HARLEY DAVIDSON REAR SWINGARM AXLE COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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INSTALLATION 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) NOTE XL Sportster 883 and XL1200R models may require loosening or removal of the rear muffler in order to install the right side rear axle cover. See the EXHAUST SYSTEM REMOVAL section of the Service Manual. 1. Support the vehicle, and loosen or remove the rear muffler if necessary. XL Sportster 883 and XL1200R models: Remove the right-side lower shock absorber mounting bolt. Save for re-installation. All other models: Remove and discard the right-side lower shock absorber mounting bolt. 2. Swing the bottom of the shock absorber out of the way. Position the right-side swingarm axle cover (2) over the swingarm and behind the shock absorber. 3. Reposition the shock absorber. XL Sportster 883 and XL1200R models: Install the shock absorber mounting bolt removed in Step 1. All other models: Install the shoulder bolt (3) from the kit. All models: Tighten the bolt to 45-50 ft-lbs (61-68 Nm) . NOTE When torquing the bolt, align two of the bolt-head flats parallel to the ground. This will allow proper orientation of the bar and shield logo on the bolt cover. 4. Position the bolt cover (4) over the bolt head (3) with the Bar-and-Shield logo oriented upright, and lock in place with the set screw (5). Tighten securely. Reposition and tighten the muffler per the Service Manual instructions. 5. Remove and discard the left-side lower shock absorber mounting bolt. Move the bottom of the shock absorber out of the way. Position the left-side swingarm axle cover (2) over the swingarm and behind the shock absorber. 6. Reposition the shock absorber and install the shoulder bolt from the kit. Tighten to 45-50 ft-lbs (61-68 Nm) , aligning two of the bolt head flats parallel to the ground. 7. Position the bolt cover over the bolt head with the Bar-and- Shield logo oriented upright, and lock in place with the set screw. Tighten securely

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Yamaha V-Star 1100 Custom and Classic cruisers Floorboard/ Footpeg Extension Installation Instructions

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

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Start on the right (brake) side. 1) Loosen the nut at the end of the brake rod. This will allow you to unscrew the brake rod from the brake lever clevis later. 2) Pull out the cotter pin and remove the pivot pin. Unscrew the clevis 3) Then using a 14mm socket or box-end wrench, remove the two bolts that hold the brake floorboard/footpeg assembly (whichever your bike has) to the frame. These bolts are torqued to 46 ft lbs, so this may be a bit difficult. 1. Loosen this nut 2. Remove the cotter pin (other side of this pivot pin) remove the pivot pin a unscrew the nut to remove the clevis nd 3. Remove these bolts When you remove the floorboard/footpeg bracket, be careful not to pull the brake switch wires loose. You may wish to cut the cable tie for more room, and then rest the bracket, with the footpeg or floorboard attached, on a short box, or block of wood, to keep it handy. Install the new brake rod, to the end of the existing brake rod. Re-install the pivot pin, and the pivot pin cotter pin. Installing the extension bar: Note that the extension bar is bolted so that it rises up in front. Use the new bolts to mount the floorboard/ footpeg bracket to the threaded holes in front. Install the Extension in the proper orientation (angled holes bolt up to the frame, with front of the bar higher than the rear – see photo) using the stock bolts for the extensions to the frame and the new bolts and washers supplied with the kit, on the forward threaded section to relocate the floorboard or footpeg bracket. The use of LocTite ® Blue here is recommended. At this point the right side Floorboard or Footpeg should be secured tightly and the brake lever hanging loose. Now install the Brake rod extension, threading the male end to the original brake rod. Don’t tighten this end yet Place the clevis over the forward most end of the brake rod extension, and threat the clevis nut onto the end of the rod. Bring the brake rod upright, to meet with the clevis at the end of the brake rod extension and replace the pivot pin. Before reinstalling the cotter pin, check the angle of the brake lever, to insure that you have the brake pedal where you want. If necessary, adjust the extension rod in or out, until you are satisfied, and then reinstall the cotter pin into the pivot pin. Check the Brake switch wire and install a new cable tie if required. Note: Due to utilizing a thicker material, 1/2″ versus 3/8″ from our competitor, the Brake rod is now positioned at a greater angle. Even with the angle, braking performance is not affected, but if you wish to bring the master cylinder in line with the brake rod, do this. Loosen the rear, and remove the front Allen bolt. Then place two washers behind the front bolt, under the bracket, and then re-install the bolts To change the angle of the brake rod, 1) loosen and remove the two master cylinder bracket Allen bolts 2) insert two washers behind the front bolt (front of the bike), behind the master cylinder bracket 3) tighten both bolts. Do not install any washers on the rear mounting hole. This will make the angle of the Brake Rod less aggressive. Step Two – Left Side For the left (Shifter) side, 1) use an open-end 10 mm wrench, to unscrew the two nuts that hold the shift rod in place. PLEASE note that one end of the shift rod has a left hand threaded nut. SAVE the nuts, as you will need them on the new longer Polished Stainless Steel Shift Rod. 2) Remove the stock shift rod. 3) Then using a 14mm socket or box-end wrench, remove the two bolts that hold the shifter floorboard/footpeg assembly (whichever your bike has) to the frame.

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