Harley-Davidson FL Caliper Mount Installation Manual

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Filed Under (Harley Davidson) by admin on 26-02-2012

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Motolight® Caliper mounts are designed to be mounted on the brake caliper mounting boss. Before removing the caliper bolt make certain you have the manufacturer’s recommended torque settings for your make, model and year. 2 . Disconnect your battery. Never work on the electrical system of a motorcycle while the battery is connected. If you’re not sure how, check your owner’s manual, or consider having your dealer install the lights. 3 . Motolights®, like any light, get hot when operating. Do not touch any part of the housing when the Motolights® are in operation and for at least 15 minutes after they have been turned off. 4 . If you are transferring your Motolights® to another bike or have obtained the lights secondhand, it is VERY IMPORTANT that you contact us at 800-567-8346 or 513-474-7530 for new caliper bolts of proper grade and size. Step 1. Unpack the Motolight® system . Take this chance to familiarize yourself with everything. Below is the list of included items: Item # Quantity Description 1 (2) º” x 20 x 5/8″ stainless steel socket head cap screws 2 (2) Housings, aluminum, assembled with lens, lamp and leads 3 (2) Mounting blocks, aluminum, left and right 4 (2) Caliper replacement bolts 5 (2) Lock washers 6 (1) Motolight wiring harness with relay and 20 amp fuse 7 incl. Special Harley auxiliary plug connector in wiring harness (included) 8 (2) Motolight decals (1 helmet size, 1 regular) 9 (1) Aiming tube (cardboard ring) 10 (1) 3/16″ hex wrench 11 (1) Pin wrench (for standard lamp retaining rings-not required for knurled/grooved rings) 12 (15) Cable ties, long and short

2000 – 2005 Celica REAR DISC BRAKE PAD INSTALLATION

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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A. Install the two brake pads with the anti-squeal shims to the brake caliper. B. Install the two (2) guide pins to fix the brake pads. 2. Install spring No. 1. A. Hook the spring upper portion to guide pin No. 1. Spring No. 1 B. Hook the spring lower portion to the center hole of the brake pad. 3. Install spring No. 2. A. Hook the spring upper portion to guide pin No. 1 Secure the guide pins with the retaining clip. A. Insert the retaining clip end into the hole of guide pin No. 1. B. Insert the other clip end into the hole of guide pin No. 2. NOTE: The retaining clip should be fully inserted into guide pin No. 1 and No. 2. If NOT, the guide pins will come off and the brake caliper will be damaged

YAMAHA FZR600 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Kawasaki) by admin on 27-04-2011

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Front Axle and Outer Tube Front Wheel Axle Holder Rear Axle and Nut Handlebar Crown and Inner Tube Handlebar Crown and Steering Stem Steering ring nut (Upper and lower) Brake Caiiper (Front/Rear) Bleed Screw and Brake Caliper Brake Hose and Union Bolt Front Master Cylinder and Cylinder Cap Front Fender and Outer Tube Handlebar Boss and Front Fork Handlebar and Handlebar Boss Engine Mounting: Front ; Rear — Upper ; Rear — Lower 1 Down Tube and Frame: Front 1 Rear l Footrest Bracket and Frame I Pivot Axle and Nut Relay Arm and Frame Connecting Rod and Swingarm Connecting Rod and Relay Arm Rear Shock Absorber and Reiay Arm Rear Shock Absorber and Frame Footrest and Footrest Bracket I Rear Footrest Bracket and Frame Rear Master Cylinder and Rear Arm Bracket Cowling and Stay Compression Bar and Brake Caliper Bracket Front Fork Pinch Bolt: Upper Lower Sprocket and Clutch Hub Brake Disc and Clutch Hub Inner Tube and Steering Stem Frame and Rear Frame: Upper

HARLEY DAVIDSON CHROME BRAKE BLEEDER SCREW COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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General This kit fits all 1984 and later model motorcycles. Installation 1. Place chrome cover over the bleeder fitting and rubber dust cap. The cutout in the cover should correspond with tab on the dust cap. 2. See Figures 1 and 2. Push the chrome cover down firmly, compressing the rubber cap so the cover meets the brake caliper. Tighten set screw with a 5/64″ allen wrench. Insure set screw is tightened up against a flat section on the bleeder screw head

HARLEY DAVIDSON REPLACEMENT BRAKE PAD/PASTE KIT

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Filed Under (Harley Davidson) by admin on 26-03-2011

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REMOVAL Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Remove the brake caliper and pad following the instructions in the service manual. Discard pin and clip. For Kit 41852-08A: Discard brake pads. INSTALLATION Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) Prepare the Replacement Brake Pads 1. Remove paper backing from the mask. 2. See Figure 2. Carefully align and apply the mask (1) to the non-friction side of the brake pad (Figure 1, Item 2). NOTES Gloves are recommended when applying the brake pad paste to keep hands clean. 3. See Figure 4. Apply paste (6) in the mask holes until the holes are filled with paste. NOTE To prevent brake paste from transferring to other surfaces, do not apply paste thicker than specified. 4. See Figure 3. Wipe away excess paste with scraper (1) until the paste is the same thickness as the mask (2)

HARLEY DAVIDSON SOFTAIL REAR AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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INSTALLATION 1. 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. 2. All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. 3. 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. 4. All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. 5. All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. 1 2 4 3 is04788 1. Axle adjuster screw 2. Jamnut 3. Castle nut 4. Cotter pin (or spring clip) Figure 1. Rear Axle Hardware

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HARLEY DAVIDSON FRONT BRAKE DISC LOCK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION Do not operate vehicle with brake disc lock in place. Operation with lock on disc will restrict movement of the wheel, which could result in death or serious injury. (00457b) NOTE Insert key all the way to the bottom of the cylinder. Turn key clockwise 180 degrees to the open position. DO NOT FORCE KEY! Key should turn freely. If key does not freely rotate, try turning key slightly left and right while inserting to align disks inside cylinder. Failure to insert key all the way to the bottom of cylinder could cause key to jam. For Models with Hydraulic Fork Front Ends 1. See Figure 1. Insert reminder cord (3) into slot on disc lock (1). 2 1 3 is 01599 1. Lock 2. Caliper 3. Reminder cord Figure 1. Installing Disc Lock 2. Slide lock (1) over front brake disc as close to rearward edge of brake caliper (2) as possible. Push button completely down to lock. 3. Roll motorcycle forward slowly until lock gently contacts caliper. 4. See Figure 3. After installing disc lock, place loop end (1) of reminder cord (2) over handlebar grip. For Models with Springer Front Ends 1. See Figure 2. Insert reminder cord (5) into slot on disc lock

HARLEY DAVIDSON XL FRONT END LOWERING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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REMOVAL Remove Right and Left Forks 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. See the service manual and remove front wheel, fender and brake caliper. 3. Spray glass cleaner on the fork tube between upper and lower fork bracket to lubricate. 1 2 2 is04050 1. Fork cap bolt 2. Pinch bolt Figure 1. Loosen Pinch Bolt 3 2 1 is00154 1. Vise grip 2. Rubber pad 3. Plastic knob Figure 2. Fork Tube Holder (HD-41177) 4. See Figure 1. While holding the fork slider to prevent the fork from dropping, loosen pinch screws (2). 5. Remove fork tube by sliding the fork tube down and out of the upper and lower fork brackets. 6. Repeat Steps 3-5 to remove opposite fork. -J04713 1 of 5
7. Move forks to bench area. Place suitable drain pan on floor beneath vise. Disassemble Left and Right Fork

Honda VTX 1800 Motorcycles EZ-Steer Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Honda VTX 1800 EZ-Steer Instruction Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Honda VTX 1800 Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Recommended Procedures • Disconnect all wiring to headlight and remove headlight, windscreen (if so equipped) and brackets from motorcycle. • Remove handle bars from top clamp. • Remove brake caliper and brackets; disconnect all mounting points on brake lines. Secure calipers to frame being careful not to damage brake lines. • The wheel and fork tube assembly can be removed as one complete unit. • Remove steering lock fromOEM bottom clamp and install on Champion’s bottom clamp. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion’s lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 35 lb. ft.. • Install covers to bottom forks if supplied with OEM motorcycle. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of forks are flush with top surface of clamp. • Torque dome nut to 75 lb. ft.. • Ensure that fork tube extensions are flush with top of upper clamp. Torque lower 8mm bolts to 20 lb.ft. and upper 10 mm clamp bolts to 30 lb. ft.. • Install handle bars to upper clamp using OEM nut and flat washers. • Reinstall brake line holders to the lower triple clamp. • Reinstall all other OEM parts as removed. • Bleed brakes. • OEM windshield # 08R80-MCH-100 can be used on this kit

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Honda VTX 1300 EZ-Steer Installation Instruction

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Filed Under (Honda) by admin on 16-02-2011

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installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Honda VTX 1300 Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Recommended Procedures • Disconnect all wiring to headlight and remove headlight, windscreen (if so equipped) and brackets from motorcycle. • Remove handle bars from top clamp. • Remove brake caliper and brackets; disconnect all mounting points on brake lines. Secure calipers to frame being careful not to damage brake lines. • The wheel and fork tube assembly can be removed as one complete unit. • Remove caps and install supplied extensions to fork tubes using the supplied o-rings. Apply lubricant to o-rings and extensions prior to installing to fork tubes. Reinstall OEM caps and o-rings. • Remove steering lock from OEM bottom clamp and install on Champion’s bottom clamp. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion’s lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 35 lb. ft. • Install fork tube covers to bottom clamp if supplied with OEM motorcycle. • Remove OEM nylon tube cover sliders from lower fork legs and replace with supplied sliders, if required for lower chrome covers on C models. See figure on the right. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of extension is flush with top surface of clamp. • Torque dome nut to 75 lb. ft. • Ensure that fork tube extensions are flush with top of upper clamp. Torque upper 8mm bolts to 20 lb. ft and lower 10 mm clamp bolts to 30 lb. ft. • Install handle bars to upper clamp using OEM nut and flat washers. • Reinstall brake line holders to the lower triple clamp. • Reinstall all other OEM parts as removed. • Bleed brakes.

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