EVO 3-Phase Charging System Installation And Owner's Manual

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Filed Under (Tips and Review) by admin on 19-11-2010

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install rotor onto sprocket shaft and seat against rotor spacer 9. Install the compensator extension shaft on the sprocket shaft 10. Using your motorcycle’s specific repair manual instructions, check for proper chain alignment. Use OEM-specified shims to bring chain alignment into specification if required. 11. Using your motorcycle’s specific repair manual instructions, install the primary drive and clutch. Assure that all driveline components line up correctly. 12. Apply Loctite Threadlocker #262 (“red”) to the threads of the sprocket nut (also supplied with compensator shaft extension kit). Tighten sprocket nut to 150-165 ft-lbs (203.4-223.7 Nm). 13. Using your motorcycle’s specific repair manual instructions, install the primary cover. 14. Connect the negative battery cable. 2.3 Factory Regulator Removal 1. Disconnect the negative battery cable. 2. Using your motorcycle’s specific repair manual instructions, remove the regulator. Save the factory-supplied hardware. 2.4 3-Phase Regulator Installation 1. Connect the 3-pin stator connector to the regulator. 2. Using the factory-supplied hardware, locate the 3-phase regulator on the mounting bracket and install using the factory-supplied hardware. Tighten to 50-80 in-lbs. 3. Attach the ground wire between the bracket mounting bolt and the bracket. Tighten to 70-100 in-lbs. 4. Trial-fit the long power wire to the motorcycle, and route to the original location of the factory regulator wire on the circuit breaker. 5. Trim any excess wire, and strip 5/16″ of insulation from the end of the wire using a wire stripper. 6. Slip the 1″ length of heat shrink (supplied) onto the wire. 7. Crimp on the (supplied) ring lug to the end of the wire, taking care that a good crimp connection is made.

YAMAHA XVS11A, XVS11AT, XVS11, XVS65A, XVS65AT, XVS65, and XV250 FACTORY MODIFICATION CAMPAIGN

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Filed Under (Yamaha) by admin on 19-11-2010

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INITIAL STEPS FOR ALL MODELS 1. Remove the passenger seat mounting bolt or nut, and then remove the passenger seat. 2. Unscrew the two mounting bolts for the passenger-seat bracket, and then remove the seat mounting bracket from the passenger seat. Save the two mounting bolts and washers for reuse. Hold the original bracket for 90 days with a Warranty Parts Tag. 3. Install the new seat bracket from the kit using the original bolts and washers. The new bracket has a larger hole for the grommet. PASSENGER SEAT BOLTS WITH WASHERS ORIGINAL SEAT MOUNTING BRACKET NEW SEAT BRACKET TORQUE: 8Nm (0.8kg-m, 5.8 ft-lb) ORIGINAL BOLTS WITH WASHERS
PAGE 4 of 15 4. Install the new grommet from the kit in the bracket hole. Continue to the appropriate instructions for the model being modified. XVS11A (V STAR 1100 CLASSIC), XVS11AT (V STAR 1100 SILVERADO), XVS65A (V STAR CLASSIC), and XVS65AT (V STAR SILVERADO) KIT PART NUMBER: 90891-20100-00 First complete the “Initial Steps For All Models” shown above to remove the passenger seat to install the new seat bracket and grommet. 1. Insert the new collar from the kit in the grom- met. 2. Hold the stud bolt from the kit at the unthreaded portion. Screw the cap nut onto the end of the stud with the longer threads until the exposed stud is 19mm long. • The cap nut is a self-locking type. The assembled stud length is important to allow the locking tab in the cap nut to be properly engaged. •Be sure the cap nut is installed on the end of the stud with the longer threaded por- tion. 3. Be sure the painted area around the stud hole is clean, then remove the backing and apply the new protective seal from the kit to the rea

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2009 BMW R1300S Slip-On Exhaust System Installation Instructions

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Filed Under (BMW) by admin on 09-11-2010

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift. 2. Remove heat shield. 3. Loosen muffler joint clamp. 4. Remove muffler mounting bolt. 5. Install TBR slip-on tube to TBR muffler using the supplied socket head cap screws, lockwashers and X-Ring provided. Leave loose for now. 6. Slide rubber lined muffler clamp over TBR muffler. 7. Install TBR muffler assembly to motorcycle using the OEM hardware. Leave loose for now. 8. Align muffler and tighten muffler joint clamp. 9. Tighten X-Ring bolts in a cross pattern. 10. Tighten muffler mounting strap. 11. Remove clip-nuts from OEM muffler assembly and install on TBR slip-tube. 12. Re-install OEM heat shield. 13. Double check to make sure that all hardware is tightened.Carefully double check your work to insure that all hardware is securely fastened. If you are using bags on motorcycle make sure you have adaquate clearance between muffler and bags to keep from causing damage, this is not covered under warranty. 14. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Also, remove any protective plastic from the name badges on the muffler canister(s) or the muffler clamp(s). Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/ manufacturing oil from inside the pipe burning off. After 50 to 100 miles, recheck all fasteners for tightness. 2009 BMW R1300S Slip-On Exhaust System Part # 005-2650406V / 005-2650407V / 005-2650408V Parts List IMPORTANT – PLEASE READ CAREFULLY Warranty two brothers racing products are intended for closed course competition purposes only, and therefore are sold “as is” without warranty. two brothers racing specifically disclaims any warranties of merchantability or fitness for a particular purpose and disclaims all responsibility for consequential and incidental damages or any other losses arising from the use of these products or parts.

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Yamaha Road Star Motorcycles Trike Conversion Removal And Installation Manual

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Filed Under (Yamaha) by admin on 09-11-2010

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. c. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for re-installation after modification are noted. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model. nstallation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster plates. Figure 3 Qty per Assm Spec Description 2 M10 x 1.25 x 70 Hex Head Bolt 2 M10 x 1.25 Hex Nut b. Install adjuster plates to rear drive pinch blocks. Hardware installs from inboard to outboard side. Snug, but do not tighten hardware at this time. Figure 4

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Kawasaki ZX-9R Ninja Installation Instructions

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

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1. Remove the lower fairing. Remove thelower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1 (blue), 2 (red), 3 (yellow), and 4 (green) by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. 2000 through 2002 models ONLY!!! Place a billet aluminum exhaust port centering flange Z on each TiForce headpipe -see figure 3 for details. 6. Attachthe assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the headpipes fit flush and snug in the ports and centering flanges Z before tightening (’00-’02 ONLY). 7. Install the S-Bend to the front section of the headpipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications -make sure the headpipes and flanges Z are centered in each port (’00-’02 ONLY!!! ) . 9. Slide the TiForce end can into place. 10. 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. 11. Place the bands approximately 108 mm from the edge of the end can. See figure 2. 12. 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. 13. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 15. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 /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 CAUTIONWHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 16. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 17. Go back and reinstall the radiator and oil cooler as per factory specifications. Verify fluid levels as needed. 18. Checkthat all hardware is properly tightened, then start the motor and check for exhaust leaks. 19. Reinstall the fairing and tighten any fasteners per factory specification

2006 TRIUMPH SPEED TRIPLE ALUMINUM, CARBON FIBER, SLIP-ON EXHAUST SYSTEM INSTALLATION

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Filed Under (Triumph) by admin on 30-10-2010

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1) Place the motorcycle in a vise or on it’s stand and make sure it is safe and secure. 2) Remove the right side muffler heat shield. Loosen the right side muffler inlet clamp. Remove and retain the muffler mounting bolt and nut. Remove the right side muffler from the motorcycle. 3) If the gasket remained on the stock muffler inlet tube, remove it and inspect. Replace if necessary and then install onto the Jardine muffler inlet tube. 4) Slide the Jardine muffler into the stock s-bend outlet. 5) Attach the rubber strip to the inside of one supplied muffler clamp. Slide the muffler clamp over the muffler withe the offset facing inward. Squeeze both muffler clamp tabs together and secure it to the muffler mounting bracket using the original bolt and nut. Do not fully tighten yet. 6) Adjust the muffler so it is straight and fully tighten the t-bolt clamp, then the muffler clamp hardware. 7) Repeat steps #2-6 for the left side muffler. 8) Clean all fingerprints from the muffler. Start the motorcycle and check for any exhaust leaks. Ratchet 12mm Socket 12mm Wrench Spring Tool or Needlenose Pliers 2 – Mufflers (Left & Right) 2 – Muffler Clamps 2 – Rubber Strips SLIP-ON EXHAUST SYSTEM TRIUMPH SPEED TRIPLE 2006 18-7008-123-02 ALUMINUM 18-7008-323-02 CARBON FIBER PERFORMANCE DELIVERED! All Jardine products are warranted against defective materials and workmanship for a period of 90 days from date of original consumer purchase. Any non-defective item may be returned within 7 working days, and will be subject to a 20% restocking/repackaging fee. WHATIS WARRANTED: Any Jardine product returned, with prior approval, for defective materials or workmanship including chrome blistering, peeling, bubbling, or any unused (new) Jardine product with rust damage

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2004-2006 Suzuki RM-Z250 Kickstand Installation Instructions

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

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To install your new kickstand: 1. Remove the lower chain roller nut, leave the factory washer installed. Install the included threaded chain roller spacer on the chain roller stud, and tighten. (DO NOT OVER TIGHTEN!) 2. Remove the sub-frame to main-frame mounting bolt. Install the provided subframe bolt spacer into the subframe bolt hole. 3. Install kickstand on the bike using the provided M8X 30mm flat head bolt, in the upper mounting hole. Install the supplied M6X 16mm socket head bolt, in the bottom mounting location. 4. Make sure that you tighten all bolts to the correct torque. 5. Periodically check the kickstand pivot bolt for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride. We recommend using a penetrating lube, such as WD-40. If necessary, you can remove the back cover plate for additional cleaning.

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2004-2005 Kawasaki KX250F Kickstand Installation Instructions

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

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1. Remove the lower chain roller nut, leave the factory washer installed. Install the included threaded chain roller spacer on the chain roller stud, and tighten. (DO NOT OVER TIGHTEN!) 2. Remove the sub-frame to main-frame mounting bolt. Install the provided subframe bolt spacer into the subframe bolt hole. 3. Install kickstand on the bike using the provided M8X 30mm flat head bolt, in the upper mounting hole. Install the supplied M6X 16mm socket head bolt, in the bottom mounting location. 4. Make sure that you tighten all bolts to the correct torque. 5. Periodically check the kickstand pivot bolt for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride. We recommend using a penetrating lube, such as WD-40. If necessary, you can remove the back cover plate for additional cleaning.

KAWASAKI ZX-10R Carbon Fiber/ Aluminum Slip-On System Installation Manual

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

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After bike is cool make sure the bike is secured before beginning the installation. 2 Remove the rear exhaust heat shield/cover from the OEM muffler. Remove the side fairing covers on both sides of the bike (this will allow you access to the seat bolts). Remove the rider seat. 3 Remove the exhaust valve cables located under the seat. Keep the servo motor plugged in (do not unplug the server motor). See figure 2. 4 Unbolt the rear foot peg muffler mount, loosen the assembly mount (header collector clamp) and unbolt the exhaust mounting bolt (figure 3). Remove the stock muffler assembly with the exhaust valve cables. Re-install the seat, seat bolts, and side fairings. 5 Apply a small amount of high temperature silicone (such as Permatex Ultra Black) to the inside of the exhaust inlet. 6 Attach the LOR exhaust canister to the slip-on tube adapter with the spring tabs aligned (make sure your hands are protected with a pair of gloves in case the tubes slip). You may have to squeeze the mid-pipe adapter tube to fit into the exhaust inlet as the mandrel bends may become slightly out of round due to a cut near the bend (the tube will take form once connected). Slide the canister all the way until the slip-on adapter seats fully against the exhaust inlet. Wipe off any excess silicone. 7 Place each spring over the exhaust side spring tabs and use the spring tool to pull the springs over the adapter spring tabs. Both springs must be secured for proper installation. 8 Apply a small amount of silicone sealer (such as permatex Ultra Black or Ultra Copper) to the inside (inlet side) of the slip-on adapter. Slide the low profile barrel clamp over the LevelOne Adapter pipe. Slide the slip-on adapter pipe over the stock header collector. Do not fully tighten the barrel clamp

Kawasaki Z1000 Frame Sliders Installation instructions

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

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1. Apply tape to the body panel area, around the bolt, for extra protection during install process, for paint protection. 2. Remove OEM right side mounting bolt using socket; hold nut going through LEFT side. Re-use OEM M10 locknut. 3. With plastic slider removed, install special aluminum bushing and torque to 45 to 62 pounds. 4. Install 1.75 inch dia. plastic slider over special aluminum bushing and install M12 washer and M10 bolt. Note: use thread lock (loctite) on M10 bolt to secure plastic slider. 5. Repeat steps 1, 2, 3 & 4 above for the left side.