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

0

Filed Under (KTM) by admin on 01-02-2012

download
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

2007 KTM EXC LED Taillight and Turn Signal Kit Installation Instructions

0

Filed Under (KTM) by admin on 31-01-2012

download
Remove the seat & fuel tank. Photo 1 Unplug 2. Unplug the two three-pin connectors that mate the taillight & turn signal power leads to the stock wiring harness on top of the airbox. See Photo 1. 3. Unbolt and remove the stock taillight & rear turn signal assembly from the rear fender. The wires & connectors will pull through the gap in the fender/airbox plastic with a little finesse. 4. Unplug the two small white plastic connectors near the upper edge of the stock taillight lens and separate the wire extension from the taillight. See Photo 2. Photo 2 Unplug these two connectors and remove wire extension Photo 3 Remove 5. Using a sharp blade or cut-off wheel, remove the two molded mounting bosses on the bottom of the fender. See Photo 3. 6. Attach the new LED taillight to the fender as shown using the provided countersunk mounting hardware. Use the two longer bolts for the front mounts. The LED cluster should not protrude beyond the edge of the fender

YAMAHA PRO-R AIR CLEANER REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Yamaha) by admin on 07-01-2012

download
STEP 1 Remove the seat, fuel tank, and OEM air cleaner assembly. Disconnect the hoses connected to the air cleaner while leaving them connected to the motorcycle. Save the clamp that secures the air duct to the carburetor and the OEM fasteners used to secure the stock air cleaner assembly to the motorcycle as some will be reused. STEP 2 Remove the carburetor according to the section in your Road Star factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. Now is a good time to proceed with re-jetting the carburetor. We have supplied jets to cover many common configurations. For jet locations and jetting recommendations with various exhaust combinations see Addendum I. Since the OEM screws retaining the float bowl are easily damaged, we have included replacement M4 socket head cap screws to replace them, if necessary. STEP 3 Insert the rubber intake duct into the main support bracket as shown in PIC. 1. The rubber nipple should be pointing toward the longest leg of the bracket. STEP 4 Insert the rubber intake duct into the Pro R-series Hypercharger in the same fashion it was installed in the main support bracket. See PIC.2. You may need to use a screwdriver to help “poke” the flange of the Rubber Intake Boot into position inside the Pro R-series Hypercharger. STEP 5 Line up the three holes in the back plate of the Pro R-series Hypercharger and the three holes in the flange of the rubber intake duct with the three holes in the main support bracket. Insert the three supplied 1/4″-20 x 5/8″ socket head cap screws from inside the Pro R-series Hypercharger and secure on the back side of the main support bracket with the 1/4″-20 thin nylock nuts. You will need to pull back the inner flange of the rubber intake duct to access the holes. Hold the nylock nuts with a 7/16″ wrench as you tighten the socket head cap screws with a 3/16″ hex key. Be careful not to over tighten and cause the rubber intake duct to pucker around the nylock nuts. See PIC.3.

Incoming search terms:

Yamaha XVS 13AW Owner's Manual REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Yamaha) by admin on 06-01-2012

download
GASOLINE IS HIGHLY FLAMMA- BLE: Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes

Incoming search terms:

Installation & Tuning Instructions For all Motorcycle Applications

0

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

download
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 TTR 250 Dual Sport Kit Installation

0

Filed Under (Yamaha) by admin on 31-12-2011

download
1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, side panels, 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? Photo 1 3. Unplug the yellow, blue and black taillight wires from the stock wiring harness (Photo 1). 4. Unplug the headlight from the stock wiring harness and remove. 3 Photo 2 5. Remove the headlight on/off switch. Unplug the red two pin connector with yellow and brown wires (Photo 2) from its mate that was under the fuel tank. 6. Clip the zip tie holding the headlight leads to the fork tube, coil it up and secure it to the frame in front of the voltage regulator as shown in Photos 3 and 4. Remove bracket shown in Photo 3. 4 Headlight Leads Remove this bracket Photo 3 Coil up wires and secure with a zip tie Photo 4 7. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean, durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5 and Photo 6. Use the templates provided at the back of this instruction manual to determine the hole locations. Note that you will also be drilling a 3/16 hole on each side as well. You may find it easier to remove the fender to drill and attach the turn signals rather than performing this modification while the fender is on the bike

Incoming search terms:

YAMAHA ROYAL STAR VENTURE CENTERSTAND REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Yamaha) by admin on 31-12-2011

download
Stand Installation. Locate the four mounting holes on the frame that correspond with the holes in the centerstand. Slide the front of the centerstand up into the frame and align the large bolt holes with those in the frame. Install the (2) 7/16″ x 1″ bolts with washers thru the frame and centerstand. Install the (2) 7/16″ nuts and make finger tight. (on California models the fuel tank vent canister must be removed and the hoses bypassed see note below) Pivot the rear of the centerstand up to align the (2) smaller holes in the stand with those in the frame. Insert a phillips screwdriver into one of the (2) remaining mounting holes and pry the other hole into alignment. Install one of the ¼” x ¾” bolt with a washer from the top down thru the frame and centerstand. Install the lock nut finger tight. Remove the screwdriver and install the remaining ¼”x¾” bolt washer and nut. Tighten the ¼ ” bolts securely 10-12 ft. lbs., then tighten the 7/16″ bolts securely 20-24 ft. lbs. 2. Stop Bumper Installation. Next install the centerstand-stop bumper and bracket onto the frame. Locate the bolt “A” in photo #1. Notice there is another 10 mm bolt just below it. Remove the lower bolt. Attach the bumper bracket to this hole using the longer bolt and washer supplied. The leg of the bracket with the bumper should face inward towards the center of the motorcycle. Adjust the height of the bracket to keep the pedal arm 3/8″ to ½” from the bottom of the exhaust pipe. Tighten securely. 3. Emissions Valve Relocation. You will notice that the right leg of the stand near the foot comes in contact with the emissions valve. The valve needs to be moved outward or to the right as you are sitting on the motorcycle approximately ¾”. This is done as follows: Remove the (2) 10 mm bolts holding the emission valve and bracket to the frame. See photo #2. With the hoses still attached pull the valve down to gain access to the (3) allen screws. Remove the (3) allen screws and (2) nuts holding the bracket to the valve, turn the bracket over and re-assemble the valve onto the bracket as shown in photo #3. Re-install the valve onto the frame. You may need to rotate the hose clamp clips out of the way and/or bend the entire valve bracket assembly outward slightly to gain clearance between the centerstand leg and foot. 4. Using Your New Centerstand. To put the motorcycle up onto the centerstand, hold the left handle bar and saddlebag guard rail. Using the ball of your right foot, lower the stand to the ground. Rock the motorcycle from side to side slightly until you feel both feet of the stand touching the ground. Now, put all of your weight on to the centerstand pedal (stand on it). Pull up and back on the grab rail using a rocking motion to rock the motorcycle up on to the stand. Remember it is a matter of using your body weight and leverage not lifting! 5. Getting the Bike Down off the Centerstand. Holding the left handle bar and saddlebag guardrail, firmly rock the motorcycle off the centerstand. You can also rock it off while sitting on the motorcycle.

HONDA CR 500R/ 500AF Hi Power Digital Ignition AND Light Coil Installation Instructions

0

Filed Under (Honda) by admin on 16-12-2011

download
Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI. 6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator.
10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 kg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012″. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012″. Use a good/no good technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap. 15. If the pulser gap needs to be adjusted loosen the pulser mounting bolts adjust the pulser up or down as needed

Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

0

Filed Under (Honda) by admin on 14-12-2011

download
Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

2000-2001 Honda CBR 929 RR Power Commander installation

0

Filed Under (Honda) by admin on 09-12-2011

download
Remove the main seat. 2) Open the passenger seat hatch. 3) Remove the fuel tank mounting bolts. NOTE: The fuel tank does not need to be removed in order to install the PCII. If you choose to remove the fuel tank to aid in the installa- tion, then all fuel must be drained prior to disconnecting the fuel lines. 4) Locate the main injector harness connector. It is on the right side of the chassis near the fuel hose fitting on the throttle bodies. 5) Disconnect the injector harness connector. 6) Plug the male connector from the PCIIIr into the female connectorm on the main harness (Fig. A). 7) Plug the female connector from the PCIIIr into the male connector from the stock injector harness (Fig. B). 8) Locate the small, red, 2 pin connector (Fig. C) from the crank position sensor. Match the corresponding connectors from the PCIIIr, in-line of the stock wiring harness (Fig. D). 9)Route the harness from the PCIIIr under the fuel tank towards the tail section. 10) Reinstall the fuel tank, make sure not to pinch the PCIIIr harness. 11) Attach the ground wire from the PCIIr to the negative terminal of the battery. (Fig. E) 12) Route the PCIIIr and wiring under the rear seat subframe. Attach to inner fender below passenger seat using supplied velcro (Fig. F). 13) Reinstall the main seat

Incoming search terms: