HARLEY DAVIDSON FRONT FENDER MEDALLION INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Locate the Medallion For XL, Dyna, and FX Softail (includingFXSTDSE): Front Fender Medallion (Kit No. 91194-04) 1. Center medallion on the fender laterally (side to side). 2. Locate the front tip of the medallion 1 3/8 in. (34.9 mm) back from the fender edge, the pin stripe, or two-tone paint line depending on the paint scheme. For Touring and FL Softail: Front Fender Medallion (Kit No. 91195-04) 1. Center medallion on the fender laterally (side to side). 2. Locate the front tip of the medallion 1 3/4 in. (44.5 mm) back from the fender edge, tip trim, tip light, the pin stripe, or two-tone line depending on accessories, trim and paint scheme. Prepare the Fender NOTE For maximum adhesive bond, the fender under and immediately surrounding the medallion must be clean and dry. 1. Clean the surface with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. 2. Allow fender to dry thoroughly. NOTE To prevent contamination, apply medallion within minutes. Apply the Medallion 1. With the protective film still in place, trial fit the medallion to the fender and adjust location to accommodate pin striping, two-tone paint, fender tips or lights. NOTE Ambient temperature should be 70 to 100°F (21 to 38°C). 2. Remove the protective film. 3. Carefully locate and center the medallion on the fender. 4. Press the medallion firmly into position. Without shifting the medallion on the fender, push hard with thumbs for about five seconds. 5. After releasing pressure, avoid direct contact with the medallion for at least 20 minutes. NOTE Allow ATLEAST 24 hours before exposing the fender to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperatures.

HARLEY DAVIDSON FRONT SPOILER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation NOTE The spoiler in kit number 58882-04BDK is finished with a primer coat. Before installation, have the spoiler painted 1. Mount the motorcycle on a lift table. 2. See the Service Parts illustration. Attach the upper front spoiler bracket (4) to the bosses on the inside front of the spoiler (1) with the two Hi-Lo screws (10) from the kit. Tighten to 15-20 in-lbs (1.7-2.3 Nm). 3. Attach the lower front spoiler bracket (5) to the two weld nuts in the cross bar at the bottom front of the motorcycle frame with two hex head machine screws (6) and split lockwashers (7) from the kit. Torque to 30 ft-lbs (41 Nm). 4. Remove the protective film from the back of the medallion. Carefully center the medallion on the recessed area on the front of the spoiler. 5. Press the Bar and Shield medallion (3) firmly into position. Hold the medallion in place, pushing hard with your thumbs, for about five seconds. Take care not to shift the medallion on the spoiler. 6. After releasing pressure, avoid direct contact with the medallion for about 20 minutes. 7. Place a flat washer (9) on one of the pan head machine screws (8) from the kit. Position the spoiler to the front of the frame. Insert the screw through the large hole in the bottom of the spoiler and thread it into the upper front spoiler bracket, but do not fully tighten at this time. 8. Place a flat washer on each of the two remaining pan head machine screws from the kit. Insert the screws through the slots in the bottom of the spoiler and thread them into the lower bracket, but do not tighten fully. 9. Position the spoiler next to the vehicle frame allowing an equal amount of minimal clearance. Alternately tighten the three screws to 72 in-lbs (8 Nm)

HARLEY DAVIDSON SHORT RAIL BACKREST PADS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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These Backrest Pad kits are designed for installation on 1984 and later models equipped with a sissy bar sideplate kit in combination with a Short Rail upright kit, Part No. 52737-94 or 52728-95. The 52513-94 Backrest Pad kit is only for models equipped with Badlander seats and one of the following Mini Rail upright, kits: 52738-94A, 52744-94 or 51512-02. The 52568-01 Backrest Pad Kit is designed for installation on 2001 FXDWG2 model motorcycles and should be used with mini rail upright part number 52744-94 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. The 52901-01 Backrest Pad Kit is designed for installation on 2002 FXDWG3 model motorcycles and should be used with mini rail upright part number 51512-02 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. Kit Contents See Figure 3 and Table 2. There are no Service Parts available with this kit. INSTALLATION NOTE Figures 1 and 2 show pad being mounted on short upright, Part No. 52737-94, before short upright is mounted on side- plates. The pad may be installed before or after short upright is mounted. 1. See Figure 1. Remove protective film from mounting bracket (1) and attach the mounting bracket with the 1/4- 28 x 3/8 in. screw (2) onto short upright, Part No. 52737- 94 or 52728-95; or onto Mini Rail upright, Part No. 52738- 94 or 52744-94. Check that mounting bracket is parallel with upright and tighten screw to 48-60 in-lbs (5.4-6.8 Nm). 2. See Figure 2. Position backrest pad (1) on the upright. Place mounting plate (2) in position and secure with two chrome screws (3) as shown. Tighten screws to 48-60 in- lbs (5.4-6.8 Nm)

HARLEY DAVIDSON STAINLESS STEEL SPLASHGUARD INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

1. Refer to the appropriate Service Manual and remove the Maxi® fuse. 2. Refer to the applicable Service Manual and remove the rear wheel. 3. See Figure 1. Remove one screw (1) and stock splash- guard (2) from swingarm (3). 4. Remove the protective film from the new splashguard. 5. See Figure 4. Using two screws (4) and nuts (2), loosely install the H-clips to the back of the splash guard vertically as shown. 2 1 3 is04881 1. P-clamp 2. Splashguard 3. Raised bar of swingarm Figure 2. Install Splashguard -J04271 1 of 2 1 3 2 4 5 is04892 1. H-clip 2. Swingarm 3. Splashguard 4. Screw 5. Nut Figure 3. H-Clips Installed on Swingarm 6. See Figure 2. Slide two P-clamps (1) around the upper bar of the rear fork. The straight side of the clamp will face rearward, as shown in Figure 4. 7. See Figure 4. Orient the splashguard with the polished side facing the rear wheel. Align the upper two holes with the P-clamp holes. Secure splashguard to the P-clips with two screws (4) and locknuts (2). Do not tighten at this time. 8. See Figure 3. Turn H-clips (1) horizontal on the splash- guard. Press splashguard (3) into place. When the splashguard is in place, rotate the H-clips down over the raise bar of the swingarm (2). Tighten the screw (4) and nut (5) to secure the H-clips. NOTE If adequate clearance does not exist between the splashguard and rear brake line and drive belt, adjust fender extension by loosening hardware and centering the splashguard. 9. See Figure 4. Ensure the splashguard does not touch the drive belt on the left side and the rear brake line on the right side, then tighten P-clip mounting screws (4) and nuts (2) securely. 10. Refer to the applicable Service Manual and install the rear wheel. 11. Refer to the appropriate Service Manual and install the Maxi fuse

1999-2001 Triumph Sprint RS Slip-On Exhaust System Installation Instructions

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Filed Under (Triumph) by admin on 29-10-2010

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the side- stand or ideally a rear service stand. 2. Loosen the clamp that holds the connector pipe to the headers under the bike. Remove the hardware that holds the stock muffler at the passenger footpeg bracket. Take off the muffler. 3. Re-using the stock Triumph clamp install the new S- bend. Leave loose for now. 4. Place a bead of the hi-temp sealant on the outside edge of the s-bend. Slide the TBR canister onto the end of the S-bend pipe. Wipe off the excess sealant that will squeeze out. 5. Carefully slide the muffler clamp over the muffler. ( Note: The stainless steel canister clamp and the name badge on the canister come from the factory with a clear plastic protective film. Please remove this film before operation.) You may need to twist and turn the S-bend a little to get it in the right place. Place the spacer between the stock footpeg bracket and the tabs of the clamp. Locate both tabs of the canister clamp on the outside of the spacer. Use the hardware provided along with the stock nut to secure it. Leave loose for now. 6. Make sure everything is aligned and tighten all hardware. Affix the two connector springs to the muffler. 7. Be sure to allow the sealant to dry per the manufacture’s instructions before starting the bike . Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/manufacturing oil from inside the pipe burning off. Check for gaps or leaks. If you find a leak, a little high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness.

Aprilia Mille And Mille R Exhaust System Installation Instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the sidestand or ideally a service lift. 2. Unhook the springs holds the stock canister to the headers under the bike. 3. Remove the hardware that holds the stock canister at the exhaust bracket. Take off the stock canister. 4. Install the new s-bend into the stock header. 5. Install VALE adapter kit using supplied kit instructions. 6. Place a bead of the hi-temp sealant on the outside edge of the s-bend that goes into the canister. Slide the TBR canister onto the end of the S-bend pipe. Wipe off the excess sealant that will squeeze out. 7. Carefully slide the muffler clamp over the muffler. (Note: The stainless steel canister clamp and the name badge on the canister come from the factory with a clear plastic protective film. Please remove this film before operation.) You may need to twist and turn the S-bend a little to get it in the right place. Locate both tabs of the canister clamp on the outside of the exhaust bracket. Use the stock hardware to secure it. Leave loose for now. 8. Make sure everything is aligned and tighten all hardware. Reinstall the stock springs at the s-bend/header junction. Affix the two connector springs to the muffler. 9. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/manufacturing oil from inside the pipe burning off. Check for gaps or leaks. If you find a leak, a little high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness