FLH Harley-Davidson Bikes/ Trikes Steering Damper Installation Manual

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Filed Under (Harley Davidson) by admin on 12-04-2012

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First, we’re going to install the upper Bracket. (#8 in Fig. 1) Start by placing a clean towel or other protective material over your front fender to protect it from falling objects. Remove the 5/16-18 Allen head bolt and washer holding the top of the crash bar to the frame. Use a ¼” Allen wrench. Access is easier if you crank the forks over to one side. Line up the hole in the new bracket with the crash bar, orienting the bracket to the crash bar as shown in Fig. 1, and re-install the bolt with a drop of blue loc-tite. Torque the bolt to 15-20 ft. lb. If you don’t have a torque wrench, well, you should have one, but if not, 15-20 ft. lb. is a bit tighter than a spark plug torque, which is 12-18 ft. lb. If you are not sure, snug it down tight, but don’t try to break it. Note than on a couple of these, I had to slightly elongate the hole in the bracket to re-install the upper crash bar bolt. (Side mount bracket installation) Next, the side bracket install. (#6 in Fig. 1) You’ll need a #35 Torx driver to remove the two screws holding the LEFT passing lamp/turn signal bar to the bike/trike. Carefully remove the upper and lower screws, holding the bar to prevent it from falling, possibly jerking the attached wiring. Once you have removed the screws, you can let the bar hang, while you orient the side bracket as per Fig. 1. Re-install the two screws you just removed, capturing the damper side bracket under the light bar. Use a drop of blue loc- tite here as well. Hand tighten the two screws, aligning the lamp bar and damper side bracket. Using your torque wrench, (you did find one didn’t you?) Tighten the two screws to 15-20 ft. lb. Ok the easy part is out of the way.

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Harley Davidson FLH EZ-Steer Installation MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2012

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Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamp of your Harley Davidson FLH Motorcycle. We recommend that you use an OEM service manual and follow the prescribed disassembly, installation and torque specifications for the upper and lower clamp assembly. Before Installing Kit (2008 & Prior) The wiring bracket of the OEM upper triple clamp needs to be modified to fit the Champion upper triple clamp. After removing / disassembling the OEM parts from your motorcycle, position the OEM wiring bracket onto the Champion upper clamp as shown. Scribe the ID of the steering stem hole onto the wiring bracket and enlarge the hole to scribe line. This will allow the wiring bracket to fit over the new Stem Lock-Nut. Install OEM handle bar mount assemblies to Champion upper clamp using Item #5 (Handle Bar Mount Spacer). The spacers are used on top of the upper clamp. Installation Notes • Be sure to use the correct fork extension. Yellow 2002 and newer (non adjustable air pressure). Black for 2001 and older (adjustable air pressure). Be sure to double check the fork cap (Fork Tube Plug) being removed. • Reinstall the OEM O-rings on Item #7 (Fork Extensions) prior to installing in the fork tubes. • On some of the Road King models with chrome headlight Nacelle, Item #9 must be mounted underneath upper clamp Item #2 to ensure enough room for air fittings. • Be sure to replace fork covers in proper order, during installation of the fork tubes. • Thoroughly clean sides of steering neck and install self adhering rubber stops where steering stop screws contact frame. • Secure wires and cables clear of steering stop bolts. • Do not torque Item # 1 (½-20 x 1-1/4″ Hex Head Bolt) until fork tubes have been installed to assembly. • Note the torque specification for the items listed in the table below.

Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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KTM EXC 2004-2007 rear fender REMOVAL

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Filed Under (KTM) by admin on 29-01-2012

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Remove lower section of rear fender • Using care not to damage the threads, drill 1/8″ pilot hole up through subframe and rear fender (fig1) • Remove fender, enlarge pilot hole in upper subframe with 1/4″ drill, do not drill out threads- take care not to damage threads in subframe. • Enlarge holes in fender to 5/8″ • Install upper section of rear fender, insert enclosed 5/8″ spacers in fender holes (fig.2) • Install cross brace (bolt holes closer to front of bike) using enclosed M6 X 50mm button head bolt (fig 3) • Re-install lower fender section using original stepped washer with enclosed 6mm nuts (fig 4) • Install side brackets as shown in fig 5 – replace subframe bolts with enclosed flat head bolts at forward mounting points if necessary.

Honda VTX 1800 Motorcycles Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 19-12-2011

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Removal of Original Parts Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. · Rider’s Seat (to be re-installed without modification) . · Passenger Seat and mounts (to be reinstalled without modification) . NOTE: OEM front and rear seat mounting bolts to be retained and reused. · Left and right passenger foot rests and mounts (to be reinstalled with modification) . · Mufflers (to be re-installed and relocated with minor modification) . · Rear Fender (complete w/ sub frame and all attaching parts) . · Swing Arm, Drive Shaft and Rear Wheel (complete w/ brake line and all attaching parts) Installation of Champion Trike Conversion Kit 3.1 Modify Frame and Passenger Footrests. a. Use 17/64″ drill and drill through frame from inside out using passenger footrest mount holes as guide. b. Enlarge the passenger footrest mounting holes on the left and right side of the frame to 27/64″. c. Enlarge the holes in the left and right passenger footrest mounting plates to 27/64″. d. Clean area of all debris. 3.2 Relocate Regulator a. Install supplied “Z” bracket to the regulator as shown using the supplied hardware. b. Attach regulator to frame using the supplied hardware. c. Tie hoses down to avoid contact with the swing arm. Qty Description 1 ¼-20×2 hex head bolt 1 ¼-20×1-1/4 hex head bolt 6 ¼-20 Nyloc nut 10 1/4- SAE flat washer 4 as spacers 3.3 Hose Stay a. For models that have a recover tank below the swing-arm, a holder has been included keep the hose connected to the water pump away from the champion swing-arm. b. Remove the hose from the top of the recovery tank. c. Push the water pump hose forward against transmission. d. Secure hose with supplied stay as shown using existing bolt. Ensure that hose is not being crushed. Bend stay if necessary. e. Reconnect hose to recovery tank

1988 – 1995 V6 Truck, 4Runner 3VZ CYLINDER HEAD INSTALLATION and REMOVAL

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Filed Under (Toyota Manuals) by admin on 06-12-2011

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Install cylinder head a. Place a new cylinder head gasket on the engine block and install cylinder head. b. Apply a light coat of engine oil on the threads and washer face of the cylinder head bolts. c. Install the plate washer to the cylinder head bolt. d. Using a 12-point socket, install and uniformly tighten the (8) 12-point bolts in several passes, in the sequence shown in the illustration. Torque: 33 ft.lbs. (44 N-m, 450 kg-cm) e. Repeat for the other head. 2. Proceed with final tightening sequences: a. Mark the front side of the top of the bolt with a drop of paint as shown in the illustration

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Sherco Engine Engine Removal and Case Splitting Manual

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Filed Under (Sherco) by admin on 20-04-2011

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Engine Removal and Case Splitting Preparation 1. Wash the bike and engine thoroughly. 2. Drain transmission oil by removing drain bolt and copper washer with 5mm Allen. 3. Drain coolant by removing 3 bolts of water pump cover and lifting off engine side case.4. Remove: a. rear fender- two bolts plus one long with washer using 4mm Allen b. fuel tank hose from petcock c. fuel tank- one short bolt and washer using 4mm Allen d. chain master link and chain from front sprocket e. kick starter- one large button head bolt and washer f. rear brake- one bolt/washer using 13mm wrench g. rear brake master cylinder- 2 button head bolts h. gear shifter- one bolt i. flywheel cover – 3 bolts j. clutch slave cylinder- two button head bolts using 4mm Allen k. clutch actuating rod by pulling it out of the case l. airbox three 4mm Allen bolts and loosening Phillips head carb hose clamp m. carburetor cap/slide assembly n. carburetor by loosening Phillips head manifold hose clamp o. spark plug cap p. spark plug q. header pipe 2 bolts into cylinder head r. silencer- 3 bolts (one with washer and nut using 10mm wrench) s. cylinder head coolant hose clamp and hose t. rear shock upper bolt u. radiator plastic cover bolt, then lever up the radiator with screwdriver until the radiator “legs” pop out of frame retaining holes 5. Remove flywheel using flywheel puller tool, taking care not to lose the small Woodruff
key by placing it inside of the magnetic flywheel for safe storage. 6. Remove ignition (3 bolts) and slide rubber grommet and ignition wiring assembly out of the case and out of the way, taking special note of the ignition timing marks. 7. Remove front sprocket and 2 retaining circlips. 8. Remove clutch side case and its 10 bolts using 5mm Allen, being careful not to lose to lose the 2 aluminum alignment pins (dowel pins). Insert the dowel pins into their holes within the Right Crankcase

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HARLEY DAVIDSON SOFTAIL LEFT SIDE LEATHER TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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Installation While handling and installing tool box, be careful not to scratch surface. 1. See Service Parts Illustration. Install tool box (1) to mounting bracket (6) using button head screws (2) and washers (5). Screws (2) should be inserted through mounting holes on inside of tool box (1) and then inserted through bracket (6) holes and threaded into weld nuts attached to bracket. 2. Remove and save the two screws that secure left rear fender support to motorcycle frame. 3. Remove two bolts, nuts, and washers that secure debris deflector to motorcycle frame. This will allow you to move debris deflector out of the way when installing new passenger footpeg support bolt. Save hardware for reinstallation. 4. For 1990 to 1999 Softails: If tool box is being installed with passenger footpeg, remove the hex head bolt and left passenger footpeg. Retain footpeg and lockwasher for reinstallation. Discard bolt . If tool box is being installed without passenger footpeg, remove hex head bolt and left passenger footpeg. Discard footpeg. Retain bolt and lockwasher. For 2000 and later Softails: See page 3 . Remove footrest from clevis. Remove clevis from frame by removing cap screw from center of clevis. If tool box is installed with footpegs, keep all hardware. If toolbox is to be installed with footboards, discard hardware. 5. Slide top of mounting bracket (6) between rear fender support and frame. Align top holes in bracket with fender support holes. Align lower bracket hole with footpeg mounting hole in frame. Install the two screws, removed in Step 2, in fender support. Do not tighten screws at this time. 6. For 1990 to 1999 Softails: Place lockwasher retained in step 4 on footpeg support hex head bolt (3) from kit. CAUTION 1 of 3 For 2000 and later Softails with footpegs: Install kit 49352-00 according to instructions included in this kit. Footpeg must fold up at a 45°angle (from vertical) toward rear of motorcycle. This angle allows footpeg to fold up if, by accident, it strikes the ground surface when making a sharp turn. Failure to set footpeg to the proper fold-up angle could result in death or serious injury. 7. For 1990 to 1999 Softails: Position footpeg so it folds up and back at a 45°angle. Install bolt (3) from kit through frame, tool box bracket (6), and spacer (4), into footpeg, as shown. NOTE If vehicle is equipped with saddlebag support bracket, Part No. 90346-90 or 90346-94, position saddlebag support bracket between tool box bracket and spacer.

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HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

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HARLEY DAVIDSON LEFT SIDE TOOL BOX KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION NOTE While handling and installing tool box, be careful not to scratch surface. 1. See Figure 1. Attach the toolbox (4) to the toolbox mounting bracket (1) using the three pan head screws (2) and Nylock nuts (3) from the kit. 2. Remove the two button head screws (I) which secure left rear fender support (B) to motorcycle frame (C). Retain screws for reassembly. 3. On models with passenger footpegs: a. For FLSTN models: Remove button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E). b. For all other models: Remove the locknut (G), hex head bolt (J), spring washer (H) and footpeg (E). Remove the socket head cap screw (K) that secures the footrest support (F) to the frame (C). c. Remove the two bolts, nuts and washers which secure the bottom of the splash guard to the swingarm. This will allow you to move splash guard when installing the new passenger footrest bolt. d. Retain all removed components. 4. On models with passenger footboards: a. Remove the screw securing the passenger footboard assembly to the frame. Remove the footboard assembly. b. Retain all removed components. 5. Slide the top of mounting bracket (1) between rear fender support (B) and frame (C). Align top holes in bracket with fender support holes. Align lower bracket hole with footrest mounting hole in frame. Install the two screws (I), removed in Step 2, in fender support. Do not tighten screws at this time. Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) 6. On models with passenger footpegs: a. For FLSTN models: Install button head screw (N) and left footrest bracket (O) with attached footrest support (F) and footrest (E) on top of the toolbox bracket (1). Tighten screw to 35-45 ft-lbs (47.5-61.0 Nm). b. For all other models: Refer to instructions in footpeg extension kit, Part Number 49352-00 for installation, and install the extention kit, footrest support and footpeg on top of the toolbox bracket (1). c. Install the two bolts, nuts and washers and secure the bottom of the splash guard to the swingarm. 7. On models with passenger footboards: a. Position footboard assembly, in the same orientation as removed, on top of tool box bracket. b. Install screw removed in Step 4. Tighten to 35-45 ft- lbs (47.5-61.0 Nm)

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