2003-2007 Kawasaki Ninja ZX6R/ RR HID Installation Removal Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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take out the original bulb and install the HID bulb. Be careful, do not touch the HID bulb at any time. Plug in the power wires into the original power plug. They go in easy and slide right in. Black wire connects into the black wire on the plug. On the right side, pink goes to red. On the left side, blue goes to red as these are positive wires. Pull the wires toward you slowly and carefully as you near the cover toward the headlight. Spin the rubber grommet if you need to line up the dust cover to the head light. Now lock it in. The arrow should point up if it is locked in properly. Left side installed the same way as the right. Mount the ballasts on the under side of the cowling covers with two nuts and bolts. Position the ballast in the proper place. Then, hold in one spot while drilling two holes for the bolts. An alternate mounting may be with industrial double sided tape or industrial Velcro. Do not use those cheap double sided tape of Velcro mounts as they will not hold the weight of the ballasts. Close up of underside of the cowling cover with ballast installed.
Top side of the cowling cover. Repeat installation on the second cowling. Then reinstall on the bike, connecting all the plug wires.

Harley Davidson Motorcycle 1982-2009 Standard Signal Mirror Kit INSTALLATION

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Filed Under (Harley Davidson) by admin on 23-02-2012

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Remove the 5/ 16 ” bolt from the mounting stem on the Signal® mirror. While seated on the motorcycle, position the Signal® mirror on the handle bar. Secure the Signal® mirror to the handle bar using the 5/ 16 ” bolt. NOTE: Use of oil is suggested if bolts do not thread easily into stem base. Make sure the bolt is tight! Guide the Signal® mirror wire harness into the cowling by going along side the existing factory wire harness. 4 Remove any slack in the wire harness. Secure the wire harness to the handle bar using a supplied tie wrap. 5 6 Adjust the position of the Signal® mirror and tighten the ball retention screws. Start on either the left or right side mirror. These instructions start with the right side mirror. Remove the factory mirror. NOTE: For motorcycles with OEM forward facing indicators, please use the instructions on the last page in lieu of step 2.

Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

Installation & Tuning Instructions For all Motorcycle Applications

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Filed Under (Tips and Review) by admin on 02-01-2012

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1) Start with a cold motorcycle, and remove the seat (see owners manual for seat removal instructions). 2) Locate a suitable place for your new PowerCard: It is generally velcroed or zip tied under the seat or behind cowling, check for the easiest mounting and wire routing. Often it is easier to place the card in the desired location, and then pull wires from there, rather than connecting the wires and trying to work the PowerCard backward. (In a 2004 Yamaha R6 for example, it is easiest to mount the card, then route connectors one by one through to the engine compartment.) 3) Disconnect the battery ground. Battery may need to be removed to aid in installation (2006 Yamaha R1 for example). 4) Remove the fuel tank and necessary cowlings – many tanks can simply be rotated up and away to allow access to the fuel injector connectors. Secure the tank. Be careful to prevent fuel spills if fuel line removal is necessary – use the quick-disconnect fittings if your motorcycle is so equipped. (see owners manual for tank removal instructions) a. Note: ZX10 installation also requires removal of the stock air box. Unbolt, disconnect fittings, and then turn clock-wise one-quarter turn to remove. Distributed Exclusively by Moss Motors, Ltd.
3 PowerCard®Instructions Injector lead #3 improperly installed (+) 2 1 (-) 4 3 Distributed Exclusively by Moss Motors, Ltd. 5) Connecting the PowerCard harness inline: a. Remove any one factory fuel injector connector from an injector (a flat blade screwdriver or long nose pliers may be used to ease removal). b. Couple the female connector from the PowerCard onto the fuel injector, and plug the male connector into the ECU/factory wiring harness. c. Repeat for the rest of the fuel injector connectors – The order is not important as long as they are installed as they are paired (in and out)

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

2003 SUZUKI SV 650 COOLING AND LUBRICATION SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • * Remove the cowling. (SV650S) (C-7–7-6) • * Loosen the radiator cap stop screw 10 . (SV650) • * Remove the radiator cap O2 and connect the radiator tester to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 120 kPa (1 .2 kgf/cm2,17.0 psi) and see if the system holds this pressure for 10 seconds . • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system . In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed specified pressure, or the radiator can be damaged. COOLING AND LUBRICATION SYSTEM 6-3 6-4COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • * Remove the cowling. (SV650S) ( r- 7-7-6) • * Drain engine coolant. (r– 72-20) • * Disconnect the right and left radiator hoses from the radiator. • * Disconnect the siphon hose from the radiator. • * Disconnect the horn lead wires. rI .rr • * Remove the radiator lower mounting bolt. • * Disconnect the cooling fan motor and its thermo-switch lead wire coupler 10. • * Remove the radiator by upper mounting bolt. • * Remove the cooling fan. • * Disconnect the cooling fan thermo-switch. • * Remove the cooling fan thermo-switch. • * Remove the horn. CAUTION When removing the horn, hold the nut by spanner to prevent the horn bracket distortion. COOLING AND LUBRICATION SYSTEM 6-5 INSTALLATION • * Install the cooling fan and horn. 0 Cooling fan/horn mounting bolt: 8 N .m (0.8 kgf-m, 6 .0 Ib-ft) • * Install the cooling fan thermo-switch. ( l”76-9) • * Install the siphon hose to the radiator. • * Install the radiator in the reverse order of removal. • * Route the radiator hoses properly. (=9-22) 9-22) • * Install the drain plug with a new sealing washer and pour engine coolant. (=2-20) • * Bleed air from the cooling circuit. (r– 72-21) • * Install the cowling. (SV650S)

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KAWASAKI 1700cc Liquid-Cooled V-Twin Engine 6-Speed Transmission with Overdrive

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Filed Under (Kawasaki) by admin on 13-12-2010

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Kawasaki’s first production bagger model is ready to take the street by force. The new Vulcan® 1700 Vaquero™ motorcycle combines the authority of a massive 1700cc liquid-cooled V-Twin engine together with low-slung, streetwise styling of a frame-mounted front cowling and lower chin fairing, sleek side-opening hard bags, and a choice of stealthy Ebony or fiery Candy Fire Red monotone paint. Besides its unmistakable style, the Vaquero also includes a smooth-shifting 6-speed overdrive transmission, cruise control, a full-feature audio system, and a host of custom-designed accessories. Get ready to rumble. 1700cc Liquid-Cooled V-Twin Engine The Vulcan 1700 Vaquero’s 1700cc V- Twin bristles with low-rpm torque, ensuring immediate and potent acceleration. 6-Speed Transmission with Overdrive With its overdrive top gear, the Vaquero’s 6-speed transmission teams up with the V-Twin engine for a relaxed highway cruising experience. Frame Mounted Front Cowling Muscular front cowling features a cut-down windscreen for a minimalist look and uninterrupted airflow, and is frame-mounted for light handling. Side-Opening Hard Bags Holding an impressive 9.2 gallons of storage apiece, the side bags integrate neatly into the Vaquero™’s smooth, clean lines. Electronic Cruise Control Conveniently located on the right handlebar, the Vaquero’s standard electronic cruise control precisely maintains speeds between 30 and 85 mph. Full-Feature Audio System High-fidelity audio system features AM/FM and weather radio, and is can be accessorized with iPod players, XM Radio and CB radios. Multi-Function LCD Instrumentation Located on the Vaquero’s stylish “muscle car” inspired dashboard, the multi-function LCD instrumentation clearly organizes and presents all essential information.
Engine Four-stroke, liquid-cooled, SOHC, four valve per cylinder, 52° V-twin Displacement 1,700cc / 103.7ci Bore X Stroke 102 x 104mm Compression Ratio 9.5:1 Maximum Torque 108 lb-ft @ 2,750 rpm Cooling System Liquid, plus cooling fins Ignition TCBI with Digital Advance Induction Digital fuel injection, dual 42mm throttle bodies Transmission 6-speed with overdrive and positive neutral finder Frame Type Steel, double-cradle with box-section single-tube backbone Rake/Trail 30° / 7.0 in. Front Suspension / Wheel Travel 45mm hydraulic fork / 5.5 in. Rear Suspension / Wheel Travel Swingarm with twin air-assisted shocks, with 4-way rebound damping / 3.1 in. Front Tire Size 130/90×16 Rear Tire Size 170/70×16 Brakes, Front / Rear Dual 300mm discs, dual twin-piston calipers / Single 300mm disc, twin-piston caliper Overall Length 98.8 in. Overall Width 38.2 in. Overall Height 50.8 in. Seat Height 28.7 in. Curb Weight 835.7 lbs.** Wheelbase 65.6 in. Fuel Capacity 5.3 gal. Color Choices Ebony, Candy Fire Red Warranty 36 months Good Times™ Protection Plan 12, 24 or 36 months ** Curb weight includes all necessary materials and fluids to operate correctly, full tank of fuel (more than 90-percent capacity) and tool kit (if supplied

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MACHINE SPECIFICATION FOR 115cc (UNDERBONE) (4-stroke horizontal layout engine)

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Filed Under (Tips and Review) by admin on 12-12-2010

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(This is for clarification only. Other parts not listed in Art. 2.5 & 2.6 can be altered or replaced. Change of specification means modification, changes or removal of the parts.) 2.6.1 Change of compression ratio is allowed. 2.6.2 Setting of carburetor, attachment or size change of air funnel. 2.6.3 Inlet opening of fuel tank for fuel charge may be modified but cannot be relocated. 2.6.4 Change of fuel pipe and fuel cork. 2.6.5 Change of exhaust pipe and muffler, but must have silencer. 2.6.6 Material of clutch discs and specifications of spring. Hand clutch is allowed. 2.6.7 Gear ratios are free. 2.6.8 Starting device and parts relative to this device may be removed. 2.6.9 Modification or removal of air cleaner box, wire harness and control wires. 2.6.10 Removal of speedometer (including meter gearbox and cable.) 2.6.11 Removal of drive chain case and cover. Change of drive chain is allowed. 2.6.12 Change of final gear ratio is allowed. 2.6.13 Attachment of bead stopper and balance weight to tyre. 2.6.14 Modification and change of rear brake part is allowed. 2.6.15 Frame body may be strengthened. 2.6.16 Modification and change to brackets and pedals including footrest. 2.6.17 Front suspension unit must remain as originally produced by the manufacturer. However, the following internal parts of the fork can be modified: Shims, hydraulic piston, oil passages, springs and spacers. 2.6.18 Attachment of stabilizer to strengthen or reinforcing rear swing arm is allowed. 2.6.19 Removal of dust seals. 2.6.20 Rear suspension unit must remain as originally produced by the manufacturer. However rear suspension unit is free. The rear linkage must remain as originally produced by the manufacturer. 2.6.21 Handle bars, clutch and front brake lever may be changed by an after market copy. Clutch springs may be changed. 2.6.22 Steering dampers may be fitted. They must not act in any way as a steering lock limiting device. 2.6.23 Materials of streamlining and material of seat cowling. (However, expensive materials such as carbon fibre and kevlar are not allowed). 2.6.24 Removal of rear mudguard and side cover. Front mudguard may be cut but not less than 6 inches from the front fork on original part. 2.6.25 All lubricants are free 2.6.26 Adjusting and polishing any parts are allowed. Adjusting is defined as : “To select each part or assembly complete with-in the limit of single or total tolerance” (i.e. that of valve clearance, ignition timing etc.) 2.6.27 Cutting unnecessary stays is

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APRILIA RSV MILLE And TUONO 1000 EXHAUST SYSTEM Installation instructions

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

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1. Put the motorcycle on a side stand, we recommend a racing stand. Make sure, that surface is solid and flat. 2. Unscrew the bolts from the muffler bracket (Figure 1). Unhook the stock springs and remove the mufflers with welded link- pipes (Figure 2, 3). T-handle 13mm wrench T-handle swiveling 10mm wrench T-handle 4mm swiveling three hexagon key wrench T-handle 4mm three hexagon key wrench T-handle 6mm three hexagon key wrench Combination 10mm wrench Combination 15mm wrench Combination 22mm wrench Spring puller Figure 1 Figure 2 Figure 3 NAV – 332 3 3. Remove the lower parts of the cowling (Figure 4, 5, 6). Unscrew and remove the oil cooler into a position which allows the stock front header tube to be removed; warning: do not disconnect the coolers tubes ; make sure not to damage the cooling fins (Figure 7, 8). Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 NAV – 332 4 4. Unscrew and remove the lambda sensor (Figure 9). Remove the rubber distance cap (Figure 10). Unhook the springs on the collector (collector – header tube joint) (Figure 11). Slightly unscrew the flanges on the stock header tubes (Figure 12, 13). Remove the collector (Figure 14). Completely unscrewthe nuts on the flanges of the stock header tubes and remove the headers (Figure 15). Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 NAV – 332 5 Figure 16 Figure 17 INSTALLATION OF THE AKRAPOVIC EVOLUTION EXHAUST SYSTEM: 1. Tighten the front and rear header tubes (Figure 16, 17). 2. Slide the collector onto the headers and attach the springs (Figure 18, 19).

DUCATI PAUL SMART BERON TURN SIGNALS INSTALLATION MANUAL

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

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WHEN MOUNTING OBERON TURN SIGNALS TO THE FRONT FAIRING LOCATION YOU WILL NEED TO REMOVE THE CLIP # 13 AS SHOWN IN THE DRAW- ING. DISCONNECT PIGTAIL CONNECTORS FROM TURN SIGNAL AND THEN REMOVE NUT, LOCK WASHER AND ONE OF THE LARGE NYLON WASHERS. LEAVE THE OTHER LARGE NYLON WASHER IN PLACE. FEED THE WIRES AND INLINE CONNECTORS THROUGH THE HOLE IN THE FRONT COWLING AND THEN THREAD THE WIRES AND INLINE CONNECTORS FIRST THROUGH THE LARGE NYLON WASHER YOU REMOVED, THEN THE LOCK WASHER AND THEN THE NUT. SNUG UP THE NUT WITH THE SUPPLIED STUBBY WRENCH AND MAKE SURE THE TURN SIGNAL IS ALIGNED CORRECTLY. RECONNECT THE INLINE CONNECTORS TO THE PIGTAIL WITH THE OEM CONNECTOR. CONNECT THE OEM CONNECTOR TO THE MATING CONNECTOR ON THE WIRING HARNESS. NOTE THAT ON THE PAUL SMART THE WIRES MAY NEED REVERSING ON THE LEFT SIDE OF THE BIKE SINCE IT APPEARS DUCATI HAS MISWIRED THE HARNESS CONNECTOR. YOU WILL HAVE THIS SAME ISSUE IF MOUNTING IN THE “STOCK” LOCATION. REVERSING THESE WIRES IN JUST A MATTER OF DISCONNECTING THE INLINE CONNECTORS AND SWAPPING THEM