HARLEY DAVIDSON BIG TWIN SPIGET MOUNT CARBURETOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 26-03-2012

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A. BEFORE INSTALLATION OF YOUR NEW ZENITH CARBURETOR, NSPECT THE RUBBER MANIFOLD SEAL FOR NICKS,CRACKS, OR DEBRIS. APPLYING A LIGHT FILM OF PETROLEUM BASED LUBRICANT AROUND THE INSIDE LIP OF THE RUBBER SEAL WILL ALLOW THE CARBURETOR TO SLIP INTO PLACE EASIER. B. BEFORE ACTUAL INSTALLATION OF UNIT INTO MANIFOLD, THROTTLE CABLES SHOULD BE HOOKED TO THETHROTTLEWHEEL.MAKESURETHATTHE PULL CABLE IS LOCATEDPROPERLY TO OPEN THE THROTTLE PLATE (IN SOME APPLICATIONS THROTTLE CABLE SLACK MAY NEED TO BE ADJUSTED FOR PROPER HOOKUP AND OPERATION) SEE FIG. #1 C. AFTER THROTTLE CABLES ARE PROPERLY HOOKED UP,UNITCAN BE INSERTED INTO MANIFOLD. MAKE SURE THAT UNIT IS FULLY SEATED. WITH CARBURETOR SEATED INTO MANIFOLD AND FUEL LINE HOOKED UP TO FUEL INLET, INSTALL CHOKE CABLE AND HOOK TO CHOKE LEVER. PLACE AIR INTAKE GASKET ON END OF CARBURETOR, NEXT PLACE INTAKE ADAPTOR OVER INTAKE GASKET. SEE FIG#2 ZENITH MOD.16P12 SPIGET MOUNT CARBURETOR -HARLEY DAVIDSON ™ BIG TWIN INSTALLATION INSTRUCTIONS FIG. # 1 FIG. # 2 D. WITH ADAPTOR IN PLACE, LOCATE THE STOCK AIR BOX OVER THE ADAPTOR, UTILIZING THE STOCK AIR BOX GASKET (THERESHOULDBENO GAPS BETWEEN ADAPTOR, AIRBOX OR CARBURETOR WHEN PROPERLY INSTALLED) STAND-OFF SPACERS PROVIDED ARE TOBEPLACEDBETWEENAIR BOX& ENGINE HEADS BEFORE INSTALLING THE VENT/RETAINING BOLTS. FOR EVALUATION ENGINES STOCK VENT BOLTS CAN BE USED WITH LARGERI.D. SPACER PROVIDED. SEE FIG#3 E. WITH AIR BOXSECURELY IN PLACE, INSTALL THE AIR FILTER COVER RETAINING BRACKET AND FILTER USING THE STOCKBOLTS, AND REPLACE AIR FILTER COVER AND SECURE WITH STOCK BOLT. SEE FIG#4 F. AFTER INSTALLATION IS COMPLETE AND FUEL FLOW HAS BEEN RE-ESTABLISHED, CHECK FOR ANY LEAKS BEFORE STARTING ENGINE. H. AFTER STARTING ENGINE, SOME ADJUSTMENTS OF IDLE AND MAIN JET MAYBE REQUIRED FOR PROPER OPERATION. AFTER ADJUSTMENTS HAVE BEEN MADE AND WITH ENGINEAT IDLE, TURN WHEEL FULLYTOLEFTANDRIGHT.ANYCHANGEIN IDLE SPEED INDICATES THROTTLE CABLES ARE TOO TIGHT AND MORE SLACK MUST BE PROVIDED.

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Yamaha 1998 XVS1100 REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 03-01-2012

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EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.
24 21 18 15 16 17 10 12 13 11 14 1 3 5 7 9 2 4 8 6 19 20 22 23 25 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Torque 15 Wear limit, clearance 16 Engine speed 17 Ω, V, A Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight lithium-soap base grease 23 Apply molybdenum disulfide grease Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply locking agent 24 and when to install new parts 25. 24 Apply locking agent (LOCTITE) 25 Replace

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2003 – 2005 Matrix WIND NOISE FROM DOOR GLASS WINDOW RUN REPAIR

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Filed Under (Toyota Manuals) by admin on 28-10-2011

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NOTE: Use the same procedure for the LH side as the RH side. 1. Place the window in the down position. 2. Remove the window run. Completely remove the double-sided tape remaining on the frame. 3. Thoroughly clean the door frame using a white body shop towel and Kent Acrysol. NOTE: Do NOT use red shop towels. These towels contain silicone. 4. Install the door glass window run. A. Position the glass run at the No. 2 and No. 3 corners of the door frame and then attach the middle part of the run. B. Insert the glass run into the window run channels. NOTE: Do NOT apply water or lubricant to the glass run when inserting it into the door. Make sure the glass run fits securely into the holes of the door frame

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HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

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HARLEY DAVIDSON TOURING SUSPENSION AIR PUMP KIT OPERATION/ INSTALLATION MANUAL

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

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OPERATION 1. Remove cap from air suspension air valve and connect pump by threading the air valve adapter (1) on the pump as shown in Figure 1. When adapter is threaded properly, the current air pressure in the system will be indicated on the gauge of the pump. Do not exceed maximum air pressure for rear suspension. Air components fill rapidly. Therefore, use low air line pressure. Failure to do so may result in possible damage to components. (00165a) NOTES See the motorcycle’s Owner’s Manual or, if installed, the air suspension lowering kit’s instruction sheet for the recommended air pressures. Using pressures outside the recommended loading range will result in a reduction of available suspension travel and reduced rider comfort. 2. To increase pressure, operate the air pump handle (4) until the desired pressure is indicated on gauge (2). Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) NOTE The pressure release button is designed to release pressure slowly. If the button is completely or rapidly depressed, no air will be released. For the best results, depress the pressure release button slowly and only partially. 3. To decrease pressure, slowly depress the pressure release button (3) on the pump until desired pressure is indicated on gauge (2)

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HONDA GL1500 Chrome Key Cover INSTALLATION MANUAL

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Filed Under (Honda) by admin on 28-02-2011

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1. Place bike on center stand. 2. Remove the OEM key cover by pressing down and turning counter clock wise. 3. Put a little lubricant on the tabs of the new part. 4. Install chrome cover and turn clock wise to secure

HARLEY DAVIDSON BATTERY CHARGING HARNESS (THREE-PIN) INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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1. Follow the instructions in your Owner’s Manual to remove the seat and any other components (side covers, etc.) necessary to provide access to the battery. 2. Refer to the applicable view in Figure 1 for your model. Break the battery negative (-) connection by removing the hardware assembly from the negative battery terminal. 3. Break the positive (+) battery connection by removing the hardware assembly from the positive battery terminal. 4. Clean the battery terminals and cable connectors using a wire brush or sandpaper to remove any oxidation. 5. Apply a light coating of Harley-Davidson electrical contact lubricant (Part Number 99861-02) to the battery terminals, cable connectors, battery charging harness ring terminals and connector located under the weather- shield cap. Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 6. Refer to the view in Figure 1 used for disassembly. Install the positive (RED) lead of the harness to the positive (+) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the positive (+) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the positive (+) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). 7. Attach the negative (BLACK) lead of the harness to the negative (-) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the negative (-) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the negative (-) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). Harness Routing Do not route the harness near any moving parts. Contact with moving parts may result in damage to harness. Refer to the following sections to determine the correct harness routing for your model. Be sure to avoid any components that may pinch or cut the harness, and avoid components that radiate heat. Take up any slack in the cable and store out of sight. Secure the harness with cable straps (H-D Part Number 10006), which can be purchased separately from any Harley Davidson Dealer. VRSC Model Harness Routing 1. See Figure 2. Route the battery harness/ connector (3) toward the front of the bike following the upper left frame tube. Cleanly tuck the in-line fuse (2) into the space in front of the battery. 2. Continue to route the harness/ gray connector to the front of the bike and behind the vent cover. Secure the harness with a cable strap and let the connector protrude past the cover for easy access. Trim any excess from the cable strap

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HARLEY DAVIDSON TOURING LOW PROFILE REAR SUSPENSION KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Refer to the Service Manual and follow the instructions given to remove the seat. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) 2. Disconnect the battery cables, negative cable first or remove the main fuse if equipped. 3. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 4. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 5. Fasten the air pump, part number 54630-03A to the rear air suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 6. Using the pressure relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 7. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air hose fittings

HARLEY DAVIDSON LOW-PROFILE REAR TOURING SUSPENSION KIT Installation

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Filed Under (Harley Davidson) by admin on 30-11-2010

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1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 2. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 3. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 4. Fasten the air pump, part number 54630-03A to the rear air-suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 5. Using the pressure-relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Failure to relieve air pressure from the rear suspension could cause injury during shock-absorber removal. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak on to the rear wheel, tire, and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 6. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air-hose fittings. NOTE Press the plastic collar down on the air-hose fitting to remove and install the air hose. 7. Remove the air hose fittings from the shock absorbers. Save the fittings for installation on the new shocks. NOTE Air-suspension shock absorbers are oil filled and must be kept upright at all times to prevent oil leakage. 8. Remove the lower mounting bolts and washers from the shock absorbers

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2004 King 50 And CM 50 clutch cover alignment and securing technique

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Filed Under (Cobra) by admin on 10-11-2010

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Some 2004 King & CM models have a thicker (brown) clutch cover gasket that requires retightening of the cover bolts several times before they remain tight. Follow this procedure to properly align the kick start gears and clutch cover. You should do this if the kick lever is not engaging properly (high frequency of not engaging the engine when you attempt to kick start the bike) . NOTE : Proper clutch cover torque value is 70 in-lb (7.9 Nm). NOTE : Lay the bike on the left hand side, or drain the clutch lubricant from the bottom end before performing this procedure. Loosen the six clutch cover screws (5mm allen) enough that the clutch cover can be moved by hand. Engage the kick lever with your hand and stroke it half way down and stop holding pressure on the kick lever (see picture)

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