Kawasaki Mule 3010 Hood Rack Installation And Operations Manual

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Filed Under (Kawasaki) by admin on 28-04-2012

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1. Install the Seizmik Brush Guard. – Have a friend hold the brush guard (G) in place while you slide the 1.0″ dia. tube clamps (K) in place over the middle tube of the OEM bumper, as shown in Figure 1. Secure each one in place with one of the 3/8″ x 2.25″ bolts (N), two 3/8″ washers (Q), and one 3/8″ nylock nut (R). Repeat at the top tube of the OEM bumper using the 1.5″ dia. tube clamps (J), and 3/8″ x 1.75″ bolts (O). VEHICLE FRONT Figure 2. 2. Mounting brackets – Attach the two hood rack mounting brackets to the mounting pads of the brush guard, as shown in Figure 2. Use four of the 3/8″ x 1.0″ bolts (P), eight 3/8″ washers (Q), and four 3/8″ nylock nuts (R) per mounting pad. Snug down the fasteners but do not fully tighten them yet. 3 Figure 3. 3. Crush sleeves – Insert a crush sleeve (B) into each cantilever arm assembly (C & D), as shown in Figure 3. 4. Cantilever arms – Position the Driver side cantilever arm (C) on the mounting bracket, and insert a 3/8″ dia. pivot bolt (M), as shown in Figure 4. Add a 3/8″ washer (Q) and nylock nut (R) on the other side and snug down the assembly; leave the fasteners loose enough so the components can be repositioned for fitment. Repeat this step for the passenger side. Figure 4. 4 Figure 5. 5. Lock pins – Insert the 1/2″ lock pins (Y) into the tabs on each side of the Brush Guard, fixing the cantilever arms in place, as shown in Figure 5.

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HARLEY DAVIDSON XL DETACHABLE SOLO RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-04-2011

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Kit Contents See Figure 2 and Table 1. There are no Service Parts available with this kit. INSTALLATION 1. See Figure 2. While standing behind the motorcycle, place the front rack notches (1) into the front docking points (2). NOTE Check alignment as shown in Figure 1. Failure to properly align the docking points and sideplates may result in damage to the rear docking points. 2. Pull the rotary latches (3) back into their rearmost position. Position the rear rotary latches over the rear docking points (6), ensuring the latches and sideplates (4) fit into the neck (5) of the rear docking points. This may require some gentle squeezing or spreading of the sideplates. NOTE The front and rear docking points must be fully engaged. If docking points are not fully engaged or docking kit is loose, it could shift position or come loose during operation. 3. Push down and close the rotary latches by pressing the latch lever (7) as far forward as it will go. You will hear a click when the latch is in place. If the latch does not easily close, do not force. Recheck alignment as described in Step 2. 4 4 3 2 2 1 1 1 2 is 00963 1. Right sideplate 2. Right front docking point 3. Correct: sideplate fully engaged in docking point 4. Incorrect: sideplate NOT fully engaged in docking point Figure 1. Sideplate Must Fit into Docking Point Correctly REMOVAL 1. See Figure 2. To remove the rack, press the release button (8), and pull the rotary latch lever back. Carefully lift the rear of the rack up and pull the rack out of the front docking points

HARLEY DAVIDSON XR1200 LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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Kit 53976-08 (XR1200 Passenger Upright Kit) is available for separate purchase. Contact your Harley-Davidson dealer for more information. Kit Contents See Figure 2 and Table 1. REMOVAL 1. Remove pillion and seat following the instructions in the appropriate Service Manual. 2. Remove the seat base following the instructions in the appropriate Service Manual. 3. See Figure 1. Remove the turn signal mounting screws (3) and discard. Allow the turn signal to hang by the harness until lower bracket installation. 4. Remove the rear fender support strut screws (6) and dis- card. INSTALLATION 1. See Figure 2. Install lower luggage rack mount bracket with screws (9), flat washers (10) and nuts (8). Bracket will mount around nut (Item 2 in Figure 1). Tighten to 19 ft-lbs (26 Nm) . 2. Install screws (7) and nuts (8) through the rear fender support strut and the lower luggage rack mount bracket. Tighten to 19 ft-lbs (26 Nm) . 3. Route the turn signal wire harnesses through the groove in the bracket. Install new turn signal mounting screws (11). Tighten screws to 3-5 ft-lbs (4-7 Nm) . 4. Install seat base following the instructions in the appropriate Service Manual. 5. Install upper luggage rack mount bracket (4) with original equipment seat base screws in the lower holes (A). Do not tighten at this time. 6. Install screws (3) into slotted holes in the upper luggage rack mount bracket (4) and flange nuts (6). Slide the upper bracket as far back in the slots as possible. Tighten screws (3) to 10 ft-lbs (13.5 Nm) 4 1 1 2 5 6 3 is05250 1. Lower luggage rack mount bracket screw (4) 2. Nut (2) 3. Turn signal mounting screw (4) 4. Upper luggage rack mount bracket 5. Luggage rack 6. Rear fender support strut screw (2) Figure 1. Luggage Rack Installation NOTE If installing the Passenger Upright Kit (part number 53976-08) (available separately), do not install spacers (2) and screws (3) in front holes. 7. Install luggage rack (1) aligning the holes with the holes in the upper luggage rack mount bracket. Install spacers (2) and screws (3) in holes. Tighten to 6-10 ft-lbs (8-13.5 Nm) . After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 8. Install pillion and seat following the instructions in the appropriate Service Manual. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a

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HARLEY DAVIDSON FXSTD PASSENGER BACKREST AND LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) INSTALLATION Passenger Upright 1. Unscrew the captive screw fastening the seat rear bracket to the fender. 2. Remove the rubber plugs from the three holes in the rear fender where the passenger upright installs. 3. See Figure 2. Fasten the studplate (2) to the fender (A) with the backing plate (3) and three flange locknuts (4). 4. See Figure 1. Fasten the passenger upright (3) to the studplate (1) with three flange locknuts (2). 5. Insert the seat front bracket into the frame, then fasten the seat rear bracket to the fender. NOTE The seat must be temporarily bowed up in the center to fit the seat rear bracket through the slot in the passenger upright. 6. Kit 51144-02 only. See Figure 2. Carefully clean the lower hole (B) on the passenger upright (1) with isopropyl alcohol to remove any grease or dirt. Remove backing from adhesive emblem (5) and press the emblem firmly in to place. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1 4 3 2 is03890 1. Stud plate 2. Locknut, flange (3) 3. Passenger upright 4. Backrest pad Figure 1. Passenger Upright, Backrest Pad and Luggage Rack Installation NOTE When temporarily removing the passenger upright, the mounting and backing plates may be left in place to simplify passenger-upright re-installation. Thread the flange nuts back onto studs to store the nuts. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) Backrest Pad See Figure 2. Fasten the backrest pad (7) to the passenger upright (1) using the button-head screw (6) as shown. Luggage Rack NOTE See Figure 2. Fasten the luggage rack (8) to the backrest with the backrest pad (7) removed from the studplate (2). -Fasten the luggage rack (8) to the passenger upr ight (1) using the luggage-rack mounting plate (11), button-head screw (12)

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HARLEY DAVIDSON SOFTAIL DETACHABLE TWO-UP TOUR-PAK LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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TOUR-PAK LUGGAGE INSTALLATION TO RACK 1. Open the lid and, if necessary, remove all items from inside the Tour-Pak luggage.  Remove the rubber mat from the luggage floor. 2. If holes ARE NOT pre-drilled in the floor of the luggage,       see Figure 1. To prevent damage to the leather while drilling, place blocks of wood underneath the Tour-Pak luggage at the drilling sites.  Use the four inboard holes (3) in the metal base of the luggage (2) as a guide, and carefully drill four 11/32 inch (9 mm)  holes through the floor of the luggage. 1 2 3 is04249 1. Front of motorcycle 2. Tour-Pak 3. Drill four 11/32 inch (9 mm) diameter holes Figure 1.  Drill Attachment Hole Locations in Tour-Pak NOTE See Figure 3. When installing the luggage to the rack in the following steps, note that holes in the luggage rack (2) provide forward (A) and rearward (B) positions for mounting the lug- gage. 3. Place the luggage on the luggage rack.  Align the holes in the luggage mounting plate with the forward or rearward holes in the rack. 4. ALL applications: Obtain the hex head cap screws (9), lock nuts (11) and plain washers (10) from the kit. Place a washer over the threads of each screw, and insert the screw threads, from the inside, through the Tour-Pak luggage mounting plate and floor, and into the holes in the rack. NOTE Always install the mounting screws from inside the luggage.  If the screws are installed from the bottom, the screw ends can tear the rubber mat and scratch objects, such as helmets, stored inside the luggage. 5. From the underside of the rack, install a washer and lock nut onto the threads of each screw.  In a crosswise pattern, incrementally tighten each screw to 19 ft-lbs (25 Nm) . 6. Install the rubber mat into the luggage.  Close and latch the lid. 7. If not already in place, install the Detachable Docking Hardware Kit to the vehicle per the instructions in that kit

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HARLEY DAVIDSON TOURING DETACHABLE SOLO TOUR-PAK RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Installation NOTE See Service Parts Ilustration. When installing Tour-Pak to Rack in the following Steps, note that holes on Rack provide two positions for mounting Tour-Pak to desired location. 1. Place Tour-Pak on support tube and open lid. NOTE In the following Step, the longer bolts (Item 7), are used for King and Chopped Tour-Paks while the shorter bolts (Item 6) are used for Leather Tour-Pak. 2. See Service Parts Illustration. Obtain bolt (6 or 7), two flat washers (4), concave spacer (5) and hex lock nut (3) from kit. Align rear center hole in Tour-Pak with same hole in support tube (9). Slide bolt with flat washer through Tour- Pak, through support tube, then through concave spacer (with concave side facing surpport tube). At bottom of support tube, install washer and nylock cap nut (3). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. 3. See Service Parts Illustration. Obtain bolt (6 or 7), flat washers (4), concave spacer (5) and hex Nylock nut (3) from kit. Align the remaining four holes in Tour-Pak over holes in solo rack. Slide bolt with flat washer through Tour- Pak, through support tube (9), then through concave spacer (5) (with concave side facing up) and Solo Rack hole. At bottom of Solo rack, install washer and nylock cap nut (3). With concavity on spacer inline with the rail, hold nut and tighten bolt until snug. Always install the mounting bolts from inside the Tour- Pak. If the bolts are installed upside down, then the ends of the bolts can tear the molded liner and scratch objects, such as helmets, stored inside the Tour-Pak. 4. Repeat Step 3 and install hardware to the remaining three holes in Tour-Pak and mounting rack

HARLEY DAVIDSON CHROME 4-CHANNEL LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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INSTALLATION Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg). Luggage Rack Assembly 1. See Figure 1. Locate inner channels (1) by rounded cuts (2) on one end. Lay inner channels side by side on a flat table with the cutout end flush with the edge. Verify that the cutouts face outside in opposite directions. 2. See Figure 2. Place the backrest support slide bars (1) inside the inner channels with the tapped holes on the cutout end of the inner channels. 3. Separate spacers by their length, two 5/16 inch, four 3/4 inch and six 1-1/16 inch. Set two 5/16 inch spacers aside, they will be used later. 4. Position the four 3/4 inch spacers (2) inside the backrest support slide bars.

HARLEY DAVIDSON SOFTAIL SPORT LUGGAGE RACK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-02-2011

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INSTALLATION NOTE Cover the rear fender with a clean shop towel to prevent scratching. Damage to the finish could result. 1. See Figure 1. Remove the four button-head TORX screws attaching the sissy bar (5) to the sideplates (4). Discard the screws 2. Remove the sissy bar and set it aside. For Rigid-Mount Sideplates only: Loosen, but do not remove, the hardware securing the sideplates to the motorcycle. 3. Position the luggage rack between the sideplates. Reinstall the sissy bar into the sideplate channels. 4. Apply Loctite 271 (Red) to the flat head TORX screws (2) from the kit, and insert through the holes in the luggage rack (1), sideplate, and sissy bar. Tighten the screws to 8-10 ft-lbs (10.8-13.6 Nm) . For Rigid-Mount Sideplates only: Apply Loctite 271 (Red) to the screws securing the sideplates to the motorcycle, and tighten to 21-27 ft-lbs (28.5-36.6 Nm) . 5. Remove the backing strip from the two rubber bumpers (3) and install onto the luggage rack. a. Align the notches in the bumper with the bottom edge of the channel on the sideplate. b. Wrap the bumper up the side of the luggage rack channel and across the bottom of the sissy bar. When properly installed the bumpers will cover the lower flat head screws, and will bend around the lower edge of the channel. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a) NOTE Maximum luggage rack weight capacity is ten pounds (4.5 Kg)

HARLEY DAVIDSON PREMIUM TOUR-PAK LUGGAGE RACK KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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INSTALLATION Template Positioning (Rack Installation WITH SPOILER only) The location of the luggage rack has a direct relationship to the location of the Tour-Pak® Spoiler. The template (7) included in this kit will locate the luggage rack in the correct position for the current or future installation of a Tour-Pak Spoiler. NOTE A template is not required if installing rack without spoiler. 1. If a spoiler is already installed, or if the installation of a Tour-Pak-mounted spoiler may be desired in the future, cut the template along the appropriate line. 2. Carefully place the trimmed template on top of the Tour- Pak, aligning the edges of the template with the top surface of the Tour-Pak lid. Tape the template to the lid in the desired location. The template will help to properly locate the rack so that a spoiler may be added in the future. Rack Installation on Tour-Pak 1. ALL installations: Open the lid, and remove all loose contents from the Tour-Pak. 2. See Figure 1. Slip the mounting pads (2) onto each of the mounting bosses (B) of the luggage rack (1). NOTES Kit 53665-87: Position rack with wide upright toward rear of vehicle. Kit 91793-85: Position rack with upright toward rear of vehicle. Carefully center the rack from left to right, and position the rack squarely on the lid for best appearance. Do not mount the rack too far forward to avoid contact with the backrest pad. 3. Position the rack on the Tour-Pak lid in the desired loca- tion. 4. Carefully raise the rack, and place masking tape (A) on the Tour-Pak lid where the four mounting bosses contact the cover. 5. Lower the rack onto the tape in the location chosen in Step 3. Using a soft lead pencil on the masking tape strips, trace a circle around each mounting boss. Remove the rack, and use a ruler to mark the exact center position of each mounting boss on the tape. 6. Drill four 1/16 inch (1.5 mm) diameter pilot holes through the masking tape and Tour-Pak lid at each mounting boss center position. Use a 9/32 inch (7 mm) diameter bit to drill the finish holes. 7. Remove the masking tape

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TRIUMPH ROCKET III SOLO RACK INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 24-12-2010

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1. Using the ignition key remove the driver’s seat. Remove the three bolts which secure the passenger seat to the rear fender and remove the passenger seat. 2. Place the lock washers and washers onto the three 6 x 25mm bolts (supplied). Place the solo rack onto the rear fender and align the bolt holes in the fender with the holes in the solo rack. Starting with the two lower holes, place the black plastic spacers (two supplied) between the fender and the solo rack. Next insert two of the bolts with the washers thru the rack and spacers then thread into the fender several turns. At the upper hole place the rubber washer (supplied) between the solo rack and the fender. Insert the remaining bolt with washers thru the solo rack, rubber washer and thread into the fender. Tighten all three bolts securely. 3. Reinstall driver’s seat.

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