Harley Davidson 6- SPEED CONVERSION KIT FOR BIG TWIN 5- SPEED TRANSMISSIONS INSTALLATION

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Filed Under (Harley Davidson) by admin on 05-03-2012

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5/16 Bolt hole boss clearance This can easily be checked with the trap door gasket. Put the gasket on the dowel pins. AII material of the boss around the hole that “sticks outside” the gasket (60 degrees forward to 60 degree backwards) must be removed (see figure A). Primary fork clearance Place the gasket on the housing and remove material as indicated for clearing the shifter fork (see figure B). WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® INSTALLATION INSTRUCTIONS FOR 6 SPEED CONVERSION KIT AND 6 SPEED BUILDER KIT speed transmission. Also make sure you have a 1990 or later Factory Service Manual available. Tools The conversion kit should only be used in new or low milage transmissions. If gears or bearings of a used Gear set Removal Refer to the Factory Service Manual Section for Mainshaft and Countershaft removal. When you get to the point of actually sliding the gear set out make sure you properly mark the 5th gear set as described in the Factory Service Manual (for used transmissions only). Further follow the factory removal procedure. Clearance Checks The 6 Speed conversion and builder kit will fit in most OEM or aftermarket transmission housings without may be needed. The following clearances must be checked before assembling the 6 speed transmission. 28-05-2008 We recommend the kits are installed by a qualified mechanic with knowledge of the Harley-Davidson 5 needed are the same as used for a 5 Speed transmission. 5 speed transmission are worn, new ones must be installed, or better, the builder kit should be used. any modification of the housing. However due to casting differences, in some instances some modification
WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® Pillow block clearance (right side) Make sure there is clearance between the pillow block and the housing. Any clearance is O.K. (see figure C). Fork shaft support clearance Again use the gasket as the template and remove the material as indicated (see figure D). Shift drum end play The end play of the shift drum must be checked prior to final installation. Install the shift drum. Measure the end play with feeler gauges at the right pillow block (see figure E). End play should be between .004″ and .010″, some 1/2″ X 7/8″ 0.008″ thick shims are included to adjust the end play

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

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SUZUKI GSX-R600 X-TRE Power Box Installation and Operation Manual

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Filed Under (Suzuki) by admin on 10-02-2012

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Installation Disclaimer: Do not attempt to install the product if you don’t have basic mechanical skills. HealTech Electronics Ltd. and its distributors shall not be liable for any loss or damage caused by improper installation. 1. Check the supplied parts: – X-TRE Power Box – Wiring harness – Yellow butt connectors, gel-filled (2 pcs) – Red tap connector, gel-filled – 4p jumper-plug – Cable ties (2+1 pcs) – Velcro strips – HealTech stickers (2+2 pcs) – Manual 2. Make sure the ignition key is in OFF position. Remove the seat. 3. Locate the ECM (Engine Control Module) under the seat. 4. Release the fuse box and relay switch to clean the area around the ECM connectors. 5. Locate the Black wire with thin dark Green stripe (B/G) , in the ECM connector. The wire position for different models is as follows: GSX-R600 K8-K9 GSX-R750 K8-K9 GSX-R1000 K7-K9 Black connector, pin no. 23 Middle row, 2nd wire from left to right at the back (wire) side of the connector ALL other years and models Black connector, pin no. 6 Top row, 6th wire from right to left at the back (wire) side of the connector

2000-2003 KTM MXC / EXC Dual Sport Kit Installation And Removal Manual

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Filed Under (KTM) by admin on 08-02-2012

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00-’03 KTM 400/450/520/525 EXC & MXC Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3
4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

2000-2003 KTM MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 01-02-2012

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3 4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

HONDA GL-1500 Trailer Wire Harness with Relay INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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Seat: (if optional accessory wire is to be used) After removing trunk pan, run a stiff piece of wire from the bottom of the left saddlebag frame behind the rear tire up until it comes out under the trunk. Then hook open end of wire harness to fish wire and tape with electrical tape. Pull the harness back down to the bottom of the saddlebag frame. Route the long part of harness wire around the back of the license plate light to the right side 6-pin vertical connector just in front of tail light assembly. Unplug the stock connector and plug wire harness in between the stock plugs. Do the same for the left side with the short side of the Y on the harness. Now pull the slack down from the bottom of the harness and tuck all of the wires under the frames tubes so that the pan can be reinstalled without any problems. You can now hook up the loose ends of the harness to any style connector to match your trailer connector using the following color codes: GREEN GROUND ORANGE- LEFT TURN YELLOW- BRAKE BLUE- RIGHT TURN BROWN- TAIL RED POWER . Note : This accessory is an electronic isolated trailer wire harness. It should be installed by a qualified mechanic . 1. Disconnect the negative from the battery. 2. Install the harness. 3. When connecting to the trailer make sure all wires are used for the proper use and are waterproof. Make sure there are not exposed wires. Consult the trailer manufacturer for proper wiring. 4. Reconnect the battery negative. Double check the functions

2002-2003 KAWASAKI ZX9R OGGY KNOBB KIT.

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Filed Under (Kawasaki) by admin on 05-11-2010

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Congratulations on purchasing your Oggy Knobb kit. It has been designed to reduce damage to your motorcycle from impact and abrasion by the road surface in an accident. We have used only the highest quality materials to achieve the strength and appearance your investment deserves. Carefully read the fitting instructions below and check you kit contents before starting installation. If you are unsure or not confident about installing Oggy Knobbs yourself, see your mechanic. Instructions-Left Side: 1. Remove the engine mounting bolt, the position of which can be seen in the photo above. There is captured nut on the engine which must stay in place. 2. Fit the Oggy Knobb assembly with the thick washer behind the Oggy Knobb. 3. Tighten the bolt securely to manufacturer’s specifications. 4. On the right side, repeat steps 1 to 3.

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Kawasaki KLX450R Dual Sport Kit Installation And Removal Manual

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

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1. Remove the seat, fuel tank, and side panels. 2. Unplug and remove the stock headlight. 3. Taillight Installation: The Baja Designs taillight will run in conjunction with the stock taillight for this installation. Start by removing the first wire guide that the stock taillight wires pass through near the end of the fender. Once removed, trim off the remaining molded mounting boss as shown in Photo 1. Drill three ¼” holes in the fender and use the provided countersunk mounting hardware to attach the Baja Designs taillight as shown in Photo 2. The rear edge of the LED cluster should line up with the rear edge of the fender. Route the wires forward between the plastics to the left of the front mounting bolt. We’ll attach them in a later step. Photo 1 Molded mounting boss removed Stock taillight Photo 2
4. Turn Signal Installation: Drill a 7/16″ hole in each side of the fender plastic in the locations shown in Photo 3. Install the rear turn signals and route the wires forward as shown in Photo 4. Photo 3 Photo 4 Zip-tie BD taillight wires to fender here Route left signal wires through fender with stock taillight wires 5. Brakelight Switch: The KLX uses a hydraulic operated switch to activate the brakelight. Installation of this switch requires bleeding the rear brake system. If you do not feel competent performing this task please refer it to a qualified mechanic. An improperly bled brake can lead to rear brake failure. Caliper Guard Modification: The hydraulic brakeswitch replaces the banjo-bolt that attaches the rear brake hose to the caliper. Because of its larger size, the plastic caliper guard must be relieved slightly to provide clearance. Remove the caliper guard and modify as shown in Photo 5.

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