Harley-Davidson MSD Pulse Ignition Installation Manual

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Filed Under (Harley Davidson) by admin on 11-03-2012

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PICKUP PLATE INSTALLATION Remove the existing trigger/points plate and rotor, points cam and advance. Refer to the bike’s Service Manual for the proper procedure. EVOLUTION AND LATE MODEL SHOVELHEAD V-TWINS 1. From inside the cam/ignition housing, feed the free end of the MSD pickup harness through the wire access port. Note: The harness includes a heat-resistant acrylic sleeve that fits snugly inside the port opening. Do not pull the sleeve completely through the port. It must be positioned to protect the wires as they pass through the port opening. 2. Mount the MSD pickup plate inside the housing (Figure 1). Note the “adjusting notch” on the edge of the plate. This notch must be located over the series of “steps” inside the housing (about the 7 o’clock position as you face the housing). One of the sensor units will be at approximately 12 o’clock. SPORTSTER MODELS 1. On Sportsters, the wire access port must be enlarged. Use a 9/32″ drill bit to enlarge the wire port. 2. Remove the wire harness clamp of the pickup assembly and route the wires through the port. 3. Mount the MSD pickup plate inside the housing (Figure 2). Note the “adjusting notch on the edge of the plate. This notch must be located over the “cast notch” inside the housing (about the 11 o’clock position as you face the housing). The shorter of the two sensors will be approximately in the 9 o’clock position. 4. Install the hold-down/standoff screws with flat washers until they are snug – do not tighten at this time (Figure 3). 3. Put the MSD rotor in place on the end of the camshaft. The locating pin in the rotor bore must align with the groove in the cam. Do not force the rotor on the camshaft! Push the rotor into place until it is tightly against the end of the cam then snug the retaining screw. 4. Check the distance from the outer surface of the pickup plate to the end of the installed rotor (Figure 4). If necessary, add shims until the measured rotor height is 9/16″ (+/- 1/32″). 5. When the rotor height has been verified, remove the retaining screw, place a drop of Red Loctite on the threads and reinstall the screw to the factory recommended torque

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Harley Davidson Electra Glides, Ultra Vent (model LV-2,3,4) Installation Manual

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Filed Under (Harley Davidson) by admin on 07-03-2012

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Remove the fairing lower from the engine guard using the procedure provided in your Harley-Davidson user/service manual. Do not remove the glove box from the fairing. Vent Placement, Hole Drilling and Cut-Out: Caution: Place cloth or cushion underneath fairing lower to protect it from getting scratched during the following procedures. LV-2,3,4 Installation Copyright 2003-2004 2 3. Working inside the fairing and using the bottom of the glove box as a guide, position a closed vent parallel to and no more than 1/16″ from the rear edge of the fairing. Position the assembly so that the vent side tabs are no more than 1/8″ below the bottom of the glove box. (You want the vent assembly as close as possible to the glove box but with enough room so that the side tabs do not touch the glove box when the vent is closed! ) Mark the back two holes with a pencil then remove the vent and replace it with the cutting template in the exact same location. See photo to the right to assist in judging the cutting template orientation. 4. Lift out the glove box, steady the template with one hand and using an 11/64″ drill bit carefully drill 1 hole near the back edge of the fairing through the bottom corner hole of the cutting template. Install one screw and nut and tighten slightly to stabilize the template’s location. On the other corner (same edge) , drill the second hole. (You cannot drill the remaining holes from inside the fairing because the front edge of the fairing lower is in the way. ) 5. Remove the screw and nut and re-position the cutting template on the outside of the fairing with the three hole side of the template towards the front of the fairing (away from the edge of the fairing) . Install two screws and nuts into the open holes. Drill the remaining two corner holes and install two screws and nuts. Change drill bit size to 1/8″ to drill the final center latch hole. Next skip down to one of the two following procedures to make the vent opening using either A) Dremel tool/RotoZip router or B) coping saw/frameless hacksaw

Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

2010 RIDGELINE MOTORCYCLE BED EXTENDER INSTALLATION AND REMOVAL

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Filed Under (Honda) by admin on 26-11-2011

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Using an awl, pierce through the seals in the holes on the left side bed lining Install the left latch to the left side bed lining with three hex bolts While wearing eye protection, drill a 3 mm hole at the mark on the left side of the tailgate. Widen the hole with a 8 mm drill bit. To prevent damage to the inner vehicle parts, wrap a tape around the drill bit tip to the root in the measurement as shown. Remove any burrs Align the non-threaded wedge with the threaded wedge at three joints between the left and center tubes, then secure the wedges with one T-20 torx screw each.

HARLEY DAVIDSON SADDLEBAG HINGE STOP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 2 and Table 1. Remove the saddlebag by opening the lid and turning the two bail head studs (1) 1/4 turn. Save the washers (A) and discard one of the studs (1). The rear stud and isolator will be replaced with new ones from the kit. NOTE Do Not remove the hinge assembly from the saddlebag lid. 2. See Figure 1. Drill the rivets out of the backing plate (C) from the lower rear saddlebag hinge. •Enlarge the backing plate holes by drilling with a #19 drill bit. 3. Remove the rear isolator and install the new rear isolator (2) from the kit to the saddlebag. NOTE It is recommended to use Loctite® 262, threadlocker and sealant on the threads of the hinge screws. 4. See Figure 2 and Table 1. Position the backing plate (C) inside the saddlebag and align with the rear hinge (B) and hinge stop (3) on the outside of the saddlebag. Assemble using the two TORX® head screws (5). 2 1 is05974 1. Rear hinge rivets (2) 2. Rear isolator Figure 1. Drill Out Rivets From Rear Hinge and Backing Plate 5. Install the saddlebag to the motorcycle using the longer bail head stud (1) from the kit and a washer for the rear of the saddlebag and the washer and front bail head stud previously removed for the front of the saddlebag. 6. Repeat steps 1-5 for the opposite saddlebag

HARLEY DAVIDSON FRONT FENDER SKIRT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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1980 and later Touring •1986 and later FLSTC •1993-1996 FLSTN •2006 and later FLST This kit is not designed for FLSTF model vehicles. Kit Contents Table 1. Kit Contents Quantity Description 1 Fender skirt 6 Screw, pan head 6 Locknut, hex 6 Washer, flat 1 Adhesive foam strip (Heritage models only) INSTALLATION 1. See Figure 1. Remove fasteners (2) from stock fender skirt. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) NOTE Some early models have rivets for fasteners. These rivets will need to be drilled out. Drill the rivet heads to a sufficient depth to remove the head from the rivet shaft. Do not attempt to drill the rivet all the way through. This may scratch the fender?s painted surface. 1 5 3 2 4 is 01097 1. Fender skirt 2. Screw, panhead 3. Locknut, hex 4. Flatwasher 5. Adhesive foam strip (Heritage models only) Figure 1. Front Fender Skirt and Assembling Hardware 2. Remove stock fender skirt (1). 3. Thoroughly clean the fender under the skirt. At this point it may be a good idea to wax this portion of the fender to prevent rust in the future. 4. For Concho style and Bar and Shield style fender skirts, cut the adhesive foam strip (5) into three equal parts. Remove the backing from the adhesive strips and apply adhesive on middle and two sides at the inside/bottom of the skirt. The foam strips will prevent rattling and unwanted noise. For V-Logo style skirts, cut foam strip into three pieces; however make two slightly larger to cover the heads of the screws that hold the V-Logos in place. Use the remaining smaller piece on the middle, inside/bottom of the skirt. NOTE On some FLT models, there may not be enough fender skirt support to allow the application of adhesive strips. If this is true for your motorcycle, you may install this kit without the adhesive strips. 5. Place the fender skirt in position, aligning fastener holes. 6. Install the screws (2) from the outside of the fender. Install the washers (4) and nuts (3) inside the fender

HONDA GL1800 WINDSHIELD VENT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 04-03-2011

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NOTE: CAUTION is required when drilling and cutting to prevent cracking and scratching the windshield material. A professional glass service is highly recommended for this purpose. Should you attempt to install the windshield vent on your own, follow the instructions below. Add On Inc. will not be held liable or responsible for any damage to the windshield. 1. Place bike on center stand. 2. Cut out the template provided and center on windshield approximately 2 ¾” above the tint line. Tape the template to windshield using masking tape. Use enough masking tape to cover the area to be cut out to prevent scratching. If using a power sabre saw to cut the pattern out, put masking tape on the foot to prevent scratching the windshield. Drill the four corners using a sharp power sabre saw, electric drill (using a 7/16″ drill bit), and or hack saw. 3. Smooth cut edges with sand paper. 3. Install the vent. The two pieces will snap together in the windshield. Use chrome screws provided to secure vent in the windshield.

HARLEY DAVIDSON FRONT FENDER RAILS AND STANCHIONS INSTALLATION MANUAL

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

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INSTALLATION 1. Carefully cut out appropriate template from sheet included in kit. One side is for FLSTS style fenders (with elliptical hole for front fender lamp), and the other side is for FLT style fenders (with rectangular front fender lamp). 2. Lay template on front fender (align around front fender lamp). 3. Underneath four holes marked on template, place high quality masking tape on fender. 4. Using a tape measure, measure from the top of the striping on the sides of each side of the fender, to the centerline of the each of the holes on the template (on some FLT models, with chrome fender trim, measure from the chrome fender trim at the bottom edge of the fender). Make sure that the distances are equal so that the template is centered on the fender. 5. Tape the template to the fender using high quality masking tape. NOTE Before proceeding, stand directly in front of the fender and carefully check to make sure the template is centered on the fender. 6. Center punch the center point of each of the four holes. 7. Remove the template from the fender. 8. Block motorcycle under frame so the front wheel is raised off the ground. 9. Follow appropriate Service Manual procedures and remove the front axle. 10. Place a rag on the top of the front brake caliper, then lower the front wheel so that it is resting on top of the brake caliper. NOTE When drilling fender holes, use care not to hit tire with drill bit. 11. While holding the fender firmly, and using caution to make sure that your drill bit does not hit the tire, drill the four holes at the points marked by the center punch. Begin with a 1/8 inch drill bit, followed by a 9/32 inch, and finally a 3/8 inch drill bit. 12. Remove the masking tape and any burrs that may have formed. 13. Remove the adhesive backing from each of the foam pads on the bottom of each of the stanchions. 14. Place the studs from each of the end stanchions into the holes (you may need to rotate the rails 180 degrees if they appear to be bowed out). 15. Reaching from the front of the fender, place kit washer, and then a locknut, over each of the studs on the underside of the fender. 16. Securely tighten each locknut so that the stanchion is firmly clamped to the fender. 17. Follow appropriate Service Manual procedures and replace the front wheel and axle

HARLEY DAVIDSON ULTRA TOUR-PAK BRAKE LAMP CHROME ACCENT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation- Corner Brake Lamp Trim 1. Carefully cut out brake lamp trim template (1) attached to this instruction sheet. 2. Position template (1) on plastic brake housing (2) as shown in Figure 2. 3. Using a punch, score two points indicated on template to mark mounting hole locations (3) on plastic brake housing (2). 4. Using a 1/8 in. drill bit, drill a pilot hole in plastic housing. 5. Use a 7/32 in. drill bit to drill through housing and fiberglass Tour-Pak. 6. See Figure 3. Insert studs on chrome brake lamp trim piece through holes drilled in plastic housing and Tour- Pak. Using two flatwashers (1), two lockwashers (2) and two acorn nuts (3) from kit, secure trim piece to Tour- Pak. Tighten finger tight. 7. See Figure 3. Locate brake lamp retaining clip (4) on inside of Tour-Pak and remove. Save clip (4) for later reinstallation. 8. Form chrome trim around corner of Tour-Pak, so that it is positioned around plastic housing evenly. While holding chrome trim in position, mark forward mounting hole position on Tour-Pak using a punch

HARLEY DAVIDSON TIMER COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) NOTE For kits 32972-04A, 32924-04A, 32675-04A, and 32923-04A, refer to step 1 and 2 for installation instructions. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. See Figure 2. Remove and discard the original screws and timer cover. 2. Place new timer cover (1) in position and secure with chrome screws (2). NOTE For kits 32584-88TA, 32668-98A, and 32571-98A, refer to steps 3 through 8. 3. Use a 3/8 in. drill bit and drill the heads off the original timer cover rivets. Remove original timer cover. NOTE If the inner timer cover has been riveted in place and access to the cam position sensor is required, use a left hand drill and carefully remove the rivet heads. If a right hand drill is used, the sensor plate screw heads could break off when trying to remove the rivet. NOTE To make the cam position sensor tamper proof, follow steps 4 through 6. If the cam position sensor is not required to be tamper proof, skip steps 4 through 6. 4. Remove and discard inner cover retaining screws. Leave gasket (if used) and inner cover in position. 5. See Figure 1. Place washers (4) over rivets (3) and place rivets into inner cover holes so the backs of the rivets go into the sensor plate screws’ tapped holes. 6. Use a standard rivet tool and install rivets, securing inner cover to sensor plate screws. 7. Use the self-tapping screw (5) to cut threads into the remaining inner cover holes. Discard screw after use. 8. Place new timer cover (1) in position over inner cover (A) and secure with chrome screws (2). NOTE For kit 32581-90TB, refer to steps 9 and 10. 9. Use 3/8 in. drill bit and drill the heads off the timer cover rivets. Remove original timer cover. 10. Place new timer cover in position and secure with chrome screws (Part Number 9462) from kit

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