Harley davidson American Classic Straights on a 1988-2001 VLX 600 Shadow Installation Instructions

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Filed Under (Harley Davidson) by admin on 01-03-2012

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Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system.
1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install nut strip into slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — DO NOT TIGHTEN NUTS! 8. Install nut strip into slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks.

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HARLEY DAVIDSON WIRE LOOM AND HORNS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 27-02-2012

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Remove the stock horn and bracket from the stud it is mounted to and unplug the 2 wires. Remove the seat. Route the end of the wire and hose loom without the connectors. Starting in front of the fuel valve, route this loom behind the valve, over the fuel line over the rear cylinder head along the existing wiring or hoses – if your model has any. Follow the frame to where the back bone and seat support rails come together. Route the loom up into the general area where the compressor will mount (i.e. see diagram). Attach the hose to the ‘Y’ connector on the horns themselves. Attach the two black wires from the loom to the relay terminals #87 and #30, located between the air horns behind chrome cover. Attach the wires from the original horn to the remaining terminals #85 and #86 (NOTE: it makes no difference which wire goes to which terminal). Attach the relay to the back of the horn bracket assembly or up under the fuel tank using the small cable tie provided. NOTE: the terminals must point downward to prevent water from entering the relay! Install the horn assembly using the 1/4″ thick chrome washer provided behind the horn mounting bracket. Use the original acorn nut and tighten securely. Check to see that the horns have at least 1/4″ clearance between the engine, shift linkage and choke knob. They should be horizontal or angle down at the front just slightly. Take any slack out of the loom, keeping it up against the frame and away from the engine or exhaust, using several of the small cable ties provided. COMPRESSOR MOUNTING AND WIRING Due to the vast differences in years and models, it is not possible to have one or two brackets that will fit all models. You may need to mount the compressor in a different position or find an alternative location, such as under one of the side covers. On 2001 and newer Tour models there is room in front of the battery to mount it horizontally. On 1997-2000 fuel injected models, under the front portion of the right hand side cover is an excellent location. On most Softtail models you can attach it to the frame tube behind the rear cylinder. On some models such as Sportsters there may not be a place to conceal the compressor; there is a chrome cover and cap available to dress it up for exposed mounting. (RIVCO part no #CMPCR) If mounting the compressor vertically as pictured, try to keep the end with the electrical terminals pointing downward. You can use the long cable ties provided to attach the compressor to the frame or an existing wiring loom. Once the compressor has been mounted securely, route the hose and one of the wires to it and connect the hose to the air outlet barb or fitting. Trim the wire and crimp on one of the female blade terminals and attach to the (+) terminal. Attach the white ground wire supplied to frame close enough to the compressor, so the wire will reach. Trim and crimp another female terminal to it. Attach this wire to the (-) ground terminal. The remaining black wire from the hose/wire loom goes to the battery (+) terminal through the fuse and holder provided. Trim the black wire allowing for the length and placement of the fuse holder. Crimp together and attach to the battery (+) terminal. Turn ignition on and test horns. Check wires and hoses for neat, secure routing and at least 1″ away from exhaust system. Reinstall seat etc.

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Yamaha Stratoliner 2006 3" Big Straights REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 02-01-2012

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1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding muffler at rear mounting bracket. 3. Remove Cables from exhaust valve. 4. Remove O2 Sensor from pipe. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 7. Remove complete pipe assembly. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install O2 Sensor onto front pipe and install front pipe onto front cylinder, taking care to not scratch chrome surfaces on pipe, engine or motorcycle. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install 3/8-16 Square nut into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe onto rear cylinder. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — (Remove chrome plastic valve cover to access top nut) — DO NOT TIGHTEN NUTS! 8. Install 3/8-16 Square nut into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration.

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2002 Honda VTX 1800 R & S 3” BIG Straights Installation Instructions

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Filed Under (Honda) by admin on 17-11-2011

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Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove O2 sensors from each muffler and cover with supplied cap plug. 3. Loosen clamps at mufflers. 4. Remove bolts that are holding mufflers at rear mounting bracket. 5. Remove mufflers. 6. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 7. Remove rear pipe assembly. 8. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 9. Remove front pipe assembly. Hard-Krome Exhaust System Installation
NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to
replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design,
configuration and location. WARNING: Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessaryon a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed

HONDA VTX 1800 AND VTX1300 SWING ARM COVER INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-12-2010

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1. Remove the two (2) 6mm bolts holding the brake hose clips in place. 2. Slide the cover in from the rear over the swing arm and align the holes. (NOTE: on Retro models and some aftermarket exhausts it is necessary to remove the two (2) muffler mounting bolts and loosen the two (2) exhaust nuts on the rear cylinder head then pull the exhaust outward to gain clearance to slide the cover into position). 3. Replace the original front bolt or bolts into the cover and hose clip. NOTE: the hose clip should go behind the chrome cover and it may be necessary to straighten out the bend in the clip slightly to gain alignment of the holes. Replace the rear bolt with the one supplied and tighten both securely. 4. Replace and tighten the exhaust bolts if removed earlier

YAMAHA Road Star Fuel Pump Relocation Kit INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)

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2007 Yamaha V-Star 1300 Classic Straights Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Stock Exhaust System Removal 1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install Nut strip into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 8. Install Nut strip into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks. NOTE: To achieve optimum performance from your Hard-Krome exhaust system we suggest installing the Dynojet jet kit for carbureted models

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Kawasaki Brute Force 750 MudSlinger Slip-On with S-Bend Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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Remove the stock muffler and rear cylinder head pipe as described in your owner’s manual. Retain the stock fasteners for MudSlinger installation. (Do not remove the front cylinder head pipe; this will be used with your new system). 2) Remove stock Heat Shield and retain for MudSlinger installation. 3) Remove and inspect the rear cylinder exhaust gasket. Retain or replace for MudSlinger installation. MUDSLINGER INSTALLATION: 1) Slide the 1 ¾ T-bolt clamp over the supplied Y pipe and attach pipe to MudSlinger muffler. (DO NOT TIGHTEN) 2) Slide the 1 ½ T-bolt clamp over the front cylinder head pipe. 3) Install the new Y pipe and muffler using the stock fasteners. Align the muffler with the rear mount point on the frame. (DO NOT TIGHTEN). 4) Tighten all clamps and fasteners starting with the two flange nuts at the exhaust port and working back to the muffler. 5) Re-install the stock heat shield. (NOTE: only 2 fasteners will be used to install the heat shield to the new system. Make sure to use medium strength Loctite on the 2 fasteners when installing). 6) Start and check for leaks then re-install all body panels. IMPORTANT: After a short test ride, check and retighten all fasteners as necessary. CLEANING & MAINTENANCE The Mudslinger system is manufactured from stainless steel and aluminum. Stainless steel is used for its high strength at high temperatures and resistance to corrosion. The aluminum is used for it’s weight and strength. Before you run your new SuperTrapp MudSlinger for the first time, clean all grease, fingerprints, and dirt from the entire system. (A good glass cleaner works well.) A clean, grease-free surface will allow even coloration. Over time, the MudSlinger will begin to take on a gold tint. The coloration will be relatively even throughout the entire system. The hotter you get the system, the darker it will become. Due to the unique properties of these materials, the care of the MudSlinger is minimal. The following instructions should be followed to maintain your MudSlinger muffler

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