Filed Under (Kawasaki) by admin on 08-05-2012
1. Remove mid and lower body panels Left and Right. There is a small plastic cover that is mounted over the main engine stud location on the left side. This cover requires a small notch to be cut out of the cover to clear the small end of the left side offset. Remove stock stud and mount the left side offset (with 10 X 1.25 X 60). Using a pencil, trace out the notch that you need to remove to clear the small end of the offset. We used a Dremel tool with a sanding roll and cleaned it up with an exacto knife. We removed a small amount of material at a time checking for clearance each time. The notch will not be visible after the body has been mounted. See photos below: 2. Once you have notched the small left side panel, mount the left side offset but only hand tight. You need to be able to move the offset by hand to its proper location. 3. Mount the left side bodywork and align the offset to the opening in the body. Mount the left side slider on the offset to ensure correct location. There is a flat notch in the slider so the body will clear. Remove the slider and body and torque down the offset to OEM specifications. (see above)
4. Mount the left side panel. Install the slider using one drop of blue thread locker and torque down to 30 to 32 ft lbs.
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Filed Under (Toyota Manuals) by admin on 26-09-2011
Jack up rear of vehicle or raise on hoist. Support frame with safety stands. Remove lower shock absorber
attaching bolts. 2. Lower axle or raise body or vehicle until suspension is fully extended. CAUTION: Observe tension on brake line – do not strain. Remove coil springs noting location of the end of the coil spring in the lower spring seat. 3. Using a 3/4” drill enlarge the diameter of the hole in the lower spring seat to 3/4”. Remove all burrs and sharp edges (Figure 2). 4. Using a socket and extension, remove the rubber bump stop from the upper spring seat and discard (Figure 1). 5. Insert air cylinder into coil spring with stem at bottom (Figure 3). 6. Raise the axle or lower the body to install coil spring into spring seats and rotate to proper location. Attach lower shock absorber attaching bolts. Torque to 25 ft. lbs.
Filed Under (Harley Davidson) by admin on 12-04-2011
INSTALLATION 1. See Figure 1. Note position of mounting brackets (1). Remove old mounting brackets and discard. NOTE On 1997-2000 models, the air fittings are installed to the two mounting holes on the right-hand right side bracket. On 2003 and later models, the single air fitting is installed to mounting hole on the left-hand side bracket. 2. See Figure 2. Install new mounting brackets from kit on each side of the motorcycle using new locknuts as follows: a. Use the 5/16-18 x 1 inch screws (5) in the upper two holes with 2 chrome washers (3) placed between the mounting bracket and the saddlebag support at each of the two locations. Install a 5/16-18 flange locknut (2) behind the screw that does not screw into a weld nut. Tighten to 15-19 ft-lbs (20-26 Nm). b. On each side, install a 1/4-20 x 7/8 inch screw (9) through the bottom hole of the mounting bracket and the saddlebag bracket as shown, with a chrome washer (3) placed between the mounting bracket and the saddlebag bracket. Tighten to 10-14 ft-lbs (13.5- 19.0 Nm). On 1997-2002 models, install the air line fittings to the lowest two holes drilled in the right side bracket. On 2003 and later models, install the single air line fitting to the lower front hole drilled on the left side bracket. c. See Figure 2. On each side, attach docking points (6) in their proper location on mounting bracket with 3/8- 16 x 1-1/2 in. buttonhead screws (7), washers (3) and locknuts (8) but leave locknuts slightly loose so docking points can be adjusted for proper fit. On 1997and later models, the docking point will attach through the front hole of the mounting bracket as shown. On 1994-1996 models, the docking point will attach through the rear hole of the mounting bracket. d. Place detachable passenger backrest into docking points as described in the Backrest Instruction Sheet. Make sure that the forward notches of the sideplates are pushed completely into the forward docking points, then tighten the rear docking points securely to 45-47 ft/lbs (61.0-64.0 Nm
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Filed Under (Harley Davidson) by admin on 07-02-2011
INSTALLATION 1. Remove the rubber mat from the bottom of the Tour-Pak. 2. See Figure 1 and Table 1 to determine the proper hole configuration to attach the Tour-Pak to your luggage rack. Holes will be drilled as explained in Step 3 in the hole location for your luggage rack. Table 1. Luggage Rack and Hole Configurations Hole Configura- tion Luggage Rack C (3 holes) Stock 1997 B (4 holes) Detachable luggage rack 53107-96 A (5 holes) Luggage rack 53118-97A and luggage rack 53118-98 A (5 holes) Stock 1998 and later racks A (5 holes) Detachable Tour-Pak rack 53276-04 B (4 holes) Solo detachable Tour-Pak rack 53655-04 B (4 holes) Detachable Tour-Pak rack 53066-00B B (4 holes) Solo detachable Tour-Pak rack 53559-04A A (5 holes) Solo detachable Tour-Pak rack 53260-02 -J03631 1 of 3 B 1 A C 2 2 2 is00163 1. Front of motorcycle 2. Bottom view of Tour-Pak interior (rubber mat removed) Figure 1. Hole configurations for Tour-Pak attachment NOTE Drilling holes in Tour-Pak without wood underneath each hole site may result in the leather becoming damaged during the drilling process. 3. Place blocks of wood underneath the Tour-Pak where the holes will be drilled to prevent damage to the leather while drilling. Use the pre-drilled holes in the metal base as a guide and carefully drill the holes through the leather in the proper location using a 11/32 inch drill bit. 4. See Figure 2. For detachable luggage racks (53107- 96, 53066-00B and 53276-04): Install black cover tube to the front bar (1) of the luggage rack, as shown. This tube is used to provide a cleaner look. The black cover tube is not for use with other luggage racks. 5. Attach Tour-Pak to rack using the mounting screws provided in the Luggage Rack kit. Put bolt through from inside of Tour-Pak. Tighten screws to specifications found in the Luggage Rack kit. 6. Place the black rubber mat on the bottom of the Tour-Pak. 7. If luggage rack was removed, reattach to motorcycle according to kit instructions or Service Manual instructions
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Filed Under (Kawasaki) by admin on 25-10-2010
before starting to perform an inspection service or carryout a disassembly and reassembly opera- tionona motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing anew part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if instal- lationorassembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing apart with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in across pattern. Conversely, to remove apart, first loosen all the bolts, nuts, or screws that are retaining the parta 1/4-turn before removing them