HARLEY-DAVIDSON DYNASTRAIGHTSHOT HS SLIP-ON INSTALLATION Manual

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

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1. Before removing the stock exhaust system note orientation particularly of the support bar between the two muffl er bodies (Figure 1) and the muffl er clamps. If necessary, using tape or another easily removable means, note the orientation on the stock support to ease re-installation. 2. Remove the four 1/2″ lock nuts that hold the support bar to the stock muffl ers and remove the stock support bar and bolts (set the nuts. bolts and support bar aside as they will be used later). 3. Using the 9/16″ deep socket, loosen the clamps holding the muffl ers onto the head pipes and remove the muffl ers from the head pipes. NOTE: May require assistance and the use of penetrating oil. 4. The stock muffl er clamps may be re-used. However Vance & Hines recommends replacing them with new clamps (Harley part number 65283-94). If using the stock clamps, be sure the T-Bolt does not twist out of the groove during tightening. This could allow the clamp to loosen with use

2000 Honda Rancher ATV Winch Mounting Kit REMOVAL AND INSTALLATION

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Filed Under (Honda) by admin on 13-01-2012

Begin by removing the front fascia and front skid plate on the vehicle as shown in figure 1. Save the fasteners as they will be used later to re-install the front fascia and skid plate. 2. Remove the 8mm bolts on both sides located inside the front tires and on the ends of two horizontal tubes on the front tube frame as shown in figure 2. 3. Place the mounting plate (A1) inside the front tube frame. The tabs with the slotted holes facing down. The slotted tabs should align where the
two 8mm bolts were removed in step 2. Reinstall these two bolts at this time thighten to just fingertight. Install the two 1/4-20 u-bolts (B3) and locking hex nuts (B1) and flat washers (B7) at thism time see figure 3, do not tighten down at this time. so the plate can be adjusted for position see figure 2. 4. Place the rear support bracket (A4) into position
and attach with the two 5/16-18 x 3/4 hex cap screws (B6), flat washer (B5) and locking nut (B4). Adjust the position of the support bracket so that it comes in contact with the frame tubes and tighten the fasteners see figures 3 and 4.
Make sure the support bracket maintains contact with the rear frame tubes and tighten down the two front 8mm mounting bolts. Tighten the bolts to a recommended torque of 12 ft-lb (17 N-m). 5. Attach the fairlead bracket support (A2) to the front frame tubes see figure 5. The support bracket attaches behind the front tubes. Space the bracket away from the tubes using the spacer brackets (A3). Attach the brackets using the 1/4- 20 u-bolts (B2), lock nuts (B1) and flat washers (B7). Before tightening the u-bolts make sure the bracket is in the correct position by fitting the front
fasica into postion and checking location. Tighten the nuts to a recommended torque of 7 ft-lb (10 N-m). NOTE: If this kit is being installed on a 00 to 03 Honda the wider fairlead bracket (A2) will need to be used. This will require the use of the
wider u-bolts (B3). The spacer brkts (A3) will not be required when installing the wider fairlead brkt

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Yamaha YZF-R1 Undertail Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 11-01-2012

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Carefully remove the tail section body work. Save all bolts, washers and plastic rivets for re-installation of tail. Disconnect and remove the brake light (with all mounting grommets and washers), license plate and turn signals, key lock (with clip) and move all wiring out of the cutting areas. Remove the two bolts at the rear end of the stock fender (inside glove box) to allow the end to hang down for cutting. 2) Using a “Dremel” tool or cutting disc (this can also be done using a sharp edged knife, but is not recommended), remove the plastic shown in the photos above and below. Be sure to take your time cutting, so that you don’t cut away any more plastic than necessary. 3) Now relocate the rear mounting holes for the glove box 1.25″ lower in the tray to raise it up in the subframe as shown. Yamaha YZF-R1 Undertail Kit (2000-01, Available in: Yamaha Red, Yamaha Blue) Need Help? If you need additional help with the installation of the undertail, go to www.hotbodiesracing.com and look for the “FAQs” link at the bottom of the home page. Most of your general questions can be answered on those pages. This installation does require a basic mechanical aptitude, if in doubt, contact your local motorcycle shop and have a professional mechanic perform the installation, 3 hours is the average installation time. * After this modification your undertail is not returnable. Paint is not war- rantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray. 5) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail, carefully mark and drill holes, install using the two (2) sets of allen bolts and lock nuts

Yamaha TDM900 Installing and removal the Vacuum Actuator

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Filed Under (Yamaha) by admin on 28-12-2011

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Attach the cable adjuster to the bracket. Position the adjuster so that it is screwed all the way in. Do not tighten the lock nuts on the adjuster yet. • Route the new ‘carburettor’ cable around and out the RHS of the bike under the frame rail as shown in the following photos. Installing the Vacuum Actuator • Mount the actuator on the RHS fairing support using the bracket provided and two bolts, nuts and flat washers. The mounting bracket fits on the inside face of the fairing bracket. The small plate fits on the outside and clamps the actuator to the faring frame.

Honda CBR 954 RR Undertail Kit INSTALLATION

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

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Carefully remove the tail section body work. Save all bolts, washers and plastic rivets for re-installation of tail. Disconnect and remove the brake light (with all mounting grommets and washers), license plate and turn signals, key lock (with clip) and move all wiring out of the cutting areas. Remove the two bolts at the rear end of the stock fender (inside glove box) to allow the end to hang down for cutting.
2) Using a “Dremel” tool or cutting disc (this can also be done using a sharp edged knife, but is not recommended), remove the plastic shown in the photos to the above and below. Be sure to take your time cutting, so that you don’t cut away any more plastic than necessary. Honda CBR954RR Undertail Kit (2002-03, Available in: Honda Red, Gloss Black and Gun Metal) 3) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail, carefully mark and drill holes, install using the two (2) sets of allen bolts and lock nuts. 4) Insert undertail left side first, then right side, be carefully not to crack
or scratch undertail. Use your stock plastic screw rivets to hold under- tail in place. Tighten all hardware on tail section, attach seat.
5) Using clips, splice your turn signal wires to the signals in the undertail. On the bike; the orange wire is the the left turn, light blue wire is the right turn and the green wires are the grounds. On the undertail the red wires are the power wires and the black wires are the ground. * After this modification your undertail is not returnable. Paint is not warrantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray. Need Help? If you need additional help with the installation of the undertail, go to www.hotbodiesracing.com and look for the “FAQs” link at the bottom of the home page. Most of your general questions can be answered on those pages. This installation does require a basic mechani- cal aptitude, if in doubt, contact your local motorcycle shop and have a professional mechanic perform the installation, 3 hours is the average installation time

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HARLEY DAVIDSON SPORTSTER ALUMINUM SHIFT LINKAGE KITS INSTALLATION MANUAL

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

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INSTALLATION 1. See Figure 1. Remove stock capscrews (4) and stock shifter rod (2). Discard stock capscrews. 2. See Figure 2 and Table 2. Loosen the lock nuts (5) and turn the rod ends on the new aluminum shifter rod (1) to match the length of the stock shifter rod. 3. See Figure 2 and Table 2. Slide longer capscrew (3) through the front rod end of new shifter rod (1). Place rod on the outside of the lever assembly. Thread capscrew (3) into the lever assembly. 4. Slide shorter capscrew (2) through the rear rod end of new shifter rod (1). Place rod on the outside of the transmission shift lever. Thread capscrew (2) into the transmission shift lever. 5. Tighten capscrews to 10-15 ft-lbs (13.6-20.3 N-m) . 6. Firmly tighten the lock nuts (5) against the rod ends to 20- 24 ft-lbs (27.1-32.5 Nm) . 1 4 2 4 3 is05394 1. Lever assembly 2. Shifter rod 3. Transmission shift lever 4. Capscrew Figure 1. Shift Linkage Components

HARLEY DAVIDSON FLSTF FENDER TRIM INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION 1. Thoroughly clean the fender tip in the area where the trim will be mounted. 2. Cover the fender with masking tape to protect the painted surface during positioning of the trim. 3. Place the trim in the desired location and hold it in position. Mark the hole locations with a felt tip pen or pencil. Remove the trim. 4. Carefully center punch the hole locations in the fender. 5. Drill the mounting holes using a 1/8 in. (3 mm) diameter drill bit. 6. Remove the masking tape from the fender. 7. Mount the trim on the fender using the screws and lock nuts provided in the kit

HARLEY DAVIDSON TRIKE CHROME REAR GUARD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Set the vehicle parking brake, open the trunk door and remove the trunk liners. 2. See Figure 1. From inside the trunk, locate four screws with washers (A) in the floor of the trunk compartment that hold the body to the rear frame. Leaving the washer in place, remove one of the screws and discard. 3. Obtain a long hex head cap screw (3) from the kit. Apply a few drops of Loctite – Blue to the threads of the screw, about 0.75 in (19 mm) from the screw head (C). 4. Insert the screw through the washer (A) and trunk floor. Thread it all the way through the U-channel on the outboard side of the rear frame (B), but do not fully tighten at this time. 5. Repeat for the remaining three screws. 6. Tighten all four screws to 18 ft-lbs (24.4 Nm) . 7. With an assistant, position the trunk rail assembly to the underside of the frame, fitting the four holes in the rail mounting brackets onto the threads of the screws installed in Step 4. 8. Apply a few drops of Loctite – Blue to the threads of each lock nut (4). 9. Install a washer (5) and locknut to the threads of each screw to hold the rail in place, but tighten only enough so the rail lightly contacts the frame. 10. Align the rear guard evenly to the contour of the lower body for best appearance, and adjust the position of the rail to provide clearance between the rail and the rear of the vehicle body. 11. With an assistant firmly holding the screw heads inside the trunk to keep them from turning, tighten the four lock nuts to 18 ft-lbs (24.4 Nm) . 12. Install an insert (2) into each end of the rear guard. Push firmly until fully seated.

BUELL XB9R REMOVABLE SADDLEBAG KIT Installation Instructions

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Filed Under (Buell) by admin on 03-02-2011

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Installation 1. Ensure that the tail section of the motorcycle is clean and dirt free. 2. See the Service Parts illustration. Using a T27 TORX drive head, remove the two screws holding the tail section underside shield. 3. Install the saddlebag bracket (3) as shown, reinstall the screws and tighten securely. Federal Motor Vehicle Safety Standard (FMVSS) 108 requires all motorcycles to be equipped with side reflectors. The mounted saddlebags will cover the factory-installed rear side reflectors on these vehicles. Reposition, or have a dealer reposition, the original rear side reflectors supplied with this motorcycle or apply new ones. If this is not done, the loss of visibility to other motorists may result in death or serious injury. NOTE New reflectors (Part number 59256-84A) are available from your Buell Dealer. NOTE When removing adhesive residue, take care to keep from scratching or damaging the reflector, mounting bracket or surrounding parts. 4. Use a thin flat blade, like that on an X-Acto knife, and carefully pry the reflectors off of their mounting brackets. Remove the adhesive residue from the brackets and the back of the reflector. 5. Mount the new reflector relocation brackets (4) to the stock reflector mounting brackets as shown. Attach each relocation bracket through the slots in the stock bracket with two screws, flat washers and lock nuts from the Hardware Kit (5). Slide the relocation bracket to the rearmost position and tighten securely. 6. Remove the outer release liner of the foam tape on the relocation bracket. Mount the stock reflector squarely to the bracket, and press firmly in place. 7. Remove the passenger pillion (and pillion cover, if mounted), and set aside. 8. Position one of the saddlebags to the side of the motorcycle tail section with the Buell logo facing out, and to the rear. Hook the mounting pocket on the back side of the bag onto the saddlebag bracket mounted earlier. Repeat for the other saddlebag. 9. Bring the saddlebag straps up and over the tail sectiion. Pull the right-side straps up through the buckle eyes on the left-side straps, remove any slack and fasten the hook-and-loop material. 10. Note the points where the saddlebags and straps contact the motorcycle tail section. Two lengths of clear protective tape have been provided in the Hardware Kit. If desired, cut and fit lengths of the tape to those areas of the tail section to prevent damaging the finish. 11. Replace the passenger pillion (and pillion cover if desired). Position the front tongue on the pillion overthe saddlebag straps

2002 GL 1800 Reverse Cable Inspection/ Adjustment PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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INSPECTION/ADJUSTMENT PROCEDURE 1. Remove the right engine side cover (see S/M Page 2-4). 2. Check the cable clearance on the N (neutral) and R (reverse) cables. Note: It is not necessary to remove the center inner fairing or inspect the reverse shift actuator. . 6. Push the reverse shift switch to “OFF” and turn off the ignition. 7. Tighten the reverse cable lock nuts. 8. Reinstall the right engine side cover. PARTS INFORMATION No parts are required for this procedure. WARRANTY INFORMATION Normal warranty. After completion of the inspection/adjustment, submit one claim per VIN using the following information only: Template #: GL#5 Flat Rate Time = 0.3 hours The reverse cable lock nuts may not have been properly tightened on some GL1800 units. We have developed a procedure to inspect and adjust any affected units. Please follow the INSPECTION/ ADJUSTMENT procedures included in this Service Bulletin. AFFECTED UNITS 2002 GL1800 units with VIN range: 1HFSC470*2A102303 through 1HFSC470*2A102622 * indicates check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection.

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