Kawasaki ZX-14 Installation And Removal Manual

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Filed Under (Kawasaki) by admin on 29-04-2012

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1) Tools needed: 36mm socket / 32mm socket / 5mm Allen wrench / cordless drill / tap handle / hammer / razor blade. 2) The frame bracket serves as the drilling guide and we provide the transfer punch, tap, drill and step by step instructions for a relatively easy installation. However, do not attempt this installation unless you are skilled enough and confident that you can drill and tap (2) holes in your frame. We’ve also provided a picture of what it will look like should you decide to sell this bike later on, with your stabilizer removed. Follow these guidelines and you’ll find it’s quite easy. 3) Some photos may not be your exact bike but depict the idea of what needs to be done. 4) It is important to use Blue Loc-tite on all fasteners if you expect them to stay tight. 5) Cover the gas tank area with something substantial to protect the paint, in case of a slip. An old sweatshirt works well. It’s cheap insurance to actually just remove the tank shroud to avoid an accident. 6) Remove the stock 36mm nut AND washer , that holds the top triple clamp tight. Make a note of how tight it is. 7) Install the new “triple clamp damper mount” (TC mount) over the steering stem allowing it to match the exact shape of the triple clamp, with the “machined register” (lip) indexing over the back of the triple clamp. (See photo). 8) Install the new 32mm aluminum nut supplied in the kit (without any washer) with the Hex drive facing up and torque to 65ft. lbs. or more. (Check your manual for the recommended torque setting of this nut). 9) There is a slight amount of play in the “register” that fits over the back of the triple clamp to allow for variations in castings from the factory. If the TC mount tries to spin clockwise during tightening, which can misalign the stabilizer ever so slightly, you can slide something thin, like the edge of a razor blade, between the register and the back of the triple clamp to space it “just right” for alignment during tightening (see photo). Once it’s tight the razor blade will be stuck, so gently turn the 32mm socket as though you were going to loosen the nut but don’t actually loosen it. It will relieve enough pressure to allow the razor blade to come out. Double check your alignment again. 10) Remove the front tank mounting Allen bolt. Retain the stock washer that’s part of the rubber grommet. 11) Temporarily install the frame bracket and be sure the outer feet are touching or are very close to the frame. On rare occasions, the casting on the head tube prevents the feet from making contact. On these rare occasions you may have to slightly file the inner side of those feet until the bracket sits down flush. Not sure on this one? Call us. (note: 2007-on bikes have a larger casting area and early kits will not fit these late model bikes. All current kits now fit 2006-on)

Harley Davidson Motorcycles Hot Grips Installation Manuals

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Filed Under (Harley Davidson) by admin on 23-02-2012

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End weights or other need to open the ends: You may drill out the outboard ends of the grips for installation of end weights or other purpose, if you use a fine tooth hole saw and do not go larger than the handlebar’s inside diameter. We have molded in a visual guide on the grip’s ends, and we recommend 7/8″ or at most 1″ diameter and be sure to center drill carefully. DO NOT use a hacksaw or you will destroy the grip, because there are resistance wires molded into the grip outboard of the handlebar diameter. Some Harley throttle sleeves are molded with raised plastic ribs or ridges to help hold the original Harley grip in place, and these will mate up with four (4) of our internal ribs by sliding our heated handgrip over the sleeve. HOWEVER, there are two axial ribs, which go circumferentially around the throttle sleeve as illustrated below, and they may have to be carefully removed with a knife of razor blade. They must be trimmed off with a file or razor knife until the Hot Grips slides over them. Do not force the Hot Grips over the ridges as the grip cannot stretch and will be damaged if forced on. These Hot Grips® have a heat output of 8 watts on “low” and 15 watts on “high” per grip. As a pair they will consume 20 watts of electrical power on “low” and 30 watts on “high”. They consume more than 8 x 2 on “low” because the resistor consumes a little

HONDA TRX 400EX Removing Stock Carb and Cables INSTRUCTION

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Filed Under (Honda) by admin on 21-12-2011

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Remove seat/fender assembly and fuel tank. 2. Remove throttle cables paying close attention to routing. 3. Remove thumb throttle housing if you are installing a twist throttle. 4. Remove air box and air box intake tube. 5. Remove stock carburetor. 6. Stuff a clean rag into intake manifold to keep debris from entering engine. Preparing machine for carburetor installation 1 . Route the provided throttle cables per manufacturer’s recommended procedure, routing them the same as the stock cables. 2 . Remove the rubber alignment tabs from the manifold using a razor blade or cutters. Be very careful not to damage the intake manifold! 3. Remove air box intake tube from the air box and use a hacksaw to cut approx. 1½” off of the air box intake tube. Your tube should resemble the one shown in Figure 1. Re-assemble the air intake tube into air box and install back onto bike. Don’t forget to tighten clamp around intake tube and reinsert crank vent into the air boot. Figure 1. Thumb Throttle Attach cable into cable wheel with the cable end at the 8: 00 position of the cable wheel, then into bracket. Secure by replacing the cable bracket end and phillips screw. See Figure 2. Figure 2. Twist Throttle 1. Install the pull (see figure 4 for cable identification) , cable end into the 8: 00 position and the idle cable end into the 11: 00 position on the cable wheel. See Figure 3

Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 14-12-2011

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Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

1996-2004 HONDA XR250R Removing stock carburetor and cables

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Filed Under (Honda) by admin on 26-11-2011

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Install the throttle cables into the supplied throttle housing and place onto clean handlebar end. 2. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or sharp cutters. This should be done with the rag left in the manifold. Be very careful not to damage the manifold or your hands while doing this!! 3. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering
adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 4. Install provided fuel line onto fuel inlet banjo and secure with pinch clamp. 5. Place Edelbrock carburetor into manifold. Do not tighten clamp yet. 6. Remove the cable bracket end from cable bracket using #2 phillips. 7. Install pull cable (see Figure 2) end into
the 4:00 position of the cable wheel and the return cable into the 1:00 position. Secure cables into cable bracket by replacing end piece and phillips screw. See figure 3.

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DETACHABLE KING SIZE WINDSHIELD FOR SOFTAIL MODELS WITH CHROME HEADLAMP NACELLE OR STREET STALKER HEADLAMP NACELLE (WITHOUT PASSING LAMPS)

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

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Installation 1. Remove upper screws that attach the chrome headlamp nacelle to the front forks. 2. See Service Parts illustration. Attach the upper docking bushings (22) using washer (21) and mushroom head screws (20) Use Loctite 242 (blue) on screw threads. Torque screws to 19 ft-lbs (25.8 Nm). 3. Remove lower screws that attach the chrome headlamp nacelle to the front forks. 4a. For vehicles equipped with the Chrome Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (23). 4b. For vehicles equipped with the Street Stalker Headlamp Nacelle, attach the lower docking bushing (22) using washer (21) and button head screw (24). Installing/Removing Windshield 1. Carefully lock bottom windshield assembly jaws into grooves of the lower rubber docking bushings. 2. Hook the top windshield assembly jaws into grooves of the upper rubber docking bushings. 3. Firmly press the windshield into place until seated on docking bushings. 4. To remove windshield, grab windshield edges on each side of center brace and firmly pull windshield loose from docking bushings. 1 WARNING Carefully inspect windshield upon completion of installation. Be sure windshield mounting does not restrict full left or full right movement of front fork assembly. Restricted movement could affect handling, resulting in personal injury. If restriction does occur, adjust windshield as needed until proper clearance is obtained. Have experienced Harley-Davidson service personnel correct any problems before riding with this accessory installed. 1 CAUTION Check mounting hardware periodically. Never ride with loose mounts. A loose mounting causes extra stress on all other mounts, as well as the windshield itself, and could result in premature failure of either or both. 1 CAUTION Do not clean Lexan®polycarbonate in hot sun or high temperature. Powdered, abrasive or alkaline cleanser will damage the windshield. Never scrape the windshield with a razor blade or other sharp instruments because permanent damage will result. Sunlight reflections off of the inside curvature of a windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan®. Lexan®is a more durable and distortion-resistant material than other types of motorcycle windshield material, but still requires attention and care to maintain. • Do not use liquid windshield “protectors” on your windshield. Although they may work well on automobile safety glass, Harley-Davidson cannot ensure the results when used on Lexan®Harley- Davidson windshields. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant®. • Do not use benzine, paint thinner, gasoline, or other types of harsh cleaning agents on windshield. They will damage the windshield surface. • Do not use benzine, paint thinner, gasoline, lubricants (including Armorall), or other cleaning agents on the rubber bushings. They will damage the bushing surfaces

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HARLEY DAVIDSON FLST REPLACEMENT WINDSHIELD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION 1. See Figure 1. Remove stock windshield. 2. Remove all hardware that secures mounting brackets to windshield. The nine screws must be removed with a T- 27 TORX® screwdriver. Save all hardware and brackets for installing new windshield. 3. Remove all old tape from brackets and apply new tape (1, 2) from kit onto brackets. Align holes in tape with holes in brackets. Do not exceed recommended torque when installing mounting screws. Damage to windshield can result. (00385a) 4. Install all brackets. Tighten all screws and acorn nuts to 48-60 in-lbs (5.4 to 6.8 Nm) . 5. Install windshield (3) on motorcycle CARE AND CLEANING Polycarbonate windscreens/windshields require proper attention and care to maintain. Failure to maintain polycarbonate properly can result in damage to the windscreen/windshield. (00483d) •Do not use benzene, paint thinner, gasoline or any other type of harsh cleaner on the windscreen/windshield. Doing so will damage the surface. •Do not clean Lexan® polycarbonate in hot sun or high temperature. •Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. •Never scrape the windshield with a razor blade or other sharp instruments, as permanent damage will result. •Sunlight reflections off of the inside curvature of a windscreen/windshield can, at certain times of the day, cause extreme heat build-up on motorcycle instruments. Exercise care in parking. Park facing the sun, place an opaque object over the instruments, or adjust the windscreen/windshield to avoid reflections. •Do not use benzene, paint thinner, gasoline or any other cleaning agents on the rubber bushings. Doing so will damage the bushing surfaces. Do not use harsh chemicals including rain sheeting products on Harley-Davidson windshields. They can cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley Glaze Polish and Sealant (00231a) NOTES Covering the windshield with a clean, wet cloth for about 15 minutes before washing will make dried bug removal easier. Harley-Davidson Windshield Water Repellent Treatment Part Number 99841-01 is approved for use on Harley-Davidson Lexan windshields

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Street Magic Magical Wizards LED Installation Instructions

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Filed Under (Tips and Review) by admin on 29-01-2011

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1. Always wear appropriate safety gear including safety glasses when soldering or performing any electrical work. It is highly recommended that safety glasses be worn throughout this installation process. Temperature of bike must be at least 60 degrees F. for tape to properly cure. Read all directions before starting project. 2. Turn fuel supply valve to off position before starting. Be sure bike is on level surface and secure and cool. 3. Important: Disconnect negative battery cable from battery; refer to owner’s manual. Failure do to so may result in electrical shock, injury, or fire. Secure negative battery cable away from positive side of battery and all other positive voltage sources on bike. 4. Select hidden locations to mount LED Accent Lights to provide best coverage. 5. Remove fuse from fuse holder. 6. Clean mounting locations on both motorcycle and accent lights with 3M promoter, promoter sponge will dry up quickly, place sponge in sealed plastic bag when not in use. Do not touch 3M promoter with bare fingers. 7. Place piece of double sided tape on accent light if needed, lights come pre-taped on back surface. Trim excess off sides with razor blade. Carefully remove backing from double sided tape and place light on selected mounting location. Press firmly and hold for 10 seconds. Repeat for all lights to be mounted on bike. 8. Route wires from accent lights back to central points near battery compartment under seat. Route wires such that they not interfere with normal operation of bike. Cut off any excess wires, strip back insulation as required. 9. Select several locations to secure wires to frame. Secure wires using tie wraps provided. 10. Join all black wires from LEDs into one Cage Clamp Connector #1. Join all Red wires from LEDs into Cage Clamp Con- nector #2, Join all Blue wires from LEDs into Cage Clamp Connector #3, Join all Green wires from LEDs into Cage Clamp Connector #4. 11. Connect Orange wire from the remote control wire harness to the Red Cage Clamp Connector, connect Blue wire from remote control wire harness to Blue Cage Clamp Connector, connect Green wire from remote control wire harness to Green Cage Clamp Connector. Connect White wire from remote control wire harness to Black Cage Clamp Connector. 12. Crimp spade connector on ends of remaining Red and Black wires from Remote Wiring Harness. Heat spade connector with heat gun so that it shrinks around wire. 13. Connect Red Wire to Positive (+) side of battery, and Black Wire to (-) Side of battery. Take necessary precautions when making connection and refer to bike’s owner’s manual. DO NOT allow any tools to touch both positive (+) side of battery and any metal surface on bike as it will cause a short which could result in serious injury and damage to the battery or other electrical circuits.

HONDA GL18000 DRIVER BOARDS REPLACEMENT RUBBER PADS INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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1. Remove any loose pads, remove any remaining rubber & glue using a blade screwdriver or razor blade. 2. Rough up the chrome surface with sand paper or by scratching with the tip of a screw driver. 3. Clean any remaining glue residue off using acetone solvent or nail polish remover. 4. Clean both the floorboards and the back side of the rubber pad with rubbing alcohol. 5. Using the supplied small brush and tube of 3M weather strip adhesive, apply a thin layer of glue to both the floorboard and the backside of the rubber pad or pads. Allow to dry for 10-15 minutes or until tacky to the touch. Apply a second thin coat to both surfaces and while still wet press the rubber firmly into place and keep pressure applied evenly for 45-60 seconds