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. ¼” 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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2004-2005 KTM 250/ 400/ 450/ 525 Side Panel Fuel Tank removal and Installation Instructions

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Filed Under (KTM) by admin on 22-01-2012

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1. Remove airbox cover. Drill stock rivet nut in frame tube through with a ¼” drill as shown in Photo 1. Drill completely through frame tube. We suggest you make a small guide hole in the top of the frame tube first so that you drill straight through the frame member and not come out the side of the frame tube. Photo 1 .Install Lower mounting bracket as shown in Photo 3 noting its orientation. Install the aluminum cone into the recess at the bottom of the stock airbox , then bolt the bracket on with the 6 x 70 mm bolt. Nylock nut threads to top of bolt on top of frame tube as shown in photo 2. Photo 3 2 3. Install the upper mounting bracket shown in Photo 4. Note that in either the MXC or the EXC installation four to six of the 6 x 18 mm fender washers should be installed between the bracket and the subframe. The counter-sunk hole should be positioned toward the rear wheel. Leave the bracket slightly loose until step 6. Photo 4 The best routing for the fuel line (Photo 5 & 6 ) requires drilling holes in the airbox. See Step 4 for hole locations. 4. Drill a 3/8″ hole at the front left corner of the airbox as shown in Photo 6. Make sure the location you choose will not result in the hole coming out behind the frame tube or into the rubber airbox boot. Be very careful drilling this hole.

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Yamaha Virago 750/ 1100 InstaTrike REMOVAL AND INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 26-12-2011

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Remove any aftermarket accessories (saddle bags, back rests, etc) before hitch installation. After installation remount accessories. NOTE: Some aftermarket accessories may not be compatible with InstaTrike hitch. 1) Place motorcycle on a smooth level surface on center stand. 2) Attach Bracket A (left) to outside of rear passenger foot peg mount. Place spacers between Bracket A and foot peg mount. Use new bolts provided. 3) Attach Bracket B (right) to outside of rear passenger foot peg. Place spacers between Bracket B and foot peg mount. Use new bolts provided. Bracket will extend over top of mufflers. 4) Attach Brackets C (left) and D (right) to rear frame bolts on
motorcycle. Located near rear turn signals Use new bolts provided. (10M x 25mm long) It may be necessary to loosen or remove backrest covers or hardware in order to easily access rear frame bolts. After Bracket C and D installation, reattach and/or tighten backrest mounts. 5) Attach Bracket E(left) / F(right) to bottom of Brackets A & B and to the TOP of the forward hitch arms. Ensure hitch is square on motorcycle and snug bolts for Brackets A, B, and E,F at this time. 6) Raise rear of hitch so bottom of Brackets C & D are flush with top of rear hitch plate. Ensuring that hitch is square with motorcycle, carefully mark hole locations for bottom of Brackets C&D on rear hitch plate. Drill rear hitch plate holes with 3/8 inch drill. This step ensures proper alignment and spacing of hitch on the motorcycle. 7) Tighten all bolts ensuring that hitch is square on motorcycle. Periodically check bolts for tightness. Bracket Identification
INSTALLATION OF THE TOW-PAC HITCH CART.
1. Place your motorcycle on a smooth flat surface, like a garage floor, and rest it on its center stand. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bo

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Honda XR 400 Removal and Installation Manual

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

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Turn Signal Switch Installation Front Wiring Connections Field Effect Transistor Installation Taillight Installation: Install the Acerbis DOT taillight over the empty well left in the stock fender using the two 5 x 20 mm bolts and 6 x 16 mm bolt found in the parts bag. Position the taillight over the previous taillight mounting well and transfer the hole locations for the top mounting holes onto the fender with a felt pen or snap punch (Photo 3) so that they are 3/8 of an inch above the edge of the taillight opening as shown in Photo 3. Drill two 3/16 inch holes for the top mounts. Attach the taillight using the top mounting screws, then pull the license plate holder down toward the bottom of the fender so that the taillight is pulled as horizontal as possible. Transfer drill a 1/4” hole at the bottom mounting location with the taillight in this position. When installing the bottom license plate mount bolt, make sure to install the 6 x 16 mm bolt from the bottom up to minimize the opportunity for the tire to grab it. Run the taillight
wires along the left frame rail using the stock wire clamps to support it. 8. 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, 3-3/4 inches back from the front edge (pointed tip of fender where it meets the side panel) and 2-3/4 “ up from the bottom edge Brake Light Switch Installation

HARLEY DAVIDSON VRSCF LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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REMOVAL 1. See Figure 1. Remove four rear fender mounting bolts (1) and washers (2). If necessary, move the ECM to access the four fender mounting bolts. 2. Disconnect the tail lamp following the instructions in the appropriate service manual. 1 2 is05463 1. Bolt (4) 2. Washer (4) Figure 1. Fender Mounting Bolts INSTALLATION NOTE There are bosses molded into the inside of the fender to use as the hole drilling templates. 1. See Figure 2. Apply masking tape to the outside painted surface of the fender at the three hole locations (1 and 2). This will protect the painted surface during the drilling operation. 2. Put the fender on a work bench, painted surface down. Use clean, soft cloth between the fender and the work bench to protect the paint finish. NOTES Drilling each hole in the fender is a two-step procedure that requires a specific type of drill bit to avoid damaging the fender. 3. See Figure 2. Use a 1/2-inch spade bit or 1/2-inch unibit (do not use a spiral-type drill bit) to drill three holes from the inside of the fender through the three pilot hole bosses (1 and 2). Stop drilling when the tip of the bit just pierces the outside surface of the fender. 4. Turn the fender over so the painted surface is now facing up. Complete each hole by using the same 1/2-inch drill bit at each of the pierced holes. Clean excess material from the holes and clean the fender surface of any debris. 5. See Figure 5. Remove the masking tape from the holes and apply the protective tape (3) to the painted surface using the drilled holes for alignment. 6. See Figure 3. Put the luggage rack (1) upside down on the work bench and align the holes in the luggage rack with the holes in the fender (2).

HARLEY DAVIDSON SOFTAIL DETACHABLE TWO-UP TOUR-PAK LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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TOUR-PAK LUGGAGE INSTALLATION TO RACK 1. Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage.  Remove the rubber mat from the luggage floor. 2. If holes ARE NOT pre-drilled in the floor of the luggage,       see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites.  Use the four inboard holes (3) in the metal base of the luggage (2) as a guide, and carefully drill four 11/32 inch (9 mm)  holes through the floor of the luggage. 1 2 3 is04249 1. Front of motorcycle 2. Tour-Pak 3. Drill four 11/32 inch (9 mm) diameter holes Figure 1.  Drill Attachment Hole Locations in Tour-Pak NOTE See Figure 3. When installing the luggage to the rack in the following steps, note that holes in the luggage rack (2) provide forward (A) and rearward (B) positions for mounting the lug- gage. 3. Place the luggage on the luggage rack.  Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. 4. ALL applications: Obtain the hex head cap screws (9), lock nuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw, and insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage.  If the screws are installed from the bottom, the screw ends can tear the rubber mat and scratch objects, such as helmets, stored inside the luggage. 5. From the underside of the rack, install a washer and lock nut onto the threads of each screw.  In a crosswise pattern, incrementally tighten each screw to 19 ft-lbs (25 Nm) . 6. Install the rubber mat into the luggage.  Close and latch the lid. 7. If not already in place, install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit

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HARLEY DAVIDSON V-LOGO TURN SIGNAL INDICATOR FORROAD KING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1. Disconnect battery cables, negative cable first. 2. Following instructions in applicable Service Manual, remove the windshield. 3. Remove the phillips screw at the bottom of the of the headlamp door (chrome ring). Remove the headlamp door. 4. Remove the seven Phillips screws to free the headlamp housing from the headlamp nacelle. 5. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside. 6. See Figure 1. Reaching inside the headlamp nacelle, remove the speed nut to release the chrome strip at the top of the nacelle. 7. Remove the wire form clip holding the halves of the nacelle together at the bottom. 8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate. 9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove). 10. Loosen the two acorn nuts from the left and right side fork studs. 11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle. 12. Carefully align the template over the handlebar shroud cover and tape into place. 13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means. 14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure. 15. Drill one 1/4″ hole and two 5/32″ holes as indicated on the Drill Template (attached)

HARLEY DAVIDSON ULTRA TOUR-PAK BRAKE LAMP CHROME ACCENT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation- Corner Brake Lamp Trim 1. Carefully cut out brake lamp trim template (1) attached to this instruction sheet. 2. Position template (1) on plastic brake housing (2) as shown in Figure 2. 3. Using a punch, score two points indicated on template to mark mounting hole locations (3) on plastic brake housing (2). 4. Using a 1/8 in. drill bit, drill a pilot hole in plastic housing. 5. Use a 7/32 in. drill bit to drill through housing and fiberglass Tour-Pak. 6. See Figure 3. Insert studs on chrome brake lamp trim piece through holes drilled in plastic housing and Tour- Pak. Using two flatwashers (1), two lockwashers (2) and two acorn nuts (3) from kit, secure trim piece to Tour- Pak. Tighten finger tight. 7. See Figure 3. Locate brake lamp retaining clip (4) on inside of Tour-Pak and remove. Save clip (4) for later reinstallation. 8. Form chrome trim around corner of Tour-Pak, so that it is positioned around plastic housing evenly. While holding chrome trim in position, mark forward mounting hole position on Tour-Pak using a punch

HARLEY DAVIDSON DASH PAD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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This kit fits 1997 and later FLHT model motorcycles. INSTALLATION 1. Refer to the appropriate Service Manual and remove the outer fairing. NOTE See Figure 1. Place the template in the left side position (as seen facing the forward side of the inner fairing) with the “L” showing. Place the template on the right side with “R” showing. 2. See Figure 1. Using the template supplied in the kit, mark the two hole locations on forward side of the inner fairing. 3. Drill a 1/8 in. pilot hole in each of the hole locations. 4. Drill a 1/2 in. hole in each of the pilot hole locations. 5. Install the dash panel above gauges on inner fairing and secure with screws and washers from kit. Tighten screws to 25-30 in-lbs (2.8-3.4 Nm) . 6. Refer to the appropriate Service Manual and install the outer fairing. L 1 is00488 1. Template Figure 1. Template Placement (Left Side Shown) SERVICE PARTS 1 3 4 2 2 is00486 Figure 2. Service Parts for Dash Pad Kit Table 1. Service Parts Part Number Description (Quantity) Item Not Sold Separately Dash pad, leather wrapped 1 Not Sold Separately Screw (2) 2 Not Sold Separately Washer (2) 3 58318-05 Template 4

Kawasaki Prairie 360,650,700 ATV PLOW Plow Mounting Kit INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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Mount Installation Note: There are different hole locations on the plow mount depending on the bike model. For Prairie 360 use the middle hole locations (B), for Prairie 650 and Twin Peaks 700 use hole locations (A) on mounting plate, as shown in Figure 1. Figure 1 Hole Locations WARN INDUSTRIES PAGE 3 67954 Rev A3 To install the plow mount to the underside of the vehicle install the front two U-bolts PN 60869, and loosely tighten the 5/16″ nuts. Pull the plow mount back in the furthest position and then fully tighten, as shown in Figure 2. For the Kawasaki Prairie 360 use the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (B) . For Kawasaki Prairie 650 and Suzuki Twin Peaks 700 drill a 3/8″ hole through the aluminum skid plate, using the plow mount as a template, as shown in Figure 3. Repeat the same process on the other side. After both holes are drilled attach the mounting plate with the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (A) . Tighten all fasteners securely. Torque 5/16″ Bolts: 20ft. lb.

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