Harley Davidson Touring Bikes 2009 Installation Manual

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Filed Under (Harley Davidson) by admin on 10-04-2012

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LegUp has developed a new, stronger attachment system which replaces the Harley-Davidson® center stand previously included in the kit! You will need to remove most all of the exhaust system, in order to install the support stand. Remove the right front floorboard the entire right exhaust pipe, and the left rear floorboard. These need to be removed to allow access to the swing arm pillow block lower bolts, which attach the support stand to the motorcycle. Leg Support Stand If you haven’t already done so, install the uprights (Blue above) to the plate. These uprights bolt to the plate on the bottom with (4) 3/8″ bolts and lock washers. The taller upright goes on the right side of the plate (the far side in this picture). Remove the bottom bolts from the swing arm pillow blocks and set them aside. The right one may have a cap rather than a bolt. These bolts are the ones under the big chrome circles where the swing arm meets the frame. Once this is done, use a helper and gently slide the plate (red above) under the bike. It gets located under the transmission, and below the cross-brace that has two large holes in it. Lift the stand until the holes in the uprights align with the holes in the pillow block. Re-install the pillow block bolts, but leave them loose. Find the 3/8″ Strap (green above) and the (2) 5/16″ bolts and lock washers. Place the strap above the cross-brace that is under the transmission, and align one of the bolts (the bolts go through the non-threaded holes in the plate) with the threaded hole in the strap, through the cross-brace. Just start the first bolt, and then repeat the process on the other side

2007-2010 Harley Davidson Dyna EFI Tuner INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2012

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Remove the seat 2 Remove the left hand side cover (Fig. A). 3 Unplug the stock wiring harness connector from the ECM (Fig. B). 4 Move the data plug (Fig. B) out of the way to access bolt. 5 Remove the 3 bolts that hold the electrical box in place (Fig. B). 6 Slide the plastic box out from the frame. 7 Route the stock connector through to the back side of the electrical box (Fig. C). Fig. A Fig. B Fig. C Remove side cover Stock connector Stock connector Dat a plug Remove bolt Remove bolt s FM814 www .fuelmotousa .com 2007-20 1 0 Harley Davidson Dyna – FM EFI Tuner – 2 8 Lay the PCIII behind the electrical box temporarily. 9 Route the GREYconnector from the PCIII through the back of the electrical box and plug it into the ECM (Fig. D). 10 Connect the stock wiring harness to the BLACK connector of the PCIII. 11 Zip tie these connectors to the front side of the electrical box (Fig E). Make sure they are situated away from the rear exhaust pipe. Fig. D Fig. E PCIII connector Stock connector PCIII connector 12 Mount the PCIII to the underside of the stock ECM (Fig. F) using the supplied velcro. Make sure to clean both surfaces with the alcohol swab before attaching. Situate the PCIII so the USB and expansion ports point to the rear of the bike. This will allow you easier access to adjust the maps if necessary

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Harley-Davidson Twin Cam Engines Performer RPM Gear Drive Camshaft Kit INSTALLATION PROCEDURE

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

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1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 INSTALLATION PROCEDURE 1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 . 7. On pre-2000 models with a cam position sensor, you may want to remove the inspection cover, unplug the wires, and remove the sensor at this time to ease installation later on. 8. Remove the cam housing cover keeping the bolts in a separate cup. ( Note: Oil will run out of the cam housing.) 9. Using the Chain Tensioner Unloader Tool, unload pressure on the outside chain tensioner, and pin it in place with the retaining pin (See Figure 2) .

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Harley davidson American Classic Straights on a 1988-2001 VLX 600 Shadow Installation Instructions

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Filed Under (Harley Davidson) by admin on 01-03-2012

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Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system.
1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install nut strip into slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — DO NOT TIGHTEN NUTS! 8. Install nut strip into slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks.

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2004 KTM 250 EXC-R exhaust system INSTALLATION

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Filed Under (KTM) by admin on 07-02-2012

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1. Remove the rear shock and the standard exhaust pipe. And attach the rear shock again. (Standard exhaust flange should remain the current position) 2. Lightly attach the front exhaust pipe to the engine. (See Photo. 2) 3. Insert the joint and tail pipe to lightly attached front exhaust pipe in step 2. Shake the whole for the better fitting. Then, attach the supplied springs to the joint. Lightly attach this tail pipe with the standard bolt. *Insert the two inner collars to the joint. 4. Lightly assemble the silencer and the silencer stay. Insert this to the tail pipe. Lightly attach this tail pipe to the standard attachment position with supplied bolt and collar. Check the best position for the silencer band. (See Photo. 3) 5. Remove the silencer attached in step 4. Securely fasten the bolt of the silencer band. Insert this silencer to the tail pipe and lightly fasten the bolt of the stay. 6. Securely attach the tail pie followed by the silencer stay. 7. Attach supplied springs to the joint of the silencer. 8. Clean all surfaces. Remove any oil on the exhaust pipe and silencer. 9. Make sure all bolts and nuts are securely fastened. Run the engine and ensure there are no exhaust gas leaks. (See Photo. 4) *Carburetor adjustment will be required in the weather and course

YAMAHA Installing the Motorcycle Enhancements Remote Oil Filter

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Filed Under (Yamaha) by admin on 17-01-2012

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In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine
There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p

HARLEY DAVIDSON BRAIDED OIL HOSES INSTALLATION MANUAL

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

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery negative cable. 2. Drain engine oil according to Service Manual instructions. 3. Removing the rear exhaust pipe may aid in giving access to the oil lines and fittings. If necessary, remove the rear exhaust pipe according to Service Manual instructions. 4. See Figure 5 and Figure 1 for description and location of the three oil hoses that are replaced with the braided hoses in this kit. Remove the original equipment oil feed, return and vent lines. 5. See Figure 2. Remove and discard the original hex threaded quick disconnect fittings (1), (2) and (3) at the engine for each of the hoses removed in Step 4. To remove the fittings, turn the hex in a counterclockwise direction until free. 6. See Figure 5. Install the threaded adapter from the kit onto the corresponding oil line. The adapters for the return and vent lines are the same size. The adapter for the feed line is larger in size. Coat the male threads of the adapters with Loctite 565 thread sealant. NOTE Be sure to install hoses on the correct fittings. If you mix up the hoses, you will change the direction of the engine oil flow, causing severe engine damage. 2 3 1 is04165 1. Oil Return Hose 2. Oil Feed Hose 3. Oil Vent Hose Figure 1. Installed Oil Hoses

HARLEY DAVIDSON LOW REAR SHOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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See Figure 3 and Table 1. INSTALLATION Shock Absorbers Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) NOTES This procedure requires that both shocks be removed prior to installing the new shock absorbers. You need to place the motorcycle on a center stand with the rear wheel raised off of the ground. The jiffy stand should be able to move through its full range of travel. The exhaust system may interfere when removing and installing the lower right shock mounting hardware. If necessary, see Service Manual and remove the rear exhaust pipe. 2 4 5 7 1 6 3 is05206 1. Lower screw 2. Upper screw 3. Lower washer 4. Upper washer 5. Cover 6. Nut 7. Shock absorber Figure 1. Remove / Install Shock Absorber 1. Block the motorcycle under the frame so that the motorcycle is securely resting upright, the jiffystand may be moved through its full range of travel, and rear wheel is just off the ground. 2. Remove the lower shock mounting screw (1), washer (3) and nut (6) from the shock absorber (7). Save the hardware for reuse. 3. Remove the upper bolt (2), washer (4) and cover (5) and remove the shock absorber. Save the hardware for reuse. 4. Repeat Steps 1 and 2 for opposite side and save the hardware. 5. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the lower mounting bolt, then install bolt, lower washer and nut to the shock. 6. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the upper mounting bolt, then install the shock cover, upper mounting bolt and washer to the shock. Verify the cutout in shock cover locates properly

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SUZUKI INTRUDER 1500 LC BOTH WHEELS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 27-02-2011

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In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later. Front wheel removal : Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution : there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine. Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal

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SUZUKI SV650/ S PERIODIC MAINTENANCE CHART

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

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Item km miles months 1000 6000 12000 18000 24000 600 4000 7500 11000 15000 1 6 12 18 24 Air cleaner Spark plugs Tappet clearance Engine oil Engine oil filter Fuel hose Engine idle speed Carburettor synchronization Evaporative emission control system PAIR air supply system Throttle cable play Clutch cable play Radiator hoses Engine coolant Drive chain Brakes Brake hoses Brake fluid Tires Steering Front forks Rear suspension Exhaust pipe bolt & nut Chassis bolt & nuts – - – R R – I I I – - I I – - – I – - T T Replace every 4 years Replace vapor hose every 4 years – - I – I I I – - Replace every 2 years Clean & lubricate every 600 miles (1000km) Replace every 4 years Replace every 2 years R R R R – - R – I I R I I R I R – Inspect and adjust, clean