Suzuki DRZ 400K Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 11-02-2012

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DRZ 400 (Kick Start) Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight from the stock wiring and remove. 4. Unplug the kill button from the stock wiring and remove (Photo 2). The connector is a gray two-conductor connector located under the fuel tank. Release detent on connector to separate. Kill switch connector Photo 2 5. Unplug the stock taillight and remove. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. ΒΌ” Photo 3 Countersunk screw and bezel, 4 Places 6. Taillight Installation Position the taillight assembly so that the edge of the red taillight extends past the edge of the fender about 1/4″ as shown in Photo 3. With the taillight positioned as shown Photos 3 & 4 , transfer the four mounting hole locations into the bottom of the fender. Drill the mounting holes at 1/4″ diameter. Use the 6 x 16 mm counter-sunk fasteners and bezels for mounting the taillight

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2000-2003 KTM MXC / EXC Dual Sport Kit Installation And Removal Manual

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Filed Under (KTM) by admin on 08-02-2012

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00-’03 KTM 400/450/520/525 EXC & MXC Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3
4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

HONDA XR 250 1996 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 06-12-2011

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, side panels, radiator shrouds, and gas tank.
If you are color blind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 3. Unplug the green and blue taillight wires from the stock wiring harness, remove the taillight lens, and remove the taillight socket and wiring. 4. Unplug the headlight from the stock wiring harness and remove. 5. Remove the kill switch. Unplug the black/white wire and the black wire from the connector near the base of the odometer. AC Regulator Unplug taillight here Photo 1 6. Locate the AC voltage regulator found mounted on the front top edge of the airbox as shown in Photo 1. Unplug the regulator from the wiring harness and remove regulator (Leave the U-bolt
attached to the airbox and save the bolt for a later step)

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