HARLEY-DAVIDSON SPORTSTER MODEL'S 215 and S 215 INSTALLATION and CLEANING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 16-03-2012

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1. Refer to Figures 1 & 2. 2. Remove taillight and remove seat. SAFETY: DISCONNECT BATTERY PRIOR TO ALL WIRING MODIFICATIONS 3. Disconnect Right turn signal connector inside taillight. Pull wire from the underside of fender. Cut the wire approximately 2 inches from the connector, 02/16/09 save for reinstallation. Ensure the wires are loose from all retaining clips under fender. 4. Remove nut located behind fender holding the turn signal. 5. On the right side only, Remove the two torx bolts from fender strut, carefully pull and rotate fender strut cover to remove. Pull turn signal wire completely out. Remove bolt holding turn signal to the fender strut cover. SADDLEBAG INSTALLATION 6. Reinstall the fender strut cover using the 1 7/8″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the front hole and the 1 1/2″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the rear hole. Refer to view “B”. Insert the chrome caps into the existing turn signal holes. Bend tabs over to ensure a snug fit. 7. Repeat disassembly and installation on opposite side. TURN SIGNAL RELOCATION 8. Install turn signal bracket between license plate and license plate bracket with ears of bracket facing the front of the motorcycle, using 1/4 – 20 x 3/4 Hex cap screws, 1/4 flat washers, and 1/4 – 20 locknuts. 9. Mount turn signals directly to bracket using 5/16 – 18 x 3/4 hex cap screws with a Black Plastic Spacer, and 5/16 star washer. For a clean installation slide rubber grommet over the wire and secure into hole in turn signal, remove top center mounting bolt on license plate bracket and run wires through this hole. Splice the connector back on the wire, and reconnect to wire harness. Ensure all wires are secure under fender. Reinstall taillight. 10. Connect battery and test turn signals for function. Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points. 11. Mount saddlebags over spools on fender strut and secure with clips retained inside bags. 12. Inspect each clip to verify each clip is properly seated in retaining groove. See View “A”

Kawasaki Vulcan Front Suspension Lowering Kit Installation manual

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Filed Under (Kawasaki) by admin on 27-02-2011

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INSTALLATION 1. This lowering method requires replacement of the front spring spacers. This is a simple task, and is completely reversible. First, raise the front tire off of the ground before you begin. Raise the motorcycle so no weight is applied to the front wheel. 2. Cover the gas tank with a thick towel to prevent scratching. Don’t omit this…you’ll be sorry if you do! 3. If the handlebar risers are OEM (stock), loosen the handlebars in their clamps and lift them from the risers, carefully placing them on the gas tank on a thick towel to prevent scratching. This will allow room for the spring spacers to be removed from the front forks. 4. Using a small knife blade, sharp screw driver, etc. in the pinch grove on each side of the triple clamp, gently pry upwards and pop the chromed plastic covers off. These are the covers on the top of the front forks, covering the spring retainers. Below these chrome caps, you’ll find a gold anodized metal plug with a small counter bore in the center. This is the part used to retain the springs within the front fork tubes. Using an extension bar, large Phillips screwdriver, etc., press down a bit in the counter bored area of the plug to take the pressure off of the small internal “C” ring. While this “gold” colored plug is depressed, remove the internal C-ring. The C-ring is made of small diameter wire. Once the C-ring is removed, slowly release the pressure on the plug and it’ll push itself out of the top of the shock. The picture below is of the upper fork leg with the gold retaining plug removed. 5. Stick a finger into the fork tube, and slide the OEM tubular spacer up and out of the fork tube. 6. The picture below illustrates the use of a Scootworks lowering spacer with the fork spring. On the right hand end of the you’ll see a Scootworks lowering spacer. The fork spring stays in the front fork, and you’ll drop in the spacer with the desired amount of lowering. The approximate amount of lowering is marked on each Scootworks spacer. 7. Select the spacers for the desired amount of lowering. The longest spacers supplied are marked as [1] and will lower the front suspension 1″. The spacers of middle length are marked as [2] and will lower the front suspension by 2″. The shortest spacers supplied in the kit are marked as [3] and will lower the front suspension by 3″. Omission of the spacers completely will lower the front suspension by approximately 4″. 8. Install the selected spacers in the fork tubes, on top of the internal fork spring. Place the gold anodized metal plugs on top of the spacers and press them back into the fork tube. Be sure to turn the metal plug so the side with the counter bore is facing outwards. Reinstall the C-rings, and gently lower the front end back to the ground. Make sure the C-rings seat themselves in their respective grooves when the weight of the bike is placed back on the front end. Re-install the chrome caps.

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