HARLEY-DAVIDSON TOURING TRUE DUAL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-04-2012

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1. Remove both saddlebags and side covers from the motorcycle 2. Remove seat and place it away from the work area; disconnect battery. 3. Cover the primary housing, transmission top, and end cover near the head pipe to prevent damage. 4. Remove the bolt for the passenger floorboard that attaches it to the frame. 5. Remove the right side rider floorboard and support brackets. Loosen muffler clamps; remove the support bolts located at the rear upper portion of the mufflers. Remove mufflers from the head pipes. Unscrew clamps on the factory heat shields, and remove heat shields from the head pipes. 6. Unplug both O² sensors. Cut and remove the ZIPSTRIP that holds the front O² sensor wire to the frame. Loosen clamp on the rear exhaust pipe; remove the left side pipe, while leaving the split pipe in place. 7. Loosen clamp on crossover pipe and remove leaving right side exhaust intact. 8. Remove nuts on the flanges located at the cylinder heads. Remove the right side pipe as one unit. 9. Use snap ring pliers to carefully remove the circlips on each pipe inlet; remove

2009 – Current Harley Davidson Trike Conversion Kit INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-02-2012

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect and REMOVE battery. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Remove and save the Passenger Handrail and two ¼ – 20 flanged hex head nuts if equipped. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove four ¼ – 20 HHCS. 13. Remove Tour Pak from Top Support Tube. 14. Remove both saddlebag support rails. 15. Loosen Muffler Clamps on both Mufflers and remove two 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 16. Remove right side rear heat shield. 17. Remove and discard Muffler Support Plates. 18. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip. 19. Remove four frame cover fasteners and the Left and Right Frame Covers. 20. Remove four Tour Pak Support fasteners and the Tour Pak Support.
7 21. Remove four rear fender fasteners and rear fender. 22. Remove four ½ – 13 HHCS and washers. Remove and discard Rear Air Shocks, Air lines and Air Valve bracket. 23. NOTE: NOTE: NOTE: NOTE: If motorcycle is A.B.S. Equipped refer to A.B.S. Installation Instructions. WARNING: WARNING: WARNING: WARNING: If A.B.S. Equipped DO NOT drain brake fluid. 24. Drain all Brake Fluid from the Rear Brake System. 25. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 26. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 27. Remove the Spring Clip and nut from the Rear Axle. 28. Remove Rear Axle and Rear Wheel Spacers. 29. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 30. Remove Rear Brake Caliper. 31. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate. 32. Remove Rear Wheel Assembly. 33. Remove two 3/8 – 16 SHCS. Remove Passenger Footboards.

BUSHTEC GL1800 STANDARD & DELUXE VERTICAL RECEIVER HITCH SYSTEM Trailer Hitch Installation Instructions

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Filed Under (Honda) by admin on 24-11-2011

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Place the motorcycle on its centerstand on level ground. Remove the four bolts in the seat handles with a 6mm Allen head socket and remove the seat. NOTE: The rubber bushingsinside the seat may fall out during removal; Make sure they are in place upon reassembly.2. Remove both side covers.3. Remove the (5) five bolts in the rear fender (license plate panel, between saddlebags)with a 5mm Allen head socket. Remove the rear fender. NOTE: The fifth bolt is behindthe license plate.4. Remove the (3) three bolts in the passenger floorboard holder cover with a 5mm Allenhead socket. Remove the cover and repeat for other side.5. Remove the (2) bolts in the rear saddlebag guard with a 12mm socket. Remove thesaddlebag guard and repeat for other side 6. Remove the bolt in the muffler hanger using a 12mm socket. Repeat for other side.7. Loosen, but do not remove, the muffler clamps using a 6mm Allen head socket. Rotatethe mufflers down slightly to allow the hitch hoop to slide between the mufflers and the saddlebag

HARLEY DAVIDSON FLSTN MUFFLER SLIP-ON KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-04-2011

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Installation 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. 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) 2. Remove mufflers according to applicable Service Manual instructions. 3. Install clamps onto mufflers and slide onto headpipes. Install muffler with the Harley Davidson script in the top position. 1 WARNING 1 WARNING 1 of 2 4. See Service Parts Illustration: Reuse fasteners and tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm), and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 5. Connect negative battery cable. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

HARLEY DAVIDSON SOFTAIL MUFFLER SLIP-FIT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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1. Disconnect negative battery cable. Perform this installation when the engine is cool. Installing these mufflers when the engine is hot could cause burns which could result in moderate to minor injury. 2. Remove mufflers according to applicable Service Manual instructions. Shotgun exhaust mufflers will come off the vehicle as a pair, attached together. Staggered dual mufflers will come off the vehicle attached to the interconnect tube. 3. For a shotgun exhaust, skip to Step 6. 1 CAUTION 1 WARNING 1 WARNING 1 of 2 4. Remove mufflers from interconnect tube and discard gaskets and mufflers. 5. Install mufflers to interconnect pipe using new gaskets (6) and existing screws. Slip muffler clamps (1) on mufflers and install assembly back on vehicle. Tighten screws to 96-120 in-lbs (10.8-13.6 N-m). Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm). Attach the interconnect tube to the frame using the existing flange lock nuts and washers. Tighten to 30-33 ft-lbs (40.7- 44.7 Nm). 6. On shotgun style assemblies, assemble top and bottom mufflers using interconnect seal. Torque screws to 96-120 in-lbs (61-81.3 Nm). Attach interconnect tube to frame using existing flange locknuts and washers. Torque to 30-33 ft-lbs, (40-7-44.7 Nm). 7. Replace fasteners and tighten as follows: muffler clamps to 45-60 ft-lbs (61-81.3 Nm), flange locknut on carriage bolt to 30-33 ft-lbs (40.7-44.7 Nm) and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 8. Reconnect negative battery cable. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Gabilan Manufacturing, Inc. warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

HARLEY DAVIDSON DYNA STREET PERFORMANCE SLIP-ON ACCESSORY MUFFLERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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PRODUCT INFORMATION Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION 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. 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) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HARLEY DAVIDSON SPORTSTER® ACCESSORY SLIP-ON MUFFLER KITS INSTALLATION MANUAL

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

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INSTALLATION 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) 1. Disconnect negative (-) battery cable. 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) 2. Remove mufflers using appropriate Service Manual instructions. 3. Discard gaskets and mufflers. 4. Install new gaskets on mufflers. 5. Slip muffler clamps on mufflers. 6. Loosely attach mufflers to the interconnect tube using existing screws and washers. 7. Position the ends of the front and rear exhaust pipes into front and rear cylinder heads and align exhaust system while tightening all nuts and bolts; begin at the cylinder head exhaust ports and work back toward the mufflers. a. Finger tighten the upper nuts to the mounting studs. b. Tighten the lower nut to 9-18 in-lbs (1.0-2.1 Nm) . c. Tighten the upper nut to 60-80 in-lbs (6.8-9.0 Nm) . d. Tighten the lower nut to 60-80 in-lbs (6.8-9.0 Nm) . 8. Tighten the acorn nut on the rear exhaust pipe support clamp to 15-19 ft-lbs (20.3-25.8 Nm) . 9. Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm) . 10. Tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm)

HARLEY DAVIDSON SPORTSTER MUFFLER SLIP-ON KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION 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) 1. Disconnect negative (-) battery cable. 2. Remove mufflers using appropriate service manual instructions. 3. Discard gaskets and mufflers. 4. Install new gaskets on mufflers. 5. Slip muffler clamps on mufflers. 6. Loosely attach mufflers to the interconnect tube using existing screws and washers. 7. Position the ends of the front and rear exhaust pipes into front and rear cylinder heads and align exhaust system while tightening all nuts and bolts, beginning at the cylinder head exhaust ports and work back toward the mufflers. a. Finger tighten the upper nuts to the mounting studs. b. Tighten the lower nut to 9-18 in-lbs (1.0-2.1 Nm) . c. Tighten the upper nut to 60-80 in-lbs (6.8-9.0 Nm) . d. Tighten the lower nut to 60-80 in-lbs (6.8-9.0 Nm) . 8. Tighten the acorn nut on the rear exhaust pipe support clamp to 15-19 ft-lbs (20.3-25.8 Nm) . 9. Tighten muffler clamps to 45-60 ft-lbs (61.0-81.3 Nm) . 10. Tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm) . 11. Connect negative (-) battery cable.

HARLEY DAVIDSON SOFTAIL SPRINGER Dual Slip-On Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK MUFFLERS 1. Loosen the bolt on the pinch clamp at the front end of each muffler. 2. Remove the two bolts that mount the muffler to the mounting bar. Repeat this step on the opposite muffler. 3. Remove the stock mufflers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the mufflers from the head pipes. INSTALLING YOUR NEW VANCE & HINES SLIP-ON EXHAUST SYSTEM 1. Remove the two 5/16″ flanged head bolts from the bracket that is welded to the backside of each muffler. Attach one of the mounting brackets (supplied) to each muffler, using two of the 5/16″ flanged head bolts (removed earlier), leaving them loose at this time. When the bracket is mounted correctly on the muffler, the single hole end should point down when the muffler is mounted to the bike. 2. Be sure there is a muffler clamp (supplied) over the front (notched end) of each muffler. 3. Slip the muffler onto the stock head pipe, mount the muffler to the rear most hole of the stock mounting bar, using one of the stock bolts and tighten. Repeat this step on the opposite muffler. Note: When installed correctly, the Vance & Hines logo on the muffler should face outwards. 4. Tighten the two muffler clamps. 5. Tighten the two 5/16″ flange bolts on each muffler bracket. 6. Wipe any finger prints or oil off any chrome parts of the exhaust system before starting the motorcycle. 7. Be sure to tighten all hardware before starting your motorcycle. RE-JETTING INSTRUCTIONS Re-jetting the carburetor will result in realizing the “full” potential of this performance exhaust system. Vance & Hines offers jet kits for most applications

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SUZUKI VZ800 MARAUDER SLIP-ON EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosenthe right hand side footrest assembly. 2. Loosenthe two head pipes at the cylinder head. 3. Loosen the muffler clamps, located on the inlet end of the mufflers. 4. Remove the two nuts that mount the lower muffler to motorcycle. Keep the two mufflers bolted together as an assembly. 5. Lift the muffler assembly up to clear the studs from the mounting holes. Pull the mufflers off the head pipes and set them aside. 6. Remove the two flanged steel spacers from the hole in the rubber cushions, where the stock muffler assembly mounted. Reinstall the steel spacers through the backside of the rubber cushions so the flanged end of the spacers are on the backside of the cushions, opposite of there original position. 7. Remove the rear most heat shields from both of the head pipes and set them aside. 8. Remove the stock exhaust gaskets from the ends of both pipes. The Vance & Hines slip-on does not use a gasket at the slip joint . 9. Install the new muffler mounting bracket (stamped with the # 233 ) to the front side of the two holes with the rubber cushions the two of the 5/16″x 1 1/4″ bolt and two 5/16″ lock nuts (hardware supplied) through the two holes in the bracket that are spaced farthest apart. When mounted correctly, the bracket should bend up and out from the motorcycle

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