Harley-Davidson 39mm Fork FXR, FXD, XL from 87 to Current, Light Bar N935 & N935E INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Remove Headlight from Headlight Shell (Screwdriver) set aside. 2. Disconnect Turnsignal wires behind or inside Headlight Shell. 3. Unbolt Headlight Shell from Eyebrow (3/4″ Socket & Wrench). Let hang from wires. 4. Remove front Turnsignal Assemblies from motorcycle. 4a. If Turnsignals are mounted to the Handlebar use the 1/2″ Wrench. 4b. For fork mounted Turnsignals, 1996 to current, use the Torx Wrench 4c. For fork mounted Turnsignals 1987-92 use the 5/16 Hex Key Set turnsignals aside, they will not be reused. 5. Remove screw from Brake Hose Clamp and Clutch Cable Guide (Hex Key Wrench, 3/16″) located on the bottom of the lower Triple Clamp. Set aside, it will not be reused. 6 . Remove the Pinch Bolts from the lower Triple Clamp (Torx Wrench, 1993 to Current, or 5/16 Hex Key, 1987 to 92). Set aside, they will not be reused. INSTALLATION 1. Mount the Light Bar Assembly: A. Hold the Light Bar assembly up to the lower Triple Clamp, the center bracket will be below the Triple Clamp. B. Start the 1/4-20 x 3/4 Screw, with Washer, through the Brake Hose Clamp, clutch cable guide then the center bracket and into the threaded hole previously used for the Brake Hose Clamp. C. Position a Spacer between the Outer Brackets and the Triple Clamp and start the 3/8-16 x 2″ Hex Bolts through the Outer Bracket, then the Spacer and into the Pinch bolt location on the lower Triple Clamp. Do this on both sides of the lower Triple Clamp.

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2001-2003 HONDA GL1800/ A ECM Replacement/ Cooling System

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Filed Under (Honda) by admin on 13-12-2011

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Use the Cylinder Head Inspection Kit for the Cyl- inder Head Inspection procedure. Use the kit for each GL1800/A you inspect. Do NOT dispose of kit items. 1) 19X20 mm cap (2) (cap B) 2) 8X15 mm cap (cap A) 3) Hose plug 4) Bottle/cap w/feed hose 5) Harness clips (10) 6) Harness tape 7) Inspection mirror A limited number of additional Cylinder Head Inspection Kits are available: call TechLine at 800-421-1900, ext. 1 if you need one. Kit con- tents are NOT available separately as parts. NOTE: • The following late ‘03 models do not have nto have their cylinder heads inspected: • Perform the following procedure with the engine at room temperature. • Both Left and Right cylinder heads must be inspected. • Use the Cylinder Head Inspection Kit for the following procedure. 1. Remove the front lower fairing. (See S/M, 2-6) 2. Remove and suspend the rear brake reser- voir, being careful not to stress the brake hose. (See S/M, 15-A-8)

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

Yamaha TW200N/ TW200NC SPECIFICATIONS AND SUPPLEMENTARY SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-04-2011

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GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts CABLE ROUTING 1 Throttle cable 2 Front brake light switch lead 3 Right handlebar switch lead 4 Clutch cable 5 Left handlebar switch lead 6 Clutch switch lead 7 Front turn signal/position light lead (left) 8 Main switch lead 9 Indicator lights lead 0  Speedometer cable A Meter light lead B Headlight coupler C Wire harness D Front turn signal/position light lead (right) E Brake hose ب Fasten the brake hose with a plastic locking tie to the brake hose grommet. ة Fasten the wire harness with a plastic locking tie PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and abjustments.If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM

2001-2003 GL1800/ A ECM Replacement/ Cooling System REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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Install the new ECM, then reinstall the cruise/ reverse control module in the reverse order of removal. NOTE: When you start the vehicle – after completing ALL procedures – the new ECM will require initialization . To initialize the new ECM, perform the following procedure: • Start the bike and allow it to warm up to normal operating temperature and remain at idle for at least 90 seconds . Do not operate the throttle during this time; if you do, the ECU will not initialize properly and the process will need to be repeated. 5. Proceed to the Cylinder Head Inspection section below. Use the Cylinder Head Inspection Kit for the Cylinder Head Inspection procedure. Use the kit for each GL1800/A you inspect. Do NOT dispose of kit items. 1) 19X20 mm cap (2) (cap B) 2) 8X15 mm cap (cap A) 3) Hose plug 4) Bottle/cap w/feed hose 5) Harness clips (10) 6) Harness tape 7) Inspection mirror A limited number of additional Cylinder Head Inspection Kits are available: call TechLine at 800-421-1900, ext. 1 if you need one. Kit contents are NOT available separately as parts. NOTE: • The following late ’03 models do not have to have their cylinder heads inspected: • Perform the following procedure with the engine at room temperature. • Both Left and Right cylinder heads must be inspected. • Use the Cylinder Head Inspection Kit for the following procedure. 1. Remove the front lower fairing. (See S/M, 2-6) 2. Remove and suspend the rear brake reservoir, being careful not to stress the brake hose. (See S/M, 15-A-8) CONNECTOR B (22-GRY) CONNECTOR C (6-BLK) CONNECTOR A (22-BLK) ECM (ENGINE CONTROL MODULE) 1 2 3 4 5 6 7 Late ’03 (Non-ABS): after VIN 1HFSC470*3A204632 Late ’03 (ABS): after VIN 1HFSC474*3A201020 Cylinder Head Inspection Kit Cylinder Head Inspection

TRIUMPH ROCKET III SWING ARM COVER INSTALLION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Locate and remove the 6mm screw which secures the rear brake hose clip to the top of the swing arm (just in front of the lower right shock absorbers mounting point. 2. Notice the double faced adhesive tape on the inside of the cover and where it will contact the swing arm when installed, clean this area with rubbing alcohol and remove the backing from the adhesive tape on the inside of the cover. 3. Place the º” washer provided on the top of the swing arm over the brake hose clip mounting hole. Starting at the rear of the swing arm slide the cover carefully into place and align the small hole in the top of the cover with the washer and the threaded hole. Place the screw thru the hose clip then the cover and finally the washer, next thread the screw into the hole finger tight only. 4. Press the front area of the cover with the adhesive tape firmly into place. Tighten the 6mm brake hose clip screw securely.

TRIUMPH ROCKET III SWING ARM COVER INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-12-2010

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1. Locate and remove the 6mm screw which secures the rear brake hose clip to the top of the swing arm (just in front of the lower right shock absorbers mounting point. 2. Notice the double faced adhesive tape on the inside of the cover and where it will contact the swing arm when installed, clean this area with rubbing alcohol and remove the backing from the adhesive tape on the inside of the cover. 3. Place the ¼” washer provided on the top of the swing arm over the brake hose clip mounting hole. Starting at the rear of the swing arm slide the cover carefully into place and align the small hole in the top of the cover with the washer and the threaded hole. Place the screw thru the hose clip then the cover and finally the washer, next thread the screw into the hole finger tight only. 4. Press the front area of the cover with the adhesive tape firmly into place. Tighten the 6mm brake hose clip screw securely.

YAMAHA ROAD STAR LONGSHOT EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 28-12-2010

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1. Remove the header flange nuts from the rear cylinder. 2. Loosen the muffler clamp on the front head pipe. 3. Remove the two muffler mounting bracket bolts, located between the two mufflers. 4. Carefully separate the front head pipe from the muffler assembly. Remove the muffler assembly with the rear head pipe attached and set it aside. 5. Remove the header flange nuts from the front cylinder. Remove the front head pipe and set it aside. 6. Remove the muffler mounting bracket from the frame. Note: The rear brake hose must be disconnected from the rear brake caliper in order to remove the muffler mounting bracket. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Reconnect the brake hose to the rear caliper. Important : Bleed the rear brake to remove any air from the system and refill the reservoir with the proper brake fluid. 2. Install the new mounting bracket (stamped 274) to the frame, by aligning the two 10mm holes in the bracket with the two holes in the frame below the right rear footrest (where the stock mounting bar was removed). Use the two 10mm bolts and lock nuts (supplied), do not tighten at this time. Note: The bracket will bend away from the motorcycle when mounted correctly. Refer to figure 1. 3. Connect the brake hose clip to the muffler mounting bracket, using the 6mm bolt and lock nut (supplied). Refer to figure 1. 4. Install the chrome flanges (supplied) on to both the new head pipes. 5. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 6. Install the front head pipe using the stock nuts, do not tighten at this time. 7. Install the rear head pipe using the stock nuts, do not tighten at this time. 8. Install one muffler clamp (supplied) over the front (notched end) of each muffler. 9. Slip one muffler onto the front head pipe. Slide one dog bone shaped nut plate under the bracket that is welded to the backside of the muffler and attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. 10. Repeat step #8 for the rear muffler. 11. Align the mufflers so they are parallel when viewing from the right side of the bike, and tighten the 5/16″ flange bolts on the back side of both mufflers. 12. Tighten the two 10mm bolts that mount the bracket to the frame. 13. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 14. Place the appropriate heat shield onto the rear pipe, wrap the hose clamps around the head pipe and tighten. Repeat this step with the front heat shield

YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 22-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove both frame covers. Remove the left cover first to access a bolt that holds the right side cover in place. 2. Remove right side floorboard assembly held in place by two bolts (Figure 1). 3. Remove exhaust port Allen nuts. 4. Remove Allen bolts securing rear muffler to exhaust system mounting bracket. 5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required). 6. Check condition of stock exhaust gaskets. Replace if damaged or worn 7. Remove two bolts attaching stock exhaust mounting bracket to frame. 8. Remove hose clamp securing rear brake hose to exhaust mounting bracket. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loop in bracket. 11. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 12. Reconnect brake hose to caliper (without bracket) and torque Banjo bolt to 25 lbs. ft. 13. Brake system must be bled or brake will not operate correctly. Refill reservoir after bleeding 1. Remove exhaust system and heat shields from protective packaging. Place exhaust on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through (Figure 2). 2. Attach brake hose clamp to mounting bracket (stamped 362-P) using one 6x16mm flange bolt and nylock nut (supplied) to tab located on top of bracket (Figure 2). 3. Install mounting bracket using two 10x30mm Allen bolts and lock nuts (supplied)(Figure 3). 4. Carefully slide heat shields onto headers.

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YAMAHA ROAD STAR EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the header flange nuts from the rear cylinder. 2. Loosen the muffler clamp on the front head pipe. 3. Remove the two muffler mounting bracket bolts, located between the two mufflers. 4. Carefully separate the front head pipe from the muffler assembly. Remove the muffler assembly with the rear head pipe attached and set it aside. 5. Remove the header flange nuts from the front cylinder. Remove the front head pipe and set it aside. 6. Remove the muffler mounting bracket from the frame. Note: The rear brake hose must be disconnected from the rear brake caliper in order to remove the muffler mounting bracket. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Reconnect the brake hose to the rear caliper. Important : Bleed the rear brake to remove any air from the system and refill the reservoir with the proper brake fluid. 2. Install the new mounting bracket (stamped 273) to the frame, by aligning the two 10mm holes in the bracket with the two holes in the frame below the right rear footrest (where the stock mounting bar was removed). Use the two 10mm bolts and lock nuts (supplied), do not tighten at this time. Note: The bracket will bend away from the motorcycle when mounted correctly. Refer to figure 1. 3. Connect the brake hose clip to the muffler mounting bracket, using the 6mm bolt and lock nut (supplied). Refer to figure 1. 4. Install the chrome flanges (supplied) on to both the new head pipes. 5. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them.

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