Yamaha R1 2007-2008 Frame Slider Installation

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Filed Under (Yamaha) by admin on 01-01-2012

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Installation Steps: 1. Remove left and right body panels. 2. Remove the left side engine stud. Mount the left side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the left side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 3. With the offset in the correct position remove body and torque down to OEM torque specs. 4. Using one drop of blue thread locker mount the left side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 5. Remove the right side engine stud. Mount the right side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the right side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 6. With the offset in the correct position remove body and torque down to OEM torque specs. 7. Using one drop of blue thread locker mount the right side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 8. Mount left and right bodywork

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Honda RC51 2000-2005 SBK Undertail Kit INSTALLATION

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Filed Under (Honda) by admin on 22-11-2011

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Carefully remove the tail section body work. Save all bolts, washers and plastic rivets for re-installation of tail. Disconnect and remove the brake light (with all mounting grommets and washers), license plate and turn signals, key lock (with clip) and move all wiring out of the cutting areas. Remove the two bolts at the rear end of the stock fender (inside glove box) to allow the end to hang down for cutting Using a “Dremel” tool or cutting disc (this can also be done using a sharp edged knife, but is not recommended), remove the plastic shown in the photos to the above and below. Your subframe may be different but the cutting position is the same on all years. Be sure to take your time cutting, so that you don’t cut away any more plastic than necessary Replace all bodywork with fasteners loosely installed, mount undertail,
notice at bottom of the tray there are 2 holes, mark and remove tray, then drill holes in battery box 6) Inset lock into undertail using stock lock mounting clip, make sure the lock is in the correct position with the lock cable arm to function
properly. Insert undertail left side first, then right side, be carefull not to crack or scratch undertail. Use your stock plastic screw rivets to hold undertail in place. Attach lock cable to lock, check movement, adjust if necessary. Tighten all hardware on tail section, attach seat. * After this modification your undertail is not returnable. Paint is not war-
rantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray.
6) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail, carefully mark and drill holes, install using the two (2) sets of allen bolts and lock nuts

Honda GL1000 Timing Belts Removal / Installation Manual

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Filed Under (Honda) by admin on 08-04-2011

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Turn engine as described above until the T-1 mark aligns with engine block marks (it looks a little ‘out’ on the photo, it’s the angle). AND (this is important) the pulley marks align with the marks on the engine cover like here on LEFT side (seen from sitting on bike … remember). and RIGHT side. Mark this position on the central pulley and engine block. Now release the tensioner bolts. (*) And remove the belt. (*) (*) When you do that the right pulley (photo-left) will ‘wander/turn’ out of position when you remove the belt, as it is ‘riding’ on cam ‘slope’ (which is under the influence of the valve springs). Don’t worry. One thing you can do to calm your nerves and keep it in position: put the new belt loosely over the pulley and holding the pulley in the CORRECT POSITION (marks aligned) ‘strip’ a spanner to the frame. Do not use the spanner to turn the pulley. Use your hands … then ‘lock’ it with the spanner. (Make absolutely sure you do not turn (release/loosen) the bolt). And, here’s a nifty trick posted by Mooseheadm5 in another thread: “..one thing that made it super easy (and 3 reduced the anxiety level quite a bit) was that I loosened the tappet adjusters all the way [...snip...] you do not have to fight the valve springs much, plus the cams do not want to snap back or forward so you do not necessarily need to use Octane’s zip-tied wrench trick.” – Thanks, Moosehead . Release left tensioner bolts . Remove belt. Put on new belt. Check the tensioners or ‘tension rollers’. You may think they are ‘fine’: they ‘roll’ and don’t make funny sounds? You won’t know until you’ve had a set of new rollers in your hands. They should be real ‘tight’ as a set of new roller bearings … which I think they are, in fact. If they appear ‘dry’ or make any sounds; renew them and get rid of that high pitched whining sound associated with ‘dry’ rollers. This is how they go on left side (remember…photo-right). And the spring gets attached . … Pulleys in correct position (crank pulley and cam pulley) . … Left belt tight at the bottom … Tension roller loosely attached (let the spring do the tension). (On photo it is not on yet … ooops.

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HARLEY DAVIDSON CONTOURED TOUR-PAK LUGGAGE RACK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION NOTE The location of the Tour-Pak spoiler has a direct relationship to the location of Tour-Pak mounted luggage rack. The spoiler template will locate the Tour-Pak spoiler in the correct position for the luggage rack so that the spoiler may be added in the future. It is recommended that the spoiler be installed first. See Figure 1. 1. Identify if the installation of a Tour-Pak mounted spoiler is desired in the future. Use the template if the spoiler will be installed. Cut the template along the appropriate line. Carefully place template on top of Tour-Pak lid, aligning edges of template with top surface of Tour-Pak. Tape template in desired location. 1 is 00579 1. Check clearance between rack and spoiler Figure 1. Tour-Pak Rack and Spoiler NOTE Position top rack with upright section toward rear of motorcycle. To avoid contact with the passenger backrest pad, do not mount the top rack in too far forward a position. 2. See Figure 2. Place the four mounting pads (1) onto the four mounting supports on top rack (2). Carefully center the rack on the lid and position the rack rear supports 5/8 inch to 3/4 inch (16 mm to 19 mm) in front of the emblem on the Tour-Pak lid, as shown. 1 is 00636 1.5/8 in. – 3/4 in. (16 mm – 19 mm) Figure 2. Locate Holes From Emblem 3. Use a grease pencil to temporarily mark the positions of the four mounting pads on Tour-Pak cover. NOTE Apply masking tape to the Tour-Pak cover painted surface at the four points where the top rack mounting holes will be drilled. The tape can be marked for hole location, and will help prevent the paint from being chipped during the drilling procedure. 4. Carefully remove top rack/mounting pad assembly. Place a strip of masking tape over each grease pencil mark on the Tour-Pak cover. Once again, position top rack/mounting pad assembly on Tour-Pak cover in the desired mounting location. 5. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting pad. Remove top rack/mounting pad assembly. Use a ruler to mark the exact center of each circle drawn on the tape strips. NOTE Remove all contents from within the Tour-Pak to avoid possible contact with the moving drill bit during the following drilling procedure. 6. Drill starter holes using a 1/16 inch drill bit. Drill the finished holes for the mounting screws using a 9/32 inch drill bit. Remove masking tape strips. 7. Apply a small amount of silicone sealant around each mounting hole on interior surface of Tour-Pak cover

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HARLEY DAVIDSON VRSC ACCESSORY SEATS AND PILLIONS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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INSTALLATION Installing Seat and Pillion Kits: 51584-01, 52028-02, 52036-01, 53432-02, or 52927-05 NOTE Proper installation of 53432-02 (Sundowner) and 52927-05 (Tallboy) requires installation of Fender Base Plate Kit 51120- 01 1. Refer to the appropriate Service Manual and remove the stock seat and pillion. 2. See Figure 2. Remove the two mounting bolts (2) from the passenger grabstrap (1). Save the bolts for re-installa- tion. NOTE The grabstrap must loop toward the rear. Check that the “Harley-Davidson” text on the grabstrap can be read from the front of the vehicle. 3. See Figure 2. Install stock grabstrap bolt, and one end of grabstrap as shown. While holding the grabstrap end parallel to the formed line of the fender, tighten the bolt to 8-12 Nm (71-106 in-lb ) . Repeat for opposite end of grabstrap. NOTES The new pillions included in Kits 52028-02 (Custom), 52036- 02 (Badlander) and 51584-01 (Leather Badlander) are installed from front-to-back. The pillion included in Kits 53432-02 (Sundowner) and 52927- 05 (Tallboy) must be installed through the grabstrap from back- to-front. To install the Sundowner or Tallboy Pillion on a motorcycle having a sissybar upright installed on Fender Base Plate Kit 51120-01, remove the upright before installing the pillion. Reinstall the upright after the Sundowner Pillion is installed. For kit numbers 52028-02 (Custom), 52036-01 (Vinyl Bad- lander) and 51584-01 (Leather Badlander) Seat Kits, be aware of the following: The 2003 Model Year 100th Anniversary VRSCA vehicle with two-tone sterling silver and vivid black paint has protective tape covering the rear under-the-seat area of the airbox cover. For the seats listed above, it will be necessary for cosmetic reasons, to carefully remove the protective tape and reapply it so it is in the correct position for these shorter-nose seats. Some trimming of the lower portion of the protective tape may be necessary to eliminate interference with the airbox cover latch. If necessary, reorder protective tape (48403-03). 4. Install new pillion into position through grabstrap. Prevent pinching TSSM control wiring by routing the cable through the channel on the underside of the pillion (see Figure 2) and away from the pillion mounting bolt. Pinched wiring may damage the TSSM system. 1 3 2 is00014 1. Pillion 2. Grabstrap 3. Pillion base mounting hole Figure 3. Pillion Base Mounting Hole 5. See Figure 3. Push the pillion (1) forward through the grabstrap (2) until the pillion mounting hole is approximately 25 mm (1 in.) forward of the hole (3) in the frame. 6. See Figure 2. Push down on the pillion and slide the pillion toward the rear to engage the pillion slot with the fender tongue (5). Push rearward until the pillion mounting holes align. After installing pillion, pull upward to be sure it is locked in position. While riding, a loose pillion can shift causing loss of control, which could result in death or serious injury. (00387a) 7. Install original pillion mounting bolt. Tighten bolt to 11-14 Nm (97-124 in-lb ) . 8. Re-install the sissybar upright, if removed earlier. 9. Position the seat (as if opened) onto the frame. Slide the seat forward to insert the seat-hinge pins into the bushings on the frame. 10. See Figure 1. Clip the plastic seat-hinge sleeve (2) over the seat hinge. 11. See Figure 1. Insert the seat tether (3) into the hole in the motorcycle frame. 12. Refer to the applicable Owner’s Manual and close the seat. Installing Seat Kits: 51595-05, 52024-01, or 51647-06 Kit 51595-05 requires the use of pillion kit 51594-05. Kit 51647-06 requires the use of pillion kit 51648-06. Kit 52024-01 requires the use of either the stock pillion or Touring Pillion 52023-01A. 1. Refer to the appropriate Service Manual and remove the stock seat.

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HARLEY DAVIDSON PREMIUM TOUR-PAK LUGGAGE RACK KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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INSTALLATION Template Positioning (Rack Installation WITH SPOILER only) The location of the luggage rack has a direct relationship to the location of the Tour-Pak® Spoiler. The template (7) included in this kit will locate the luggage rack in the correct position for the current or future installation of a Tour-Pak Spoiler. NOTE A template is not required if installing rack without spoiler. 1. If a spoiler is already installed, or if the installation of a Tour-Pak-mounted spoiler may be desired in the future, cut the template along the appropriate line. 2. Carefully place the trimmed template on top of the Tour- Pak, aligning the edges of the template with the top surface of the Tour-Pak lid. Tape the template to the lid in the desired location. The template will help to properly locate the rack so that a spoiler may be added in the future. Rack Installation on Tour-Pak 1. ALL installations: Open the lid, and remove all loose contents from the Tour-Pak. 2. See Figure 1. Slip the mounting pads (2) onto each of the mounting bosses (B) of the luggage rack (1). NOTES Kit 53665-87: Position rack with wide upright toward rear of vehicle. Kit 91793-85: Position rack with upright toward rear of vehicle. Carefully center the rack from left to right, and position the rack squarely on the lid for best appearance. Do not mount the rack too far forward to avoid contact with the backrest pad. 3. Position the rack on the Tour-Pak lid in the desired loca- tion. 4. Carefully raise the rack, and place masking tape (A) on the Tour-Pak lid where the four mounting bosses contact the cover. 5. Lower the rack onto the tape in the location chosen in Step 3. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting boss. Remove the rack, and use a ruler to mark the exact center position of each mounting boss on the tape. 6. Drill four 1/16 inch (1.5 mm) diameter pilot holes through the masking tape and Tour-Pak lid at each mounting boss center position. Use a 9/32 inch (7 mm) diameter bit to drill the finish holes. 7. Remove the masking tape

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1995 – 1999 HONDA CBR 900RR AKRAPOVIC BOLT-ON STREET LEGAL EXHAUST SYSTEM Installation instructions

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

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REMOVAL OF STOCK EXHAUST SYSTEM 1. put the motorcycle on a side stand, we recommend a racing stand 2. unscrew and remove bolts from the muffler at the muffler – link pipe (header assembly) connection (Figure 1) 3. unscrew and remove the bolt from the metal hanging bracket and remove the muffler (Figure 2 & 3) INSTALLATION OF THE AKRAPOVIC BOLT-ON EXHAUST SYSTEM installing the muffler: 1. remove the stock gasket and install the copper gasket from the Akrapovic kit in the groove in the CNC ALU flange (Figure 4) 2. correctly orient the muffler and place it near the link pipe/header assembly 3. when the muffler and the link pipe are together, attach using the titanium bolts from the Akrapovic kit. Coat each bolt individually with bolt sealant before installing. (Figure 5) Tighten the bolts only hand tight – do not fully tighten! (Figure 6) 4. correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp viewed from the rear (Figure 7). 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 8) 5. tighten the carbon-fiber clamp onto the stock bracket on the frame – use the stock bolts or the replacements from the Akrapovic kit, if supplied (Figure 9) 6. make sure that the BOLT-ON system is not touching any other parts of the motorcycle ! 7. example of the correct position of the installed Akrapovic BOLT-ON system (Figure 10) final installation: 1. Tighten the titanium bolts on the CNC ALU flange at the muffler – link pipe connection and also tighten the bolts on all of the brackets and clamps to which the exhaust system and the other dismounted parts of the motorcycle are attached 2. 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 Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 3. 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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Yamaha Rear Suspension Lowering Kit installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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1. This lowering method requires replacement rear suspension coupling components. This is a simple task, and is completely reversible. In addition, this kit provides for a 0″ setting, to easily return your bike to its original height. First, raise the rear tire off of the ground by the frame before you begin. Raise the motorcycle so no weight is applied to the rear wheel, allowing the rear wheel to spin freely. 2. Next, become familiar with your lowering kit. You’ll notice that there are two corners of the lowering component with two holes each, and one corner with a single hole. The corner with the single hole attaches to the swingarm (the bolt that is closest to the rear wheel). The only important part of this familiarization process, is to make sure that you get the part oriented in the correct position. The following photos will explain the purpose of the different holes, and also help you turn the part in the correct position before you install it. Look at the first photo on the next page: In the photo above, the part is positioned just as it should be, for installation on the left-hand side (kickstand side) of the motorcycle. A quick measurement will show that Dimension “A” on Side “A” should be shorter than Dimension “B” on Side “B”. If not, flip your part over (turn the face you are viewing away from you, but keep the corners with two holes on your left), and measure again. Next, study the photo below for info on the different heights you can set your bike to… When installed, Hole “0″ will place the bike at it’s original height. Placing the top bolt in Hole 1, and the bottom bolt in Hole 0, the bike will be lowered approximately ¾”. Placing the top bolt in Hole 1, and the bottom bolt in Hole 1, the bike will be lowered approximately 2″. Simple, eh? Now, let’s move on to installation. 3. Below is a photo of the factory suspension coupling as installed in your motorcycle. This photo was taken from the LH side of the bike, to keep things in perspective with our previous photos. Loosen the three bolts holding the original suspension coupling, and remove. Be aware that the rear wheel will drop down when the bolts are removed, just so there are no surprises!

Electronic Gear Actuator Installation Instructions

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Filed Under (Tips and Review) by admin on 31-10-2010

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Fault Finding Mechanical If this is a new installation then there are checks that should be made to ensure that the unit can operate correctly. • Check the gear linkage for free play; this represents an effective loss of stroke. Tighten or replace any ball joints or other linkages as necessary • Check that you have oil in your gearbox, if the level is low the gears will run hot after a short period and become tight. • Check that the clutch is clearing properly, any clutch drag will cause the gears to mesh and prevent you changing gear cleanly. If your installation has been working satisfactorily, but has begun to change erratically check the following: • Ensure that the bearing in the clamp is tight and that there is no wear in it, if there is excessive play then replace the bearing. • If you are using a ball joint to connect to the shift lever check this for wear, replace if necessary. • Check all alignments, in particular if you have clamped onto a tubular frame it is possible that this has moved slightly over time • Check the gear linkage for free play; this represents an effective loss of stroke. Tighten or replace any ball joints or other linkages as necessary – if your linkages are all tight you may still have some play in the gearbox itself. – 3 – When offering up the actuator it must also be borne in mind that the angle between the actuators connecting rod, and the pivot point of the lever should be as near as possible to 90 degrees. This ensures that the effort is equal in both directions. When looking for a suitable mounting location you may be able to pick up on existing bolts, the back-plate on the clamp can be drilled to pick up on these. If there is no convenient mounting point then you will have to make up a transition bracket to get the unit into the correct position. The following photographs show some of the common options. See our web site for a full index of mounting arrangements

KYMCO MAXXER 300/ 250 MONGOOSE 300/ 250 SERVICE MANUAL

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Filed Under (Kymco) by admin on 26-10-2010

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apply or add designated greases and lubricants to the specified lubrication points. ÑAfter reassembly, check all parts for proper tightening and operation. ÑWhen two persons work together, pay attention to the mutual working safety. ÑDisconnect the battery negative (-) terminal before operation. ÑWhen using a spanner or other tools, make sure not to damage the motorcycle surface. ÑAfter operation, check all connecting points, fasteners, and lines for proper connection and installation. ÑWhen connecting the battery, the positive (+) terminal must be connected first. ÑAfter connection, apply grease to the battery terminals. ÑTerminal caps shall be installed securely. 1 . GENERAL INFORMATION 1-6 ATV 300/250 ÑIf the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. ÑAfter operation, terminal caps shall be installed securely. ÑWhen taking out the connector, the lock on the connector shall be released before operation. ÑHold the connector body when connecting or disconnecting it. ÑDo not pull the connector wire. ÑCheck if any connector terminal is bending, protruding or loose. Confirm Capacity 1 . GENERAL INFORMATION 1-7 ATV 300/250 ÑThe connector shall be inserted completely. ÑIf the double connector has a lock, lock it at the correct position. ÑCheck if there is any loose wire

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