Kawasaki Teryx Electric Steering Installation Manual

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Filed Under (Kawasaki) by admin on 29-04-2012

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installation Instructions for Kawasaki Teryx 1. Before installation, center steering wheel and verify tires are straight. 2. Begin by removing all Phillips screws retaining the plastic hood to the front grill, headlights, and frame structure and remove front clip assembly. 3. Remove plastic shroud by removing the 4 phillips screws that retain it to the frame. 4. There are 2 bolts that hold the steering column tube in place and you need to reach up under frame work to get to them. They are 14 mm and you need a box and open end wrench to access them. Loosen the upper one and remove the lower one. Remove the pinch bolt at the column shaft and u-joint. Remove the lower pinch bolt at the rack and u-joint and while tilting the column up and down remove the stock steering shaft.
5. Once the shaft is removed, you are ready for installation. Your bracket and motor has come completely assembled as shown below. You will need to remove the lower shaft from the motor to install it. After removal of the shaft you will need to loosen the 3 mounting bolts from the bracket to the motor to allow clearance for the bracket to slide over the frame piece where it will mount

Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 14-12-2011

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Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

HARLEY DAVIDSON HIGH INTENSITY DISCHARGE (HID) DUAL BULB HEADLAMP KIT INSTALLATION MANUAL

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

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REMOVAL 1. Remove seat according to the instructions in the service manual. 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. 2003-Earlier Models: Disconnect battery cables, negative (-) cable first. Refer to the service manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 3. 2004-Later Models: a. Remove left saddlebag. Refer to the service manual. b. Remove left side cover and main fuse. Refer to the service manual. 4. Remove fuel tank according to the instructions in the service manual. 5. See Figure 1. Remove the Phillips screw (1) at the bottom of the bezel and remove the bezel. Save parts for installa- tion. 1 2 is03916 1. Phillips screw 2. Bezel Figure 1. Remove Bezel 6. See Figure 2. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle. 7. Gently pull headlamp assembly out far enough to disconnect wiring. Save short wire harness for installation. 8. Remove wire connector at the back of the headlamp bulb. 9. See Figure 2. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation

HARLEY DAVIDSON V-LOGO TURN SIGNAL INDICATOR FORROAD KING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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1. Disconnect battery cables, negative cable first. 2. Following instructions in applicable Service Manual, remove the windshield. 3. Remove the phillips screw at the bottom of the of the headlamp door (chrome ring). Remove the headlamp door. 4. Remove the seven Phillips screws to free the headlamp housing from the headlamp nacelle. 5. Squeeze the two external tabs (if present) to remove the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside. 6. See Figure 1. Reaching inside the headlamp nacelle, remove the speed nut to release the chrome strip at the top of the nacelle. 7. Remove the wire form clip holding the halves of the nacelle together at the bottom. 8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate. 9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove). 10. Loosen the two acorn nuts from the left and right side fork studs. 11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle. 12. Carefully align the template over the handlebar shroud cover and tape into place. 13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means. 14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure. 15. Drill one 1/4″ hole and two 5/32″ holes as indicated on the Drill Template (attached)

HARLEY DAVIDSON CRUISE CONTROL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION NOTE if the motorcycle is equipped with the optional Harley-Davidson Smart Siren, the main fuse MUST be removed BEFORE the alarm is activated. This WILL happen within 5 seconds of turning the ignition switch to the OFF position (except for HD- Japan models). If the main fuse is not removed promptly, the siren WILL SOUND. 1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Remove the outer fairing per the instructions in the service manual. For FLHR models: Follow the instructions in the service manual to remove only the handlebar clamp shroud. Removing the nacelle is not necessary. a. Remove the windshield and headlamp door. Remove the headlamp housing assembly. b. Release the chrome trim strip at the top of the nacelle. c. Remove the two Phillips screws beneath the fork lock plate. d. Loosen the Phillips screw at the front of the handlebar clamp shroud, and the four acorn nuts on the side of the headlamp nacelle. e. Raise the shroud slightly, separate the nacelle halves and slide the shroud forward to remove it from the nacelle. NOTE Before disconnecting the handlebar switch wiring, note the wire routing. 3. For ALL models: Refer to the service manual. Disconnect the right-side handlebar MOLEX socket housing from the black six-way main harness pin housing [22B] inside the fairing or headlamp nacelle

TRIUMPH AMERICA AND SPEEDMASTER FRONT TURN SIGNAL RELOCATORS

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Filed Under (Triumph) by admin on 29-12-2010

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1. Remove the front turn signals as follows. The turn signal wire plugs are located inside the handlebar switch housings. Remove the two Phillips screws located on the forward facing side of the switch housing, remove the covers, unplug the turn signals and reassemble the switch housings. Unbolt the signals from their black mounting brackets, remove the brackets from the bottom side of the switch housings, reinstall the nuts and tighten securely. 2. Disassemble the two halves of the turn signal mounting clamps supplied, place the M6 X 25mm button head screws thru the hole in the side of the clamp from the inside, place the spacers supplied over the screw threads. Screw the clamps and spacers onto the turn signals. Hold the signal/clamp assemblies up to the front fork, position the signals so that the housing/lens seam is vertical and straight, carefully remove the assemblies from the forks and tighten the screws securely. Install the signal/clamps onto the forks, set to the desired height and angle and tighten the clamp screws securely. 3. Using a sharp knife slit the black wire loom from the turn signal plug back 7″. Pull the turn signal wires and plugs out from the loom. Fold the wires along the loom going down towards the headlight. Leave 2-3″ of the wire next to the plug exposed and neatly tape the rest of the wire to the loom and the loom closed back up to the handlebar switch. 4. Connect the signal wires to the plugs from the wire loom. Using the cable ties supplied tie up any loose or unconcealed wire and the plugs.

KAWASAKI VOYAGER AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 27-12-2010

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1. Remove the false fuel tank cover to expose the battery. Remove the right hand lower leg fairing. (4 phillips screws). Unplug the stock horn and remove the (2) 10mm bolts securing it to the frame. 2. See photo #1 using the stock horn bolts attach the black horn mounting bracket and the white ground wire supplied as shown. Next locate the relay supplied. Plug the stock horn wires into the relay terminals #85 & #86. (see wiring diagram on back side of instructions) 3. Attach the air hose to the compressor air outlet fitting. Attach the short red wire supplied to the compressors positive (+) terminal and the white wire installed earlier to the compressors ground (-) terminal. As shown in photo #2. Attach the compressor to the frame with the hose clamp provided. Note: position the top of the compressor as shown touching the bottom of the horn mounting bracket and approximately 1 Ω” to the rear of radiator and shroud. Also the air hose and fitting should be in front of the frame tube with the hose routed inside the hose clamp without pinching the hose. Attach the red wire from the compressor to one of the relays remaining outer terminals #30 or #87. Attach the remaining long red wire (supplied) to the remaining relay terminal #30 or #87. Secure the relay to the frame with a cable tie supplied. Route the red wire up to the battery positive (+) terminal. Locate the fuse wire assembly provided. Attach the fork end of the fuse wire to the battery positive (+) terminal. Cut the red wire to the desired length, strip the end and crimp to the fuse assembly. Turn on the ignition and press the horn button, you should hear the compressor motor run. Re-install the false fuel tank lid. Re-install the right lower leg fairing while routing the air hose out next to the black horn mounting bracket 4. See photo #3, Bolt the horn set to the black mounting bracket using the 5/16 x æ”bolt, washer and lock washer provided. Trim the air hose to length if necessary and attach the air hose to the horn assembly. Install the trumpet covers. (see instructions enclosed with covers) Turn on the ignition and test the horns

RUNE PASSENGER FLOORBOARDS INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 21-12-2010

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1. Remove the seat. Remove the Phillips screws securing the two small black covers on either side of the battery and remove the covers. Next remove the two Phillips screws securing the chrome side covers. Remove the side covers by prying out on the lower front corners with your fingers. Slide the covers to the rear and down to disengage from their rear mounting hooks. Set the covers aside. 2. Beginning on the right side locate the lower sub frame mounting bolt (17mmm wrench size) see (1A) Located behind the sub frame near the head of this bolt you will find a wire clip. Using a blade screwdriver open the clip and push the wires up out of the way. Remove the lower sub frame nut and bolt. Remove the muffler mounting bolt (1B). 3. Locate the right hand mount assembly. Remove the small “L” shaped clamp from the mount. Locate the large (12x 50mm) bolt and two 12mm washers (supplied). Place the bolt thru the hole in the mount. Next place the two washers onto the bolt. Install the assembly onto the frame as shown in photo (2). Reinstall the muffler mounting bolt. It may help to lift on the muffler while trying to get the bolt started). Install the original 12mm flange nut removed earlier onto the new 12mm bolt. Tighten the 12mm bolt and muffler mounting bolts securely (55 ft. lbs. on the 12mm and 12 ft. lbs. on the muffler). Install the “L” clamp as shown in (2A) with the tab facing downward and resting on the muffler mount and tighten securely. Place the wires back into the clip and snap the clip closed