Honda RC-51 / VTR-1000 SP1 – Installation Instructions

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Filed Under (Honda) by admin on 23-11-2011

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Remove the lower fairing. Remove the existing exhaust system from the mid pipes rearward. Save the exhaust clamps for reuse Save the stock exhaust can mounting bolts and nut for the end can to the passenger footpegs for reuse as well. Inspect the original exhaust gaskets. Replace as necessary. Slide the tail pipes into place. Do not tighten the clamps at this point. Slide the TiForce end cans into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to each end can using the supplied 6mm hardware H. See figure 1 for details. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G
(see figure 1). Attach the supplied springs to all the joints (from the tail pipes to the TiForce end cans). Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can, then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO
BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN(s).

Honda CBR-600 F4 / F4i – Installation Instructions (slip-on)

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

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Remove the lower fairing. Remove the existing exhaust system from the middle of the stock pipe. Save the stock exhaust can mounting bolt and nut for the end can to the passenger footpeg for reuse as well. Remove the clamp from the stock exhaust system and save for reuse. Install the S-Bend to the rear of the stock head pipe. Reuse the stock clamp, but do not tighten at this time. Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. See figure 1 for details. Place the bands approximately 190-200mm from the edge of the end can. See figure 2 for details.
Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount
the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G.
Attach the supplied springs to fasten the end can to the S-bend pipe. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. Carefully align the two stainless bands K so that they are parallel to each other, and spaced prope rly on the can (refer to step 7 / figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system

Honda VT1100C Shadow, Aero, Sabre SPECIFIC-FIT SADDLEBAGS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-04-2011

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The saddlebag supports are hinged 3 so they can adjust to any variance in your motorcycle’s fender strut bolt locations. The supports have a one-inch offset 4 that angles the supports outward so they space the bags away from the motorcycle’s chassis components, wheels, brakes, and moving parts. Before removing or changing any hardware, hold the supports next to the motorcycle to familiarize yourself with how they will be installed. Remove the original fender mounting bolts from one side of the fender strut and temporarily mount one support with a 10mm bolt, a plastic and steel spacer, and two washers into the front fender stay bolt hole. Then insert an 8mm bolt, a plastic and steel spacer, and two washers into the rear fender stay bolt hole. Verify that each bolt is the proper length. IMPORTANT: The VT1100 Shadow Classic, Aero, or Sabre models have 10mm (front) and 8mm (rear) threaded holes in the fender strut. Use care to not insert the wrong size mounting bolt in the strut. When installing a bolt into the fender strut, check to be sure that it does not extend inside the fender further than the original fasteners. If it does, the excess length of the bolt must be cut off, or exchanged for a shorter bolt you obtain from the hardware store or a motorcycle shop. After verifying the mounting bolts are the proper length, remove the support from the motorcycle’s fender strut. Install a grommet in each of the large holes 5 on the back side of each saddlebag. Then insert a plastic spacer 6 in each of the grommets TIP: Use soapy water to lubricate the grommets so they will slip into the holes in the bag. The vehicle images in this instruction set may be different than your motorcycle. Continued on next page… 3 Lay a support 7 (with the joint towards the rear of the bag) on the back of a bag. Temporarily put the mounting bolts 8 through the support’s holes and into the plas- tic spacers in the grommets. Place one of the support clips 9 over the center of the lower portion of the support, so the two holes in the clip align with the predrilled holes in the bag. Use the 3/16” screws and nuts from the hardware kit to attach the support clip to the backup plate inside the bag. Place the nuts on the outside of the bag. Do not over- tighten the hardware, as this may cause damage to the saddlebag. Remove the mounting bolts from the support and the plastic spacers

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HARLEY DAVIDSON SOFTAIL 6 SPEED TRANSMISSION – COMPLETE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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Removal of Original Transmission 1. Position motorcycle on a suitable lift. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) 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. (00049a) 2. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 3. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps. 4. Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 5. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly. 6. Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. 7. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation. 8. Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch. 9. Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. 10. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. 11. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. 12. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. 13. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation

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HARLEY DAVIDSON DYNA BATTERY COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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INSTALLATION 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) 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. (00049a) 2. Disconnect battery cables, negative cable first. 3. Follow instructions in applicable Service Manual to loosen and lower battery tray. 4. Remove top and side covers and discard. 5. See Figure 1. Install cover from kit as follows: a. Align bottom of cover with tray (2) making sure that three clips on bottom properly seat (center) on both sides of retaining lip (6) at the base of the battery tray. b. Position top of cover (5) under the frame tube. 6. Raise tray and cover following instructions in Service Manual and tighten bolts (3,4) securely. 5 3 2 1 4 6 is 01648 1. Battery 2. Battery tray 3. Upper mounting bolt 4. Lower mounting bolt 5. Battery cover 6. Retaining lip Figure 1. Battery Cover and Mounting Hardware 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) 7. Connect battery cables, positive cable first. 8. Install seat

HARLEY DAVIDSON VRSC REAR AXLE COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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This kit fits 2002 and later VRSC model motorcycles. Kit Contents There are no Service Parts available with this kit. INSTALLATION 1. Using a suitable lift, support the vehicle beneath the frame until the rear tire is just slightly off the ground. 2. See Figure 1. Remove the right side upper shock mounting bolt (2) and spacer (4). Retain the shock mounting nut (not shown) which passes through the fender support and side rail assembly. 3. Pivot the shock towards the vertical position. 4. Remove the left side lower shock mounting bolt (1) and washer (5). 5. Pivot the shock towards the horizontal position. 6. Insure that the shocks are clear of all components and carefully lower the vehicle to provide access to the right side lower shock bolt. 7. Support the right shock and remove the lower shock mounting bolt (1), washer (5) and nut (6). 8. Position the right side cover provided in the kit over the swingarm 9. Reposition the right side shock and re-install the lower shock mounting bolt (1) and washer (5) by inserting through the shock, cover and swingarm. Thread into nut (6) and tighten to 41-68 Nm (30-50 ft-lbs)

HARLEY DAVIDSON LOW REAR SHOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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See Figure 3 and Table 1. INSTALLATION Shock Absorbers 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) NOTES This procedure requires that both shocks be removed prior to installing the new shock absorbers. You need to place the motorcycle on a center stand with the rear wheel raised off of the ground. The jiffy stand should be able to move through its full range of travel. The exhaust system may interfere when removing and installing the lower right shock mounting hardware. If necessary, see Service Manual and remove the rear exhaust pipe. 2 4 5 7 1 6 3 is05206 1. Lower screw 2. Upper screw 3. Lower washer 4. Upper washer 5. Cover 6. Nut 7. Shock absorber Figure 1. Remove / Install Shock Absorber 1. Block the motorcycle under the frame so that the motorcycle is securely resting upright, the jiffystand may be moved through its full range of travel, and rear wheel is just off the ground. 2. Remove the lower shock mounting screw (1), washer (3) and nut (6) from the shock absorber (7). Save the hardware for reuse. 3. Remove the upper bolt (2), washer (4) and cover (5) and remove the shock absorber. Save the hardware for reuse. 4. Repeat Steps 1 and 2 for opposite side and save the hardware. 5. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the lower mounting bolt, then install bolt, lower washer and nut to the shock. 6. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the upper mounting bolt, then install the shock cover, upper mounting bolt and washer to the shock. Verify the cutout in shock cover locates properly

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HARLEY DAVIDSON FXDWG ENGINE GUARD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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FXDWG ENGINE GUARD KIT General This kit is designed for installation on 1993 and later FXDWG Dyna Wide Glide. QTY DESCRIPTION 1 Engine guard 2 U-Bolt 4 Locknut 1 Bolt, 3/8-16 x 7/8 in. 1 Lockwasher, 3/8 in. 1 WARNING This engine guard may provide limited leg and cosmetic vehicle protection under unique circumstances (fall over while stopped, very low speed slide). However, it is neither designed nor intended to provide protection from bodily injury in a collision with a vehicle or any other object. Installation 1. Lift engine guard into place. Align top center mount of guard with frame crosspiece member between frame downtubes. 2. Secure top center mount to frame crosspiece member using 3/8-16 x 7/8 in. bolt and lockwasher included in kit. Do not fully tighten at this time. 3. On right side of motorcycle, install U-bolt from kit around the frame member and into the holes in the lower mounting bracket. Secure loosely into place using two locknuts from kit. 1 CAUTION Left U-bolt must be installed between the frame and the clutch cable. Do not pinch clutch cable between the U- bolt and the frame. 4. On left side of motorcycle, install remaining U-bolt from kit around the left frame member and into holes in lower mounting bracket. Secure loosely into place using two locknuts from kit. 5. Tighten upper mounting bolt installed in step 2, to 30-33 ft-lbs. Alternately tighten U-bolt hardware to 25 ft-lbs. Tighten left and right side U-bolts evenly, so that approximately the same length of bolt protrudes from end of nut

HARLEY DAVIDSON CHROME IGNITION SWITCH COVER INSTALLATION MANUAL

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

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This Chrome Igition Switch Cover fits all 2004 and later XL (Sportster®) model motorcycles. It is a direct replacement for the original equipment (OE) switch cover. NOTE There are no Service Parts available with this kit. Installation 1. See Figure 1. Remove the ignition switch face nut (3). NOTE To avoid damaging the fuel tank finish, lift the front of the tank to provide clearance for removing and installing the screw. 2. Remove the front mounting bolt on the fuel tank. 3. Remove the ignition cover mounting screw, then remove and discard the original ignition switch cover. 4. Place the chrome ignition switch cover in position, and install the original mounting screw. Tighten the screw to 3-7 ft-lbs (4-9 Nm). 5. Reinstall the front fuel-tank mounting bolt. Tighten the bolt to 8-16 ft-lbs (11-22 Nm). 6. Install the face nut to secure the switch to the cover, and tighten securely. ® Kit Number 71527-04 Figure 1. Ignition Switch Cover Installation

HARLEY DAVIDSON FLSTN SADDLEBAG GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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REMOVAL All Models 1. If equipped with saddlebags, removal may ease installation. Follow the instructions in the appropriate Service Manual or Instruction Sheet. 2. See Figure 1. Remove and discard the forwardmost fender support bolt (1). Repeat for the other side. 3. See Figure 2. On the left side, remove the footrest support mounting bolt (1) and footrest support bracket assembly (2). Discard the mounting bolt. 2005 – 2006 Models 1. Loosen the exhaust shields as necessary following the instructions in the appropriate Service Manual. Move as necessary for access. 2. Loosen the exhaust header nuts following the instructions in the appropriate Service Manual. 3. See Figure 3. Remove bolt (1) connecting the exhaust system (2) to the support bracket (3). 4. See Figure 4. Remove the two rear muffler bracket bolts (1). 5. See Figure 5. Move mufflers enough to access the rear bolt attaching the exhaust mounting bracket to the frame. Remove bolt (1) and discard. 2007 – Later Models NOTE On 2007 – later models, the frame tab (4) has a plug instead of a bolt (see Figure 6, item 1). 1. Remove plug and discard. 1 is05313 1. Fender support bolt (discard) Figure 1. Remove Docking Hardware 1 2 is05320 1. Footrest support mounting bolt 2. Footrest support bracket assembly Figure 2. Footrest Support Bracket Assembl NSTALLATION Right Side See Figure 5 or Figure 6. 1. See Figure 7. Install upper screw (7) in the fender support. Tighten screw finger-tight. 2. Install the lower screw (4 or 5) with the saddlebag guard, washer (9) and locknut (6) inside the frame. Tighten screw finger-tight. 3. Tighten the upper screw to 30 ft-lbs (41 Nm) . 4. Tighten the lower screw to 40 ft-lbs (54 Nm) . Tighten nut to 30 ft-lbs (41 Nm) . 5. 2005 – 2006 Models: a. Loosely install the exhaust header bolts. b. See Figure 4. Loosely install two rear muffler bracket bolts (1). c. See Figure 3. Loosely install bolt securing exhaust system (2) to support bracket (3). d. Tighten exhaust header bolts following the instructions in the appropriate Service Manual. e. Tighten support bracket bolt and rear muffler bracket bolts following the instructions in the appropriate Service Manual. f. Tighten exhaust shields following the instructions in the appropriate Service Manual. 6. Install saddlebag (if removed) following the instructions in the appropriate Service Manual or Instruction Sheet. 1 2 3 4 is05333 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Exhaust support bracket Figure 5. Install Saddlebag Guard – Right Side Shown (2005 Models) -J04645 2 of 4
2 1 3 4 is05332 1. Lower saddlebag guard screw 2. Upper saddlebag guard screw 3. Saddlebag guard 4. Frame tab Figure 6. Install Saddlebag Guard – Right Side Shown (2007-Later Models) Left Side 1. Loosely install upper screw (7) through the saddlebag guard and the fender support. NOTE Spacer (8) must be installed with the chamfer facing out. 2. See Figure 7. For 2005-2006 Models: Install lower screw (3) through the saddlebag guard, saddlebag guard spacer (8), footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . For 2007 and later Models: Install lower screw (10) through the saddlebag guard, footpeg support and the frame. Tighten to 30 ft-lbs (41 Nm) . 3. Tighten upper screw to 30 ft-lbs (41 Nm)

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