Honda 400EX Hub installation instructions

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Filed Under (Honda) by admin on 20-12-2011

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Remove all contents from its packaging and verify that all parts are present and free from damage. You should have the following items: (2) wheel hubs (2) smaller tapered bearings (2) large tapered bearings (2) wheel bearing nuts (2) dust caps (2) inner bearing seals (6) M3 x .5 screws (2) cotter pins (2) inner bearing spacers 2. Completely remove the old hubs from your quad and clean the spindle and the surrounding areas. It is very important to keep the new bearings and seals clean during installation for long life. Be sure to remove the factory inner bearing spacers from the spindle and discard. They will not be used in re-assembly. 3. Pack your new Timken tapered wheel bearings with a liberal amount of high quality wheel bearing grease. A wheel bearing packer works best, however you can accomplish the task by placing the grease in the palm of your hand and manually working it in between the bearing rollers. We also recommend that you pack the area between the bearing races in the hub with grease for additional lubrication and protection against moisture. 4. Place the large wheel bearing (inner) into the hub and install the inner seal. The seal should bottom out against the step in the bore and the face should be flush with the hub. 5. Remove the brake rotors from your old hubs. Re-install the rotors on your new hubs and be sure to use medium strength Loctite on the threads. 6. Apply a light film of grease or oil to the large diameter of the spindle stud. Install the new o-ringed bearing spacer onto the spindle. 7. Apply a thin film of grease to the seal surface on the bearing spacer and the inside diameter of the seal to prevent the seal from running dry. Install the hub onto the spindle and slide the outer bearing over the spindle and install the new bearing nut furnished with your hubs. Do not use the factory nut or washer. 8. SETTING THE BEARING PRELOAD: It is first necessary to seat the bearing before setting the preload. This aligns the rollers and prevents the bearings from loosening after a short period of use. To seat the bearing, tighten the spindle nut while you rotate the hub until the hub becomes difficult to spin. With the bearing now seated, you must set the bearing preload. Preload means placing a small amount of force against the bearings to remove any clearance between the bearing race and the rollers. This is done by backing the nut off completely and re-tightening it with your fingers. Do not rotate the hub while setting the preload . If a hole in the spindle is not accessible for installation of the cotter pin, adjust the nut tighter to bring a hole into alignment. Install the cotter pin and bend the pin around the outside of the nut. Do not attempt to bend the pin toward you (over the end of the spindle) or it may rub on the inside of the dust cap.

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HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

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

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INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

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STREET TUNNEL RAM INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 07-02-2011

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PREP AND TUNING FOR POWER: 1. Specific applications may show an increase in performance through additional carburetor tuning. 2. Aftermarket distributor curve kits and aftermarket ignitions may be used with the Street Tunnel Ram intake manifold. 3. Use modified or high performance cylinder heads such as our Performer RPM, and port match the intake manifold to the heads. 3. The engine’s compression ratio should be at least 9.5:1 to work properly with Torker-Plus or Performer RPM camshafts. INSTALLATION PROCEDURE INTAKE MANIFOLD BASE 1. Use only recommended intake gaskets set when installing this intake manifold. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4. Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ΒΌ” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5. Install the intake manifold hold-down bolts (We offer an Intake Manifold Bolt Kit #8504 that includes small-head silver Cadmium-plated bolts and matching hardened washers). Apply a small amount of RTV silicone to the threads of the eight inner bolts (1,2,3,4,5,7,9, & 11) (See Figure 1) . This will prevent oil weepage, as generally these are not blind holes in the cylinder head. 6. Torque all of the manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. INTAKE MANIFOLD TOP 1. Apply Edelbrock Gasgacinch sealant P/N 9300 to the gasket mating surface and install the gasket and manifold top. 2. Install and tighten the supplied hold down bolts using a liquid thread-locking compound on the bolt threads. As an extra safety precaution, we suggest you drill a small safety wire hole in the head of each bolt and safety wire them together. Edelbrock Corporation expressly disclaims any liability for any and all consequential damages

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HARLEY DAVIDSON FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Remove stock gas cap from fuel tank. 2. Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. 3. See Figure 1. Install gas cap into fuel tank. is00407 Figure 1. Screw in Gas Cap is00466 Figure 2. Note Position of Arrow on Trim Ring 4. Push down on gas cap and rotate clockwise one-eighth of a turn to lock. To unlock, push down on gas cap and rotate counterclockwise one-eighth of a turn. 5. See Figure 2. Before removing adhesive backing, note position of arrow on inside diameter of chrome trim ring. NOTE As you rotate trim ring, you will see gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. Rotation of trim ring should be minimal. 6. See Figure 3. With the arrow pointing toward front of motorcycle, rotate chrome trim ring slightly to determine best position of bottom chrome trim ring to contour of the fuel tank 7. See Figure 4. Mark position of chrome trim ring with masking tape or grease pencil. 8. Carefully cut masking tape with a hobby knife making sure not to scratch chrome trim ring or paint surface on fuel tank. 9. Peel off adhesive backing from chrome trim ring. 10. Using gas cap to center and masking tape (or grease pencil mark) to align, press chrome trim ring firmly into position for about ten seconds. 11. Peel off masking tape (or remove grease pencil mark) from chrome trim ring and fuel tank. 2 1 is00414a 1. Masking tape 2. Cut masking tape Figure 4. Align Trim Ring and Press into Place NOTE Allow adhesive trim ring to cure for about 5-7 minutes before you continue with kit installation. Install Flush-Mount LED Fuel Gauge 1. Remove the seat following the instructions in the service manual. 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) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 2. Disconnect battery cables, negative (-) cable first. 3. Remove stock fuel gauge. Refer to service manual for instructions. 4. Insert wires down tube of fuel tank from LED fuel gauge. 5. See Figure 5 and Figure 6. Insert LED fuel gauge in the fuel tank cup

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