2001-2008 Suzuki V-Strom DL650 And DL1000 Adapter Installation Manual

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Filed Under (Suzuki) by admin on 15-02-2012

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Adapter Parts List Item Desc. Quantity A. Front Adapter 1 B. Rear Adapter 1 C. Frame Grabber, Front 2 D. Frame Grabber 1 E. 5/16 x ½” Button Head Screws 4 F. M8 x 50mm Bolts 2 G. Washers (Not shown) 6 2. Assembly Instructions Familiarize yourself with all of the parts in the Main Arm and Motorcycle Adapter assemblies. Follow these installation instructions FIRST . The following instructions include our recommended torque values for all fasteners used to assemble the Johnny Rack™. Do not exceed those torque values when installing the rack, otherwise damage to the Main Arm may occur. When stock mounting points are used to mount the rack to the motorcycle, refer to the motorcycle user’s manual for recommended torque values. 1. Remove the seat, the rubber rack cover on the rear rack or if you have a Givi Top Case mounting plate remove it too. Remove the 4 bolts shown (A and B). 2. Align front frame grabbers over front grab bar mounting holes (A). 3. Reinstall original bolts that you removed. Torque to 150in.lbs. 4. Place rear frame grabber over holes on rear rack (B). 5. If you do not have side luggage racks installed on the motorcycle, you will need to place 3 stacked washers (3/4 ” OD) over each hole and under the frame grabber to take up the extra space.

YAMAHA FZR600 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Kawasaki) by admin on 27-04-2011

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Front Axle and Outer Tube Front Wheel Axle Holder Rear Axle and Nut Handlebar Crown and Inner Tube Handlebar Crown and Steering Stem Steering ring nut (Upper and lower) Brake Caiiper (Front/Rear) Bleed Screw and Brake Caliper Brake Hose and Union Bolt Front Master Cylinder and Cylinder Cap Front Fender and Outer Tube Handlebar Boss and Front Fork Handlebar and Handlebar Boss Engine Mounting: Front ; Rear — Upper ; Rear — Lower 1 Down Tube and Frame: Front 1 Rear l Footrest Bracket and Frame I Pivot Axle and Nut Relay Arm and Frame Connecting Rod and Swingarm Connecting Rod and Relay Arm Rear Shock Absorber and Reiay Arm Rear Shock Absorber and Frame Footrest and Footrest Bracket I Rear Footrest Bracket and Frame Rear Master Cylinder and Rear Arm Bracket Cowling and Stay Compression Bar and Brake Caliper Bracket Front Fork Pinch Bolt: Upper Lower Sprocket and Clutch Hub Brake Disc and Clutch Hub Inner Tube and Steering Stem Frame and Rear Frame: Upper

ARLEY DAVIDSON FXDL INSTRUMENT CONSOLE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-03-2011

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Installation CONSOLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury (00049a). 1. Remove seat and disconnect battery, negative cable first. 2. Remove fuel tank mounting bolts. Lift fuel tank far enough to remove the speedometer sensor cable from the mounting clips under the tank. 3. See Figure 1. The 3-place speedometer sensor connector is located on the frame beneath the seat. Remove from t-stud and disconnect the connector. Cut the cable strap that holds sensor wires to right rear frame tube. 4. Remove instrument console mounting screws and lift console from tank. SPEEDOMETER REMOVAL 1. See Figure 2. Disconnect 8-place connector under console. Remove assembly from tank. 2. Cut remaining cable straps holding wires to instrument mounting bracket. Remove screws holding bracket to back of instruments. Remove bracket. 3. See Figure 3. Remove nuts and washers from terminal studs (1, 2 and 3). Remove wires from studs. 4. Unscrew the rubber function switch cover that protrudes from the left side of the console. Remove the function switch (3). 5. Gently push on bottom of speedometer and remove speedometer from top side of console. Remove gasket from speedometer. TACHOMETER REMOVAL 1. See Figure 3. Remove nuts and washers from terminal studs (3, 4 and 5). Remove wires from studs. 1 WARNING 1 WARNING

HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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HARLEY DAVIDSON FOUR-POINT DETACHABLE DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. See Figure 3. Remove the screw (A) retaining the rear of the chrome cover to the rear frame extension on each side of the vehicle. 2. Place a washer (7) over the threads of each of the larger TORX® head screws (6) from the kit. Apply 2 or 3 drops of Loctite 262 Threadlocker and Sealant – Red to the threads of each screw. Install the screws through the docking plates (1) and fender covers, and into the threaded holes in the frame extensions on each side of the vehicle, and tighten to 17 ft-lbs (23 Nm) . NOTE See Figure 1. The docking points must be attached to the docking plates (2) with the chamfer (1) facing the plate and the flat side facing out. 1 2 is05506a 1. Docking point chamfer (bevel) 2. Mounting plate Figure 1. Docking Point Installation 3. See Figure 3. Slide a spacer (2) onto the longer pin (B) of each docking plate. Install the four docking points (3), chamfer end first, onto the long and short docking plate pins using the washers (5) and smaller TORX screws (4). Tighten to 10.5 ft-lbs (14.2 Nm) . NOTE Protective tape must be installed to the rear saddlebag mounting bracket to prevent damage to the saddlebag finish when the lid is opened. 4. See Figure 2. Apply protective tape (2) to the rear mounting bracket (1) on the saddlebag in the location shown. Repeat for the other side. 2 1 is05533 1. Rear saddlebag bracket (2) 2. Protective tape %lengthT=0

HARLEY DAVIDSON TRIKE CHROME REAR GUARD KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Set the vehicle parking brake, open the trunk door and remove the trunk liners. 2. See Figure 1. From inside the trunk, locate four screws with washers (A) in the floor of the trunk compartment that hold the body to the rear frame. Leaving the washer in place, remove one of the screws and discard. 3. Obtain a long hex head cap screw (3) from the kit. Apply a few drops of Loctite – Blue to the threads of the screw, about 0.75 in (19 mm) from the screw head (C). 4. Insert the screw through the washer (A) and trunk floor. Thread it all the way through the U-channel on the outboard side of the rear frame (B), but do not fully tighten at this time. 5. Repeat for the remaining three screws. 6. Tighten all four screws to 18 ft-lbs (24.4 Nm) . 7. With an assistant, position the trunk rail assembly to the underside of the frame, fitting the four holes in the rail mounting brackets onto the threads of the screws installed in Step 4. 8. Apply a few drops of Loctite – Blue to the threads of each lock nut (4). 9. Install a washer (5) and locknut to the threads of each screw to hold the rail in place, but tighten only enough so the rail lightly contacts the frame. 10. Align the rear guard evenly to the contour of the lower body for best appearance, and adjust the position of the rail to provide clearance between the rail and the rear of the vehicle body. 11. With an assistant firmly holding the screw heads inside the trunk to keep them from turning, tighten the four lock nuts to 18 ft-lbs (24.4 Nm) . 12. Install an insert (2) into each end of the rear guard. Push firmly until fully seated.

BMW Motorcycle R 1100 RS – Rear Frame

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Filed Under (BMW) by admin on 16-11-2010

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Complaint: On R 1100 RS models (above serial numbers only) with luggage racks, a crack may develop in the rear section of the frame (see drawing) if a load exceeding the permitted 11 lb. is applied to the luggage rack, or if a top case is used. Remedy: Please check all R 1100 RS models (in serial number range above) which pass through your workshops for cracks on the rear section of the frame. Cracked frames should be exchanged with the new part listed below. The new rear frame has been reinforced to use with larger loads. New Part: 46 51 2 320 698 (reinforced rear frame) Caution: Since the introduction of the rear luggage grid to accommodate the 33 liter removable top box, it is vital that this luggage grid and 33 liter top box not be installed on any of the above unless the reinforced rear frame is fitted, or a frame reinforcement kit is installed (a kit will be made available in the future to reinforce the rear frame of the above models, in order to install the 33 liter top box). The new reinforced rear frame (46 51 2 320 698) has been fitted since May 1995 production. Use of the new rear section of frame on an earlier production bike requires a new rear section of the dual seat as follows: Parts 52 53 2 325 121 Flash Green 52 53 2 325 122 Red Needed: 52 53 2 325 123 Black 52 53 2 325 120 Light Gray 52 53 2 325 211 Anthracite Warranty: Please explain to your customers that the top case can only be installed on bikes with reinforced rear frames. Claims for frame cracks which result from operation with large loads beyond specification will not be honored under the terms of the Limited Motorcycle Warranty.

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2000-2007 BMW F650GS Adapter Installation Manual

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

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1. Remove both of the rear stock luggage rack screws with a Torx wrench. 2. Install the Rear Frame Grabber by sliding it up under the rear fender and in front of the stock luggage rack mounting tabs. 3. Attach the Rear Frame Grabber with the 2 replacement M8 screws (stock ones are too short). The tabs on the Rear Frame Grabber should face outward toward the rear of the bike (see A in picture). Torque both screws to 110in.lbs. 4. Install the Rear Adapter as shown. 5. Attach the Rear Adapter with 2 5/16 Button Head Screws. Torque both screws to 110in.lbs. 6. Remove the motorcycle seat and remove the 2 torx screws shown in the picture. 7. Install Frame Grabber Nuts under the passenger grab bar mounts. The long end of the nut goes to the rear of the motorcycle. 8. Support the nut under the mount with your fingers and attach the Front Frame Grabber with a 5/16 Button Head Screw. 9. Reinstall the Torx screws to attach the plastic side cover of the motorcycle. There will be some overlap of the plastic cover and the Front Frame Grabber. 10. Install the Front Adapter. 11. Attach the Front Adapter with two 5/16 Button Head Screws and Locking Nuts. Snug but don’t tighten the screw until after you have installed the Front Main Arm. 12. Reinstall the Seat and compartment cover. Depending on the year of your motorcycle you may need to push the rear of the seat forward to get it around the Front Adapter. It’s a close fit, but it will fit. A B D J C E F G H F