HARLEY-DAVIDSON SPORTSTER MID-LENGTH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-04-2012

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1. Find and unplug the O² sensor wires from the wiring harness and remove the ZIPSTRIP holding front O² sensor wires to the frame. Feed the end of the wire through the frame so they are free from the motorcycle. Note: pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear head pipe to gain easier access to the mounting nuts. 3. Remove the two head pipe mounting nuts from the flange at the heads. 4. Remove the clamp bolts that mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffler body where they attach to the stock mounting bracket. Carefully remove the exhaust system from the motorcycle and set aside. 6. Using a 7/8″ wrench, carefully remove the O² sensors from the stock head pipes and save for re-use on your RUSH system. 7. Remove the drive belt cover and remove the bracket off the rear cover bolt, bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T-30 torx socket. 9. Remove the three mounting bolts and washers attaching the exhaust mounting bracket. 10. If equipped with mid-controls, remove right side foot peg before installing your new RUSH system.

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HARLEY-DAVIDSON SOFTAIL STRAIGHTSHOTS 2-2 INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2012

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1. Under the oil tank on the right hand side, locate the rear O2 sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifi er on front of the frame to gain access to the front O2 sensor connector. Unplug sensor from harness. Remove cable tie holding wire to frame and feed the end of the wire through, freeing it from motorcycle. 3. On FLSTC, FLSTF, FLSTN and FLSTSC models, loosen the right hand fl oor board mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the two mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTN, FLSTF and FXSTD models, you will need to remove the right side passenger footpeg and hanger, as this is attached to the exhaust mount bracket. Remove hanger, and replace the passenger foot peg assembly using the 3/8″ x 2 1/2″ Allen bolt (supplied). 8. If equipped, unbolt the carriage bolt and clamp attached to the bracket under the right side transmission cover. 9. Remove the entire exhaust system and set it aside. 10. If equipped, remove the bracket from under the right side transmission cover. 11. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 12. Remove the two lower mounting studs from the frame (Figure 1). 13. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A

HARLEY-DAVIDSON SPORTSTER SHORTSHOTS STAGGERED BLACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2012

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1. Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 3. Remove the two head pipe mounting nuts from each fl ange, located at the cylinder head. 4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffl er body where they attach to the mounting bar. Carefully remove exhaust pipes from the motorcycle and set aside. 6. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T30 torx driver. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar (save hardware for re-use). 10. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A.

2006 Harley Davidson VROD / Screamin' Eagle VROD Installation Manual

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

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Check top clamp holding on rear heat shield be sure this is mounted forward not in middle of pipe. 2. Slide rear head pipe into collector and leave loose. 3. Mount head pipes into exhaust ports using stock Harley gaskets hand thread nuts onto head studs, leaving play in pipes. 4. Slip muffler onto collector and leave loose. 5. Slide D&D bracket included with kit onto chassis and muffler together. 6. Hand thread nuts onto chassis studs 7. Align muffler flush with bracket, hand thread bolts onto muffler.
8. Push system together tightly, Tighten rear head pipe collector clamp. 9. Holding muffler into place (finger width between shock bolt) tighten down muffler clamp all the way. 10. Snug (do not torque) chassis bracket bolts, snug muffler bolts until all is correctly aligned, then tighten down bolts. 11. Tighten head bolts down using factory torque specs, as you tighten the pipe check muffler clearance. If to close to swing arm push in on head pipe. If to far away push in on head pipe. 12. Once all is tight start bike and check for leaks This system is designed to be used with a high flow air filter and D&D VRDSEDD2.MT4 Race Tuner map.

YAMAHA V-STAR 650 CA SHORTSHOTS STAGGERED INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 29-12-2011

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Check condition of stock exhaust gasket. Replace if damaged or worn. 2. Install mounting bracket (stamped 384-P) in the original bracket mounting position using two 8mm bolts (supplied)(Figure 1). Note: Install two 5/16″ x 5/8″ fl ange bolts (supplied)(Figure 1) into top holes of bracket before installing bracket onto motorcycle. 3. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside (Figure 2). Place each heat shield on a non abrasive surface such as a blanket or carpet. Lay each head pipe/muffl er onto its respective heat shield (Figure 3). 4. Loosely install each hose clamp by feeding tail end of clamp into heat shield clip (Figure 2). #20 hose clamps are for head pipes and #28 hose clamps for muffl er area. Take note of clamp screw head direction (Figure 4). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Note: Do not tighten yet. 5. Install 6″ fl ange bolts (supplied) engaging nut plate. Leave T-bolt clamp onto front muffl er (Figure 4&5). Slide muffl er onto front head pipe. Slide nut plate (supplied) inside bracket welded to backside of front muffl er (Figure 6). Attach muffl er to mounting bracket 384-P using two 5/1head pipe/muffl er assembly loose at this time. 6. Using stock Allen bolts, carefully install rear head pipe/ muffl er assembly into exhaust port. (Assistance may be required). Note: Do not tighten yet. 7. Slide nut plate (supplied) inside bracket welded to backside of rear muffl er (Figure 6). 8. Align muffl ers so they are parallel when viewed from the right side of the motorcycle and muffl er tips align at the same length. Tighten 5/16″ fl ange bolts securing muffl ers to bracket. 9. Tighten cylinder exhaust port bolts securing head pipes to cylinder head. 10. Tighten T-bolt clamp securing front muffl er to head pipe. 11. Adjust heat shields so that muffl er tips protrude 1/4″ from heat shields (Figure 7) and rotation of heat shield matches muffl er tip. Tighten all hose clamps securing heat shields. 12. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. Note: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up. 13. All hardware must be properly tightened before starting motorcycle

2007-2008 HONDA CBR 600RR DUAL CANISTER SLIP- ON INSTALLATION

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Filed Under (Honda) by admin on 04-12-2011

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INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR CENTERSTAND OR SERVICE TABLE. 3. REMOVE BOTH THE FRONT AND REAR SEATS. 4. REMOVE THE 4 BOLTS HOLDING THE TAIL
FAIRING TO THE SUBFRAME AND REMOVE THE TAIL FAIRING. REMOVE 5. REMOVE TRIM PLASTIC JUST ABOVE RIGHT SIDE FOOTPEG. (REMOVE THE ONE BOLT AND UNCLIP) TRIM PLASTIC UNCLIP REMOVE 6. REMOVE LOWER FOOT PEG BRACKET AND REMOVE THE HEAT SHIELD BOLT. ALLOW THE FOOT PEG BRACKET TO HANG BY THE HOSE AND WIRES

HONDA HT1500 GOLD WING CONVERSION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 25-11-2011

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Cut-off the saddlebag support tubes where the vertical tube meets the angled tube in the front and back. All you want left is the tour pack support. Loosen tour pack support at bottom bolts, remove top bolts, and then lift up a little. This allows the body to go under the support. If you have the fuel tank: Secure the two black control boxes, facing each other, one on top of the other. Secure to frame using the green ground wire hole at center of frame. Use the 2 ¼”
spacer tube and long screw provided to hold them together. If no fuel tank: leave rear half of fender in place Install machined studs in the swing arm pivot hole with some blue Locktite on them. This provides a 5/8” stud on the side of the frame for the suspension side plates. Screw in until flush with frame. Remove the 6mm bolts from the exhaust heat shield on the outside of the frame rail. nInstall the shock replacement bars on the top shock stud and re-install bolts, leave bars hanging loose for now. Install air-compressor relocation bracket (1 ½” x 4″ w/ 3 holes) and remount compressor. After
mounting, secure the compressor to the bracket with a wire tie.

HONDA AERO 750 CRUZER EXHAUST SYSTEM REMOVAL And INSTALLATION

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Filed Under (Honda) by admin on 18-11-2011

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Install mounting bracket (stamped 363-P) in the original muffler mounting position, using two 10mm bolts and
one 10mm nut. (supplied)(Refer to figure 2). 2. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside.(Refer to figure 3).Place each heat shield on a non-abrasive surface such as a blanket or carpet. Position each head pipe/muffler over its respective heat shield. (Refer to figure 4).
3. Feed tail end of each hose clamp through each mounting clip welded to back side of front and rear heat shields. Take note of clamp hex screw head direction. (Clamp head direction is critical for adjustment when system is installed on bike.) Wrap each clamp around back side of head pipe threading tail end into clamp head. (Refer to figure 3 & 4).
4. Install front head pipe/muffler using stock flange nuts. Slide dog bone shaped nutplate (supplied) inside
bracket welded to backside of muffler. Attach muffler to mounting bracket 363-P using (supplied) 5/16” flange
bolts engaging dog bone nutplate. Leave head pipe/muffler assembly loose at this time (Refer to figure 4). Repeat this step with the rear head pipe.5. Align mufflers so they are parallel when viewing from right side of the motorcycle. Tighten 5/16” flange bolts securing upper and lower muffler positions.. Tighten cylinder exhaust port flange nuts securing head pipes to cylinder heads. 7. Adjust heat shields so they meet front of muffler taper. (Refer to figure 6). Tighten all hose clamps securing heat shield locations. NOTE: Heat shields should cover muffler/head pipe weld joint.

HONDA CBR 1000 RR AKRAPOVIC SLIP-ON & SLIP-ON STREET LEGAL EXHAUST SYSTEM REPAIR

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Filed Under (Honda) by admin on 17-11-2011

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INSTALLATION OF THE AKRAPOVIC SLIP-ON STREET LEGAL SYSTEMbinstalling the independent link pipe:m1. onto the stock collector properly install the metal ring for attaching the spring (Figure 27, 28) 2. install the metal clamp onto the Akrapovic independent link pipe (Figure 29) 3. slide the Akrapovic independent link pipe onto the stock collector; do not tighten the metal clamp (Figure 30) 4. attach the spring (Figure 31) 5. make sure the link pipe is not touching the frame and other parts installing the muffler: 1. correctly position the carbon-fiber clamp and slide it onto the muffler. WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! Do not fully tighten the bolts of the clamp (Figure 32) 2. position the muffler correctly and slide it onto the outlet side of the link pipe (Figure 33) 3. position and attach the springs (Figure 34) 4. tighten the carbon-fiber clamp onto the stock chassis hanging bracket on the frame (both sides of the motorcycle (Figure 35, 36, 37) 5. tighten the metal clamp at the independent link pipe – stock collector connection (Figure 38) 6. tighten the bolts of the carbon-fiber clamp. 7. reattach the stock heat shield (Figure 39, 40)8. reattach the rider’s footrest bracket (Figure 41) 9. make sure the muffler is not touching other parts of the motorcycle 10. reattach the license plate holder and turn signal lamps (Figure42, 43)11. reconnect the electrical leads for the rear light and reattach the fastback and both seats

2007 HONDA CBR600RR DUAL OUTLET SLIP-ON EXHAUST INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 07-11-2011

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Make sure the motorcycle is cool and place securely on a service lift or stand. 2) Remove the two bolts securing the rider seat to the motorcycle. Remove the seat. See Figure #1 3) Using the key, remove the passenger seat. 4) Remove the bolts and push pin fasteners securing the tail section to the sub frame. Carefully spread the tail section and remove it from the motorcycle. See Figur ) Disconnect the turn signal & tail light plugs on the left side of the sub frame. 6) Remove the four bolts securing the complete rear fender assembly (including the tail light & turn signals) and the rear reflectors to the sub frame. Remove from the motorcycle. See Figure #2 7) Remove the two nuts from the back side of the reflectors and retain to be used elsewhere in Step #38. 8) Remove the two bolts securing the right side passenger peg. Remove the passenger peg. See Figure #4 9) Remove the bolt from the inside of the stock s-bend heat shield located behind the rear brake reservoir. See Figure #5 10)Remove the bolt securing the silver plastic heel cover from the right side rider peg mount. Remove the cover. See Figure #6 11)Remove the bolt securing the rear brake reservoir to the sub frame. Allow the reservoirto dangle

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