KAWASAKI KX450F SPARK XCR SYSTEM INSTALLATION INSTRUCTIONS

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

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1. Place the machine on a stable work stand. 2. If you are not familiar with removing the original exhaust refer to the owner’s manual before you start work. 3. Always allow your machine to cool down before attempting to remove the exhaust. 4. Remove the two bolts from the right side panel. Then remove the side panel. 5. Loosen the stock mid-pipe clamp, then remove the stand-off bolt and bracket bolt that supports the muffl er. 6. Remove stock muffl er and clamp from the stock head pipe. 7. Slightly loosen the stock head pipe at the cylinder head to aid in aligning the parts. INSTALLING THE NEW XCR SYSTEM 1. Installer must use supplied hardware. 2. Slide mid-pipe onto head pipe. Rotate the mid-pipe slightly to obtain proper alignment with sub-frame mount. 3. Install the supplied M8x16mm bolt through sub-frame into the stand-off mount on mid-pipe (Finger tight). 4. Slide the muffl er onto mid-pipe, align muffl er mount with the stock muffl er mount hole, and install and fi nger tighten the OEM bolt. 5. Once you have the system fully aligned, install and tighten all the bolts securely to factory specifi cations. 6. Replace the side panel and secure the mounting bolts. 7. Re-tighten stock head pipe at the cylinder head. TEST RIDING 1. When you fi rst ride the bike be aware that the characteristics are often quite different so start out slowly. TUNING 1. On the KX450F, we suggest using stock jetting based on our testing condition. These specifi cations should only be used as a guideline. Riding at different elevations or climates may require using different settings to obtain peak performance. If you need additional assistance, please refer to your Kawasaki owner’s manual. 2. To convert system from Offroad to Competition specifi cations, remove the 5mm Allen bolt and Spark arrestor. Two different Db lowering inserts are also available (see accessories section on page 2). To return the system to Offroad specifi cation re-install the Spark arrestor into the rear of the muffl er using a small amount of blue thread locking compound (Loctite® 243) re-tighten the 5mm Allen bolt (6.5 ft pounds)

Kawasaki KVF650/ 700, KSV 700 Camshaft Installation Instructions

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Filed Under (Kawasaki) by admin on 29-04-2012

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Liberally apply assembly lube to every surface of the camshaft. Install the camshaft into the cylinder head (the lobes should be pointed down) and align the decompressor shaft dowels with the weight arms. Install one of the camshaft sprocket holder bolts and tighten to less than finger tight, you should be able to move the camshaft very slightly back and forth, roll the crank over until the other bolt hole is exposed and insert the sprocket bolt and tighten to less than finger tight. Install the cam chain tensioner assembly, do not install the spring, spring dowel, washer, and bolt. Using the spring from the cam chain tensioner very slowly push the tensioner shaft in until the cam chain slack has just been taken out, this is witnessed by the very slight lifting of the opposite end of the cam out of the cylinder head cam journal, do not over tighten the cam chain at this point, if you do, remove the tensioner assembly and retract the plunger again and start over. (If it stays too tight it will stretch the cam chain prematurely and cause cam sprocket damage when the engine is assembled) Roll the camshaft toward the back of the machine (clockwise) loading the sprocket bolts against the back of the sprocket bolt holes, while holding the camshaft in that direction, tighten the sprocket mounting bolt to 14 ft/lb of torque. Rotate the engine in the opposite direction that you rotated it earlier and align the TDC mark, tighten the other sprocket-mounting bolt to 14 ft/lb of torque. Verify the cam timing and crankshaft TDC marks are in alignment

HARLEY-DAVIDSON SOFTAIL CROSSOVER REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-04-2012

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EXHAUST SYSTEM REMOVAL READ ALL INSTRUCTIONS BEFORE BEGINNING 1. Under the oil tank on the right hand side, locate the rear O² sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifier on front of the frame to access to the front O² sensor connector. Unplug sensor from harness. Remove ZIPSTRIP holding wire to frame and feed the wire through freeing it from motorcycle. 3. On floorboard equipped models, loosen the right hand floorboard mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTD and FLSTF models, you will need to remove the right side passenger foot peg and hanger, as this is attached to the exhaust mount bracket. Replace the passenger foot peg assembly using the BOLT 14 Allen bolt (supplied). 8. Remove the entire exhaust system and set it aside. 9. Remove the two lower mounting studs from the frame See figure 1 . Recommended replacement exhaust port gaskets, H-D P/N: 65324-83A. 10. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. See figure 2 . NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. 11. Remove O² sensors from stock head pipe and set aside for re-installation on your new RUSH exhaust system. PAGE 1 OF 4 RUSH RACING PRODUCTS EXHAUST SYSTEM INSTALLATION P/N 7020 – 7120 BEFORE INSTALLATION PLEASE READ ALL INSTRUCTIONS 1. Remove header and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through See figure 3. 2. Apply a small amount of anti-seize compound to the threads of the O² sensors and install them into the new head pipe. NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor function. 3. Install circlips and flanges from stock system onto the new head pipe See Figure 2. Note: Replace circlips if bent or damaged 4. Attach BRKT-007 to frame using two BOLT 12 Tighten to factory specs. 5. Install complete assembly into exhaust ports (rear port first). Use stock flange nuts, Do Not Tighten .

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HARLEY-DAVIDSON SPORTSTER SHORTSHOTS STAGGERED INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-03-2012

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1. Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 3. Remove the two head pipe mounting nuts from each fl ange, located at the cylinder head. 4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffl er body where they attach to the mounting bar. Carefully remove exhaust pipes from the motorcycle and set aside. 6. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T30 torx driver. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar (save hardware for re-use). 10. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition

HARLEY-DAVIDSON DRESSER BIG SHOT DUALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2012

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1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. Note: On older model Dressers, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er. 4. Remove the stock muffl ers with sliding hangers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Remove the right hand fl oor board. 6. Remove both passenger fl oor boards. 7. Loosen the heat shield clamps on both front and rear exhaust pipes. 8. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 9. Remove the clamp holding the front head pipe to the transmission housing. 10. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 11. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new mounting bracket (stamped 353-P), and torque to (13-16) ft. lbs. (Figure 1). Make sure the battery ground cable is secure and properly routed. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. Note: Pre 1998 dressers do not come with this mounting post. It can be ordered from your local dealer, Harley part number: 65619-98. 12. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them

HARLEY DAVIDSON DYNA SIDESHOTS BLACK INSTALLATION AND REMOVAL PROCEDURE

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove seat to gain access to rear oxygen sensor connector. Unplug sensor and feed end of wire through frame so that it is free from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Remove two bolts holding rectifi er onto front of frame (near front tire). Open plastic cover to gain access to front oxygen sensor connector. Unplug sensor from harness. Remove cable tie holding wire to frame and feed end of wire through so that it is free from motorcycle. 3. Loosen heat shield clamps on both the front and rear head pipes. 4. Remove two cylinder exhaust port fl ange nuts from each head pipe, located at the cylinder head. 5. Remove front head pipe clamp bolt. 6. Remove the bolt that attaches muffl ers to the frame mounting bar. 7. Remove the complete exhaust system and set aside. Assistance may be required. 8. Remove stock mounting bar and the studs in the transmisson cover. Save the bolts, one will be re-used. 9. Remove left bolt below the transmission cover. Position mounting bracket 405-P over mounting location to determine which bolts to remove (Figure 1). Install this bolt in the top hole left vacant by the new bracket. 10. Carefully remove the fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check condition of stock exhaust gaskets. Replace if worn or damaged. (Recommended replacement exhaust port gaskets, Screamin’ Eagle part number 17048-98)

YAMAHA YFM 350 Removing stock carburetor and cables.

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Filed Under (Yamaha) by admin on 19-01-2012

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Remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Preparing motor for carburetor install 1. Remove stock manifold from cylinder head. 2. Place supplied o’ring into aluminum flange as pictured in figure 1. Figure 1. 3. Install aluminum and rubber flange to motor using supplied bolts. See Figure 2. The shorter 25mm bolt will need to be placed in the bottom hole. IMPORTANT NOTE: Install the aluminum flange with the o’ring towards the motor and the thick side up.

Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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YAMAHA V-STAR 650 CA SHORTSHOTS STAGGERED INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 29-12-2011

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Check condition of stock exhaust gasket. Replace if damaged or worn. 2. Install mounting bracket (stamped 384-P) in the original bracket mounting position using two 8mm bolts (supplied)(Figure 1). Note: Install two 5/16″ x 5/8″ fl ange bolts (supplied)(Figure 1) into top holes of bracket before installing bracket onto motorcycle. 3. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside (Figure 2). Place each heat shield on a non abrasive surface such as a blanket or carpet. Lay each head pipe/muffl er onto its respective heat shield (Figure 3). 4. Loosely install each hose clamp by feeding tail end of clamp into heat shield clip (Figure 2). #20 hose clamps are for head pipes and #28 hose clamps for muffl er area. Take note of clamp screw head direction (Figure 4). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Note: Do not tighten yet. 5. Install 6″ fl ange bolts (supplied) engaging nut plate. Leave T-bolt clamp onto front muffl er (Figure 4&5). Slide muffl er onto front head pipe. Slide nut plate (supplied) inside bracket welded to backside of front muffl er (Figure 6). Attach muffl er to mounting bracket 384-P using two 5/1head pipe/muffl er assembly loose at this time. 6. Using stock Allen bolts, carefully install rear head pipe/ muffl er assembly into exhaust port. (Assistance may be required). Note: Do not tighten yet. 7. Slide nut plate (supplied) inside bracket welded to backside of rear muffl er (Figure 6). 8. Align muffl ers so they are parallel when viewed from the right side of the motorcycle and muffl er tips align at the same length. Tighten 5/16″ fl ange bolts securing muffl ers to bracket. 9. Tighten cylinder exhaust port bolts securing head pipes to cylinder head. 10. Tighten T-bolt clamp securing front muffl er to head pipe. 11. Adjust heat shields so that muffl er tips protrude 1/4″ from heat shields (Figure 7) and rotation of heat shield matches muffl er tip. Tighten all hose clamps securing heat shields. 12. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. Note: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up. 13. All hardware must be properly tightened before starting motorcycle

2004 CBR 1000RR CYLINDER HEAD COVER INSTALLATION

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Filed Under (Honda) by admin on 17-12-2011

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COLOR TABLE MARCH, 2004 ©2004 American Honda Motor Co., Inc. 9 When ordering a colored part: 1. Confirm the color code for the required part from the color table according to the part name and color type. 2. Select the corresponding part number from the appropriate PAGE/GRID. 3. Parts marked “X” are unused. 4. “*” = Basic Part Number, no extension (i.e. ZA, ZB). CBR1000RR’04 2004 No. COLOR CODE BASE COLOR NH1 Black NH1 R258B Winning red R258 NH411B Force silver metallic NH411M A R E A DESCRIPTION BASIC PART NO. 1CLIP, PANEL FIXING 91549-MW0-790 ZA ZA ZA 2COWL (UPPER) 64211-MEL-000 ZA ZB ZC 3COWL SET, L. (LOWER) (WL) 64450-MEL-670 ZF ZG ZH 4COWL SET, L. MIDDLE (WL) 64350-MEL-670 ZA ZD ZE 5COWL SET, R. (LOWER) (WL) 64400-MEL-670 ZF ZG ZH 6COWL SET, R. MIDDLE (WL) 64300-MEL-670 ZA ZD ZE 7COWL SET, RR. SEAT (WL) 77210-MEL-010 ZE ZF ZG 8FENDER, FR. 61100-MEL-000 ZA ZC ZB 9FRAME 50100-MEL-670 ZAZAZAA 10 FRAME 50100-MEL-770 ZA ZA ZAAC 11LABEL, COLOR 87565-MEL-000 ZD ZE ZF 12MARK, COWL (LOWER) 64819-MEL-000 ZD ZE ZB 13MARK, L. TOP SHELTER 64852-MEL-000 — ZA ZC 14MARK, L. TOP SHELTER 64856-MEL-000 ZA — — 15MARK, MIDDLE COWL 64811-MEL-000 ZA — — 16MARK, R. TOP SHELTER 64851-MEL-000 — ZA ZC 17MARK, R. TOP SHELTER 64855-MEL-000 ZA — — 18MARK, RR. SEAT COWL 64841-MEL-000 ZA ZB ZD 19MARK, RR. SEAT COWL 64842-MEL-000 ZA ZB ZD 20RAIL ASSY., SEAT 50200-MEL-010 ZA ZA ZA 21SHELTER SET, TOP (WL) 83150-MEL-670 ZA ZD ZE 22STRIPE A, L. MIDDLE COWL 64814-MEL-670 — ZC ZA 23STRIPE A, R. MIDDLE COWL 64813-MEL-670 — ZC ZA 24STRIPE C, L. MIDDLE COWL 64817-MEL-670 — ZA ZB 25STRIPE C, L. MIDDLE COWL 64818-MEL-670 — ZA ZB 26STRIPE, L. TOP SHELTER 64854-MEL-000 — ZB ZB 27STRIPE, R. TOP SHELTER 64853-MEL-000 — ZB ZB 28STRIPE, WINDSCREEN 64805-MEL-000 ZA ZA ZA 29WHEEL SUB-ASSY., FR. 44650-MEL-000 ZA ZA ZA 30WHEEL SUB-ASSY., RR. 42650-MEL-010 ZA ZA ZA 31WINDSCREEN SET 64250-MEL-000 ZA ZA ZA