiver hitch and double check all bolts Remount rear fender and tighten saddle bags Assemble InstaTrike hitch cart Attach InstaTrike to motorcycle via receiver hitch Attach leanstop brace bolts to receiver hitch Align InstaTrike wheels Double check all bolts for tightness Test ride InstaTrike slowly in an open area to familiarize yourself with handling characteristics Receiver Hitch Installation NOTICE: Install all bolts and brackets loosely until all bolts and brackets are in place 1) Place motorcycle on center stand. NOTE: Some Goldwings are not level when on center stand. Shim underneath center stand to level motorcycle. 2) Remove side covers 3) Loosen saddle bags and remove rear fender cover. 4) Modify rear fender cover. See diagram 5) Remove muffler bolts. Replace with enclosed muffler bolts. (hex bolt head toward inside with washers on bolt head side) This allows clearance between the hitch and muffler bolt. 6) Replace existing motorcycle rear crashbar bolts with those provided (2 each side). Ensure new crashbar bolts are securely tightened before attaching brackets A and B. 7) With brackets A (left) and B (right) attached to bottom of forward arms of hitch, slide hitch under bike and loosely attach A and B to bottom of rear crash bar with provided U-bolts. Use caution not to crush crash bar with U-bolt

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