KAWASAKI 1500 9408 PRO HYPERCHARGER INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 26-04-2012

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STEP 1 Remove the seat STEP 2 Disconnect the battery positive cable to prevent sparking that could cause ignition of spilled fuel, and personal injury. STEP 3 Remove the fuel tank. IMPORTANT- Throughout this installation, we strongly recommend labeling all hoses, and the nipples they were removed from. STEP 4 Remove the intake ductwork, air inlet, right and left air cleaner housings, air cleaner, cold start components (see PIC. 1), air mass sensor, and support bracketry. The wires that were unplugged from the cold start solenoids, may be neatly bundled and tucked out of harms way and out of sight. Be sure the terminals are insulated so they cannot short to any surrounding parts. Insert plugs (3/8″ x 1/2″ socket head bolts work well) into the two hoses that connected to the cold start circuit lines. (See PIC.2.) Also unplug the crankcase breather hose from the right angle fitting at the bottom of this enclosure, and the large diameter hose from the fresh air injection valve. (Don’t forget to label.) The fuel drain hose will not be re-used. PIC.3 shows what you’ll have left when all components are removed. STEP 5 From the hardware kit, find the front and rear support tabs and the four M6 x 1.0 x 16mm socket head cap screws. Install the support tabs to the threaded holes in each cylinder, and to the holes in the throttle body as shown in PIC.4. STEP 6 From the hardware kit, find the M6 x 1.0 x 16mm hex bolt and lock tab washer. Also find the intake gasket (oval shape with two large holes) and the manifold adapter body. See PIC.5. Screw the air temperature sensor into the back of the manifold adapter body. Place the intake gasket over the mouth of the throttle body so all holes line up. Insert the M6 hex bolt through the lock tab washer, and secure the adapter body to the throttle body, again making certain all holes line up perfectly. Tighten the hex bolt, but do not bend the lock tabs yet

Harley-Davidson CHROME HANDLEBAR SWITCH CAP KITS installation and REMOVAL manual

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Open or remove seat according to the instructions in the Service Manual. 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. Disconnect battery cables, negative (-) cable first. 3. Remove left and right-hand switch housing assemblies. Refer to HANDLEBAR SWITCHES in Service Manual. NOTE It is not necessary to disconnect the switch wiring to replace the switch caps. 4. Remove individual switches from switch housing. Refer to SWITCH REPAIR/REPLACEMENT in Service Manual. INSTALLATION Upper Housing Switches 1. For HORN and START switch caps, release torsion spring leg from hole in switch cap tab. Take note of how the spring is installed. The other leg of the spring can remain in the switch bracket hole. 2. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on left side of switch. -J02633 1 of 5 5 2 1 1 3 4 is 01405 1. Switch cap installed correctly 2. Switch cap removal from splined shaft 3. Switch cap removal from pivot pin 4. Switch cap installation onto pivot pin 5. Switch cap installation onto spined shaft Figure 1. Switch Cap Removal and Replacement 3. Pry the switch cap up and away from pivot pin (3) on right side of switch, and remove cap. NOTE Use the clear protective cover film to protect the chrome surface of the switch caps during installation. Remove the film after the installation is complete. 4. See Figure 5. Select proper chrome replacement switch cap from kit. 5. See Figure 1. Place cap onto switch, angling the hole on right side over pivot pin (4) on switch. 6. Carefully press switch cap down onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 7. For HORN and START switch caps, insert torsion spring leg into hole in switch cap tab. 8. Toggle switch back and forth, checking for proper opera- tion. Turn Signal Switches 1. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on switch. 2. Pry the switch cap up and away from pivot pin (3) on switch, and remove cap. 3. Select proper chrome replacement switch cap from kit. Peel a clear protective installation cover from the sheet and place it over the surface of the cap. 4. See Figure 1. Place cap onto switch, angling the hole on top over pivot pin (4) on switch. 5. Carefully press switch cap onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 6. Toggle switch back and forth, checking for proper opera- tion.

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TOYOTA TACOMA BODY LIFT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 22-09-2011

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Disconnect both battery cables. Be sure to disconnect the negative cable first, then the positive cable. Remove
the airbag fuse from the fuse box. 4. Remove the wire loom that runs from under the alternator to the battery from the mounting brackets. One bracket is on top of the frame. The other bracket is on the fender well. The plastic mounting-collar will slide off the bracket by pushing on the tab on the collar. 5. Remove the fuse that controls the air bag system from the fuse box (refer to the owners manual for the exact location). 6. Remove the ground wire that runs from the back of the engine to the top of the firewall. Remove the wire loom from the mounting bracket on the firewall. Remove the bracket from the firewall. Turn the bracket upside down. Insert the mounting bolt through the ground wire removed from the firewall, Then through the bracket. Tighten securely. Reinstall the bolt that mounted the ground wire to the firewall. Tighten the bolt securely. Do not attach the wire loom at this time

HARLEY DAVIDSON POWER LOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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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) 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 the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove seat following the instructions in the appropriate Service Manual. Preparing the Saddlebags for Power Locks 1. Remove saddlebags following the instructions in the appropriate Service Manual. 2. See Figure 1. Remove lid (1) and hinge (2) from sad- dlebag. 3. Remove lock (3) from saddlebag. 4. See Figure 2. Set drill template on hinge surface of the saddlebag aligning the template (5) with hinge mounting holes (7). 5. See Figure 3. Drill 0.344 (11/32) inch diameter hole (1). 6. Place the template on the back of the saddlebag (4) aligning front mounting grommet (2) and forward latch bracket (1). 7. See Figure 4. Drill 0.500-0.515 inch diameter hole (1). 8. Repeat on the other saddlebag. 1 2 3 is04988 1. Saddlebag lid 2. Saddlebag hinge 3. Saddlebag lock Figure 1. Remove Lid, Hinge and Lock from Saddlebag

HARLEY DAVIDSON FLSTC SOFTAIL SADDLEBAG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Additional Fitment Information Detachables NOTE If motorcycle has not been altered from fixed saddlebag hardware to accessory mounting detachable docking points. the separate purchase of Turn Signal Mounting Bar (Part Number 68611-98) is required for sufficient lock clearance. This kit is available at your Harley-Davidson Dealer. Installing these saddlebags on models equipped with a detachable sissy bar or detachable luggage rack requires the additional purchase of mounting hardware kit as follows: Hardware Kit Fitment 53075-03 2003 and later FLSTC models with detachables 53009-03 1987 through 2002 FLSTC models with detachables See Service Parts Page for kit contents. Additional weight can affect motorcycle stability, handling characteristics, and safe operating speed. Do not exceed 7 lbs. (3.18Kg) maximum load in each saddlebag. Evenly distribute weight between each saddlebag. Improper loading can cause vehicle handling problems leading to death or serious injury. Wide Tire If a wide tire kit has been installed, utilize the hardware and installation instructions found in that kit to reorient the fasteners to come from the inside to the outside of the finder. Button head screws from wide tire kit must be installed from the inside out, with the button heads on the inside of the fender. Failure to do so could result in bolt contacting tire, which could result in death or serious injury. Installation NOTE A Service Manual for your vehicle is available at your Harley-Davidson Dealer. 1. Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect the negative (-) battery cable first. If positive (+) cable should contact ground with the negative (-) cable connected, the resulting sparks may cause a battery explosion which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. 3. Following instructions in applicable Service Manual, remove original saddlebags from supports. Install Turn Signal Mounting Bar If motorcycle is not equipped with accessory mounting detachable docking points, install Turn Signal Mounting Bar (Part No. 68611-98) following instructions provided with the kit. See Figure 1

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HARLEY DAVIDSON NARROW BEACH HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Preparation 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) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Loosen the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a

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 AUXILIARY BRAKE/RUN/TURN SIGNAL CONVERTER KIT INSTALLATION MANUAL

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

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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) 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 the battery cables, negative side first. 2. Remove the seat according to the procedures in the applicable Service Manual. NOTE Federal regulations require that red turn signal lenses need to be a minimum of 4 inches from the tail or stop lamp, edge to edge. In order to ensure this spacing requirement, new directional stand-offs are provided in kit and must be used to replace the original (stock) directional stand-offs. To install the new directional stand-offs, perform the following. 3. See Figure 1. Insert a small screwdriver into middle hole (1) of license plate light cover assembly (2). Push forward to release tail lamp spring clip. -J03679 1 of 4 2 1 is01493 1. Middle hole 2. License plate lamp assembly Figure 1. Removing Tail/Stop Lamp Assembly 4. See Figure 2. Lift tail lamp assembly upward and disconnect tail lamp connector (1). Disconnect left (2) and right (3) turn signal 2-place connectors. 5. See Figure 3. Remove two left side fender support front socket head screws (1). Save hardware for installation. 6. Remove left fender support capscrew (2) (under fender) near end of support and washer (3). Remove capscrew (4) at approximate midpoint of fender support and washer (5). Save hardware for installation. 7. Remove directional lamp screw (6) and washer (7). NOTE Prior to removing turn signal wires, carefully note routing. In particular, pay close attention to the locations of cable straps which must be replaced. 8. Carefully remove fender support (8), turn signal lamp (9) and directional lamp support (10) along with wiring through elongated hole in fender (11). Discard directional lamp support and cap screw. Save turn signal lamp for installa- tion. 9. Perform Steps 5 through 8 for the right fender support and signal lamp assembly. NOTE At this point, the two turn signal pin terminals must be removed from the two-place connector in order to remove the turn signal and directional stand-off from the fender support. The pin terminals will be re-installed to the connector after routing wiring through new directional stand-off and installing stand-off and turn signal to fender support. Follow the instructions under AMP MULTILOCK CONNECTORS in the applicable Service Manual to remove the pin terminals from the two-place con- nector. 10. See Figure 3. Obtain new directional stand-off and cap- screw from kit. Route wiring from turn signal lamp (9) through new directional lamp support (10) and elongated fender support hole (11). Install capscrew (6) through fender support, new directional lamp support then into turn signal. Tighten capscrew securely. 1 3 2 is 01494 1.4-place tail/stop lamp connector 2. Left turn signal 2-place multi-lock connector 3. Right turn signal 2-place multi-lock connector Figure 2. Disconnect Tail Lamp and turn Signal Connectors 11. Perform step 10 for the right side

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

ARLEY DAVIDSON FXDL INSTRUMENT CONSOLE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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Installation CONSOLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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. Remove seat and disconnect battery, negative cable first. 2. Remove fuel tank mounting bolts. Lift fuel tank far enough to remove the speedometer sensor cable from the mounting clips under the tank. 3. See Figure 1. The 3-place speedometer sensor connector is located on the frame beneath the seat. Remove from t-stud and disconnect the connector. Cut the cable strap that holds sensor wires to right rear frame tube. 4. Remove instrument console mounting screws and lift console from tank. SPEEDOMETER REMOVAL 1. See Figure 2. Disconnect 8-place connector under console. Remove assembly from tank. 2. Cut remaining cable straps holding wires to instrument mounting bracket. Remove screws holding bracket to back of instruments. Remove bracket. 3. See Figure 3. Remove nuts and washers from terminal studs (1, 2 and 3). Remove wires from studs. 4. Unscrew the rubber function switch cover that protrudes from the left side of the console. Remove the function switch (3). 5. Gently push on bottom of speedometer and remove speedometer from top side of console. Remove gasket from speedometer. TACHOMETER REMOVAL 1. See Figure 3. Remove nuts and washers from terminal studs (3, 4 and 5). Remove wires from studs. 1 WARNING 1 WARNING