Ktm 625/ 640/ 660 LC4's and some 640 Adventures Removal and Installation Manual

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Filed Under (KTM) by admin on 24-01-2012

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1. There are 3 pages of instructions here. Review all 3 first! These model bikes normally require modifications. 2. Warning: Once the triple clamp is loose, the forks can roll away from the bike . Follow step 2 carefully. 3. Block the front and rear tire securely before removing the top triple clamp, keeping the weight pushed on the front wheel so the front tire cannot move forward and the forks are forced upward, keeping the bearing in the head tube. 4. Remove the 4 bolts holding your bars tight and lay the bars forward out of the way. 5. Using Loc-tite, change the lower nuts on the under side of your triple clamp that hold your bar perches. Use the “low profile” version that we have supplied in the kit. You will need access to the Allen head bolts in the lower perch halves. Without these low profile nuts the triple clamp will not be free to turn lock to lock. There are occasions where you may have to grind on the frame bracket to allow a little extra clearance for even the low profile nuts (see photo). Because the bars are rubber mounted, this clearance varies from bike to bike. Turn the triple clamp lock to lock and be sure you have clearance. You must change them now, as later you won’t have room to do so. 6. Now remove the top triple clamp taking note of how tight the main nut is, so you can re-tighten to the exact amount. 7. Remove the tin bearing shroud (cover) and rubber seal. The lips of the seal face downward for correct installation. 8. The new shorter bearing shroud will replace the stock tin shroud, giving the frame bracket more room to seat. 9. Grease your bearings while you have them exposed. (Keep the grease off the area where our frame bracket mounts). 10. Only if your model is equipped with one, you will need to cut off the upper portion of the square steering lock receiver box (see photo). The steering lock stays functional as the lock-pin still engages the lower the portion of the box. Mark and cut the top of the box off. You must cut enough to allow our frame bracket to drop down far enough so the entire bracket grabs the head tube. If you don’t allow the frame bracket enough clamping surface it will come loose. The upper edge of the frame bracket should be level with the step where your stock bearing seal seats. (See photo). 11. Install the frame bracket so it matches the clamping area on your head tube, but do not tighten it yet. Do not remove the paint on the frame where the frame bracket fits. The paint is calculated as part of the correct dimension. On most LC4′s you will need to grind the weld at the back of the head tube, so the bracket can drop all the way down flush. Each bike is a little different; some require a lot of grinding and some very little. Try to remove the weld while retaining the original diameter of the head tube where our bracket will clamp. It is essential for the frame bracket to clamp to a symmetrical, round head tube. When you’ve removed the majority of weld the finished removal should be done with a file for precision clearance, without touching the area where the clamp will seat

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2008 CBR1000RR replace the clutch inner

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Filed Under (Honda) by admin on 06-11-2011

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Clamping Centerstand to Frame. Notice the centerstand is shipped with (2) white plastic washers. Note: See photo #2-A These are in place to overcome the spring tension or lock the stand in place and allow you to pivot the lower stand down partially to make installation easier. Pivot the upper stand about half way from the retracted to the extended (down) position. Note: This will require some force. If the stand will not stay in the position you can further tighten the two 9/16” pivot nuts. Remove the bolts from the four band clamps. Wrap the (2) small clamps around the small upper frame tube and start the bolts so that the bolt will be at the bottom of the tube and the wrench head facing towards the rear of the motorcycle. Note: See photo #2. Center the stand on the frame from side to side so as to gain even clearance between the feet on the centerstand and the rear tire when the stand is in the retracted position. Holding the larger cradle up against the frame, tighten the (2) small clamps enough to hold the centerstand in place. Install one of the large clamps as shown in photo #3-A. Install the 2 nd large clamp as shown in photo #2-C. Again retract the stand and check that the feet have even amounts of space from the side of the rear tire. Tighten the flour clamps securely 5-7 ft. lbs. Next remove the (2) 9/16” pivot nuts and the white plastic washers as shown in photo #2-A. Re-install and tighten the 9/16” pivot nuts securely 8-12 ft lbs. With the stand in the retracted position-adjust the stop bolt and lock nut, see photo #3-B, so that the stand is parallel with the ground and does not come incontact with any parts of the motorcycle

HARLEY DAVIDSON VRSC REAR AXLE COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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This kit fits 2002 and later VRSC model motorcycles. Kit Contents There are no Service Parts available with this kit. INSTALLATION 1. Using a suitable lift, support the vehicle beneath the frame until the rear tire is just slightly off the ground. 2. See Figure 1. Remove the right side upper shock mounting bolt (2) and spacer (4). Retain the shock mounting nut (not shown) which passes through the fender support and side rail assembly. 3. Pivot the shock towards the vertical position. 4. Remove the left side lower shock mounting bolt (1) and washer (5). 5. Pivot the shock towards the horizontal position. 6. Insure that the shocks are clear of all components and carefully lower the vehicle to provide access to the right side lower shock bolt. 7. Support the right shock and remove the lower shock mounting bolt (1), washer (5) and nut (6). 8. Position the right side cover provided in the kit over the swingarm 9. Reposition the right side shock and re-install the lower shock mounting bolt (1) and washer (5) by inserting through the shock, cover and swingarm. Thread into nut (6) and tighten to 41-68 Nm (30-50 ft-lbs)

HARLEY DAVIDSON VRSC SADDLEBAG SUPPORT KIT (WIDE TIRE) REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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REMOVAL Remove Pillion and Rear Fender NOTE If possible, lift the rear of the motorcycle up so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender when installing the mounting brackets. 1. Open the rider seat. 2. See Figure 1. Remove rider seat post (1), nut (2), and washer (3) from passenger pillion. Slide grabstrap (4) forward off pillion. Save mounting hardware for kit installation. 3. Push passenger pillion forward to release slot on bottom of pillion from post on fender tongue. 4. See Figure 2. Lift pillion up to remove lanyard (1) from hole in center of passenger pillion (2). Then lift pillion away from motorcycle. 5. Disconnect turn signal and tail light electrical connections from back of rear electrical caddy. Note position for later installation. 6. See Figure 3. Unsnap rear electrical caddy (1) from rear inner fender. 7. Remove and save two fender support bolts (2), washers (3), and grabstrap (4) from rear fender. 1 2 3 4 is03548 1. Rider seat post 2. Nut 3. Washer 4. Grabstrap Figure 1. Passenger Pillion and Mounting 2 1 3 i03571 1. Seat lanyard 2. Hole in pillion 3. Passenger pillion Figure 2. Seat Lanyard and Passenger Pillion 8. Remove four remaining fender support bolts (2) and washers (3) near center of rear fender. 9. Remove rear fender from vehicle. 3 2 4 2 3 2 3 1 is03544 1. Rear electrical caddy 2. Fender support bolt (6) 3. Washer (6) 4. Grabstrap Figure 3. Grabstrap, Rear Electrical Caddy, and Fender INSTALLATION Install Attach/Release Weldment, Rear Fender, and Grabstrap NOTE Apply Loctite 243 (blue) to last four threads of leave-on bracket screws. 1. See Figure 4. Install leave-on bracket (1) to outside surface of inner fender using two button head screws (2) and nuts (3). Tighten screws to 48 Nm (35 ft-lbs). Repeat for opposite side. 2. See Figure 5. Install release/attach weldment (1) to leave- on brackets (2) using two washers (3) and socket head cap screws (4). Tighten screws to 25 Nm (18 ft-lbs). Repeat for opposite side.

HONDA GL-1500 Trailer Wire Harness with Relay INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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Seat: (if optional accessory wire is to be used) After removing trunk pan, run a stiff piece of wire from the bottom of the left saddlebag frame behind the rear tire up until it comes out under the trunk. Then hook open end of wire harness to fish wire and tape with electrical tape. Pull the harness back down to the bottom of the saddlebag frame. Route the long part of harness wire around the back of the license plate light to the right side 6-pin vertical connector just in front of tail light assembly. Unplug the stock connector and plug wire harness in between the stock plugs. Do the same for the left side with the short side of the Y on the harness. Now pull the slack down from the bottom of the harness and tuck all of the wires under the frames tubes so that the pan can be reinstalled without any problems. You can now hook up the loose ends of the harness to any style connector to match your trailer connector using the following color codes: GREEN GROUND ORANGE- LEFT TURN YELLOW- BRAKE BLUE- RIGHT TURN BROWN- TAIL RED POWER . Note : This accessory is an electronic isolated trailer wire harness. It should be installed by a qualified mechanic . 1. Disconnect the negative from the battery. 2. Install the harness. 3. When connecting to the trailer make sure all wires are used for the proper use and are waterproof. Make sure there are not exposed wires. Consult the trailer manufacturer for proper wiring. 4. Reconnect the battery negative. Double check the functions

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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KAWASAKI VULCAN 700/750 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Place the bike on the center stand. 2. Remove the three clamps attaching the heat shield to the left hand head pipe and set the heat shield aside. 3. Remove the two heat shield clamps attaching the heat shield to the right hand head pipe and set the heat shield aside. 4. Loosen the pinch clamps where the mufflers slip onto the muffler box (the black box in front of the rear tire). Remove the bolt attaching the mufflers to the footrest. 5. Remove the left and right hand mufflers and set them aside. 6. Remove the right hand foot rest and brake pedal assembly from the frame. 7. Loosen the pinch clamps where the head pipes slip into the muffler box. 8. Remove the two nuts that secure the right head pipe to the cylinder head. Repeat this step on the left head pipe and save the nuts for reuse. 9. Remove the left and right hand head pipes. Remove the header flange from each head pipe and save the two flanges for reuse. Set the head pipes aside. 10. Remove the two bolts (one on each side) that mount the muffler box to the frame. Lower the muffler box down and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Remove the two bolts from the charcoal canister mount, the canister is located in front of the rear tire. Using the two 6mm x 16mm bolts (supplied) install the centerstand stop bracket, (stamped 205), by aligning the holes in the bracket with the holes in the canister mount. Be sure the bend closest to the holes in the bracket angles towards the rear of the motorcycle and the tang is pointed to the left hand side. Tighten the two 6mm bolts at this time. 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns. Repeat this step with the rear heat shield. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 3. Install a three hole mounting bracket to each muffler as shown in figure 1. Slide one dog bone shaped nut plate under the bracket that is welded to the backside of each muffler. Attach the mounting bracket using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note : The muffler bracket stamped #284 is for the right hand muffler, bracket #285 is for the left hand muffler. 4. Install the rear exhaust assembly, with the heat shield attached, to the rear cylinder using the stock flanges and nuts. Install the stock muffler mounting bolts through the rear footrest brackets, the supplied muffler brackets, and finger tighten the nuts. Leave them loose at this time. 5. Repeat step #4 with the front head pipe

HONDA VTX 1800R AND VTX 1300R SOLO RACK INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Remove the stock passenger seat. And “U” shaped mounting bracket from the rear fender. 2. Install the 2 “L” brackets provided (NOTE: there is a left and a right) onto the rear fender using the bolts from the stock bracket. Snug the bolts just enough to still allow them to slide. 3. Using the 3 knobs provided re-install the stock seat using the knob with the long stud in the rear hole. Center the slot in the seat and tighten the knob. Install the 2 knobs with the short threaded studs through the front seat mounting holes and into the new brackets. Center the bracket holes to the seat holes and snug the knobs. This will align the forward brackets. Carefully remove all three knobs and the seat. Tighten the forward bracket securely. 4. Install the solo rack starting with the 2 short knobs at the front then the long knob at the rear with the black spacer between the rack and the fender. Tighten all 3 knobs securely, as tight as you can by hand. Lost knobs are not a warrantable item. Now you can switch from your new cool solo rack look back to your stock passenger seat in seconds without any tools. NOTE: when using the stock seat, place the black spacer on the long rear knob and install them over the stock rear seat bracket. This keeps the long stud from extending below the inside of the fender and possibly contacting the rear tire if the rear shocks should bottom out

Cobra Vintage Bike Service And Parts Manual

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Filed Under (Cobra) by admin on 10-11-2010

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BEFORE EACH USE, REMOVE THE COVER PLATE OF THE THROTTLE ASSEMBLY AND CHECK THE THROTTLE CABLE FOR FRAYING. IF THE CABLE SHOWS ANY SIGNS OF WEAR, FRAYING OR UNWINDING, REPLACE BEFORE USE. ALSO CHECK THE CABLE FOR STICKING OR PINCHING ON THE FRAME. IF THE CABLE DOES NOT WORK SMOOTHLY, REPLACE BEFORE USE. IT IS RECOMMENDED THAT THE THROTTLE CABLE BE REPLACED AT LEAST ONCE A MONTH. 2. Change engine transmission oil every 2 to 3 hours. See “specifications” for proper fluid type. Fill to hole. 3. Change fork and shock oil every 9 hours. See “specifications” for proper fluid type. 4. Keep all moving parts sprayed with WD-40 or light oil. 5. Keep ignitions clean and dry. Spray with WD-40. It is very important to keep the ground wire going from the frame to the engine clean and connected. 6. Check all nuts, bolts and screws for proper torque. 7. Check the chain for proper adjustment. See “chain tension” section for details. 8. We recommend 15 pounds of pressure in the rear tire in rainy and muddy conditions and 20 pounds on hard packed conditions or where there are a lot of jumps. 9. INSPECT: • chain rollers • swing arm for stress cracks or signs of fatigue • frame for stress cracks or signs of fatigue • wheels for cracks and signs of fatigue • handle bar clamps • make sure kill switch works • make sure engine is running properly and the carburetor jetting is set correctly

Yamaha Rear Suspension Lowering Kit installation Manual

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

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1. This lowering method requires replacement rear suspension coupling components. This is a simple task, and is completely reversible. In addition, this kit provides for a 0″ setting, to easily return your bike to its original height. First, raise the rear tire off of the ground by the frame before you begin. Raise the motorcycle so no weight is applied to the rear wheel, allowing the rear wheel to spin freely. 2. Next, become familiar with your lowering kit. You’ll notice that there are two corners of the lowering component with two holes each, and one corner with a single hole. The corner with the single hole attaches to the swingarm (the bolt that is closest to the rear wheel). The only important part of this familiarization process, is to make sure that you get the part oriented in the correct position. The following photos will explain the purpose of the different holes, and also help you turn the part in the correct position before you install it. Look at the first photo on the next page: In the photo above, the part is positioned just as it should be, for installation on the left-hand side (kickstand side) of the motorcycle. A quick measurement will show that Dimension “A” on Side “A” should be shorter than Dimension “B” on Side “B”. If not, flip your part over (turn the face you are viewing away from you, but keep the corners with two holes on your left), and measure again. Next, study the photo below for info on the different heights you can set your bike to… When installed, Hole “0″ will place the bike at it’s original height. Placing the top bolt in Hole 1, and the bottom bolt in Hole 0, the bike will be lowered approximately ¾”. Placing the top bolt in Hole 1, and the bottom bolt in Hole 1, the bike will be lowered approximately 2″. Simple, eh? Now, let’s move on to installation. 3. Below is a photo of the factory suspension coupling as installed in your motorcycle. This photo was taken from the LH side of the bike, to keep things in perspective with our previous photos. Loosen the three bolts holding the original suspension coupling, and remove. Be aware that the rear wheel will drop down when the bolts are removed, just so there are no surprises!

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