2000 & later Harley Davidson Softails Drag Specialties Shocks Installation Manual

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Filed Under (Harley Davidson) by admin on 31-03-2012

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1. Place motorcycle securely on stand or blocks so the rear wheel is slightly off the ground. 2. Per instructions in a authorized shop manual, remove your old shocks. Note location of the mounting hard- ware. 3. Before reinstalling a Drag Specialties adjustable ride height shock, spin the non-flanged nut all the way onto the stud mount, followed by a bushing-cup, bushing, and sleeve. Then install shocks as you would a stock unit, following an authorized shop manual. With the non-flanged nut spun all the way onto the stud, the stock ride height is achieved. Once you have installed the other bushing, bushing-cup, and flanged nut you can now install the safety E-clip. This E-clip is snapped into the groove near the end of the stud mount where the threads stop. This is to serve as a reference point ONLY – when the flanged-nut reaches it you have lowered your ride height the maximum 2 inches. DO NOT torque the flange-nut against the E- clip (see figure 1). 4. Tighten all shock mounting bolts to the proper torque specifications (see shop manual for specs). 5. Drag Specialties shocks have adjustable pre-load to compensate for varying weights. A Harley Davidson pre-load adjustment wrench is necessary to adjust the pre-load setting. Progressive Suspension, Inc. wrenches are available as Part # SW-784 from most Dealers and Accessory Stores and the Harley Davidson wrench is available as part #94455-89 from any Harley Davidson Dealer. Spring preload is set by us to the lightest setting. To increase preload for heavier riders/loads/passengers, loosen locknut with the inside portion of the supplied wrench or a 1 1/ 16 ” wrench and back it off several turns. Use the supplied wrench or a Harley

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YAMAHA SINGLE SIDED SWINGARM REMOVAL AND INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 27-12-2011

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1. Disconnect Battery 2. Lift and secure bike 3. Remove brake-side floorboard 4. Remove exhaust. 5. Remove rear fender 6. Remove front pulley cover 7. Remove wheel, pulley, and brake assembly simultaneously. Now remove front pulley from transmission. (Keep up with the stock nut and lock washer; these will be used during assembly) 8. Remove Passenger pegs; now remove the plastic covers in the frame that cover the pivot tube bolts. 9. Remove the stock shock bolts ( keep for re-assembly) 10. Remove the pivot tube bolts. 11. Remove the stock swingarmb12. Install “new” belt at this time. 13. Install supplied pivot tube, and bearings in RC swingarm. 14. Install shock bolt with red loctite in RC swingarm. (Do not tighten bolt at this time) 15. Insert supplied pivot bolts with red loctite through frame and supplied bushings into the RC swingarm. (Right side bushing has flats) 16. Torque shock and pivot bolts to factory specs. 17. Install belt adjustment bolts and single side keys into swingarm.

HONDA ST1100 SHOCK MOUNTING INSTALLATIOAN AND REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 24-11-2011

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Works Performance Products, Inc. constructs two types of shocks for the ST1100. Both have an integral reservoir (often
referred to as a “piggyback” reservoir). This reservoir increases the shock fluid capacity. This additional fluid helps
dissipate heat generated by the damping in the shock. The reservoir contains a polyurethane bladder which separates
the nitrogen from the shock oil. The shocks differ in the external adjustments. RACER The Racer shock features a large 1.375” damping piston and Works’ exclusive check-ball and orifice damping system. This damping system allows an extremely wide range of damping through the high-, medium- and low-speed circuits that are incorporated in the design. It has spring pre-load adjustment to change the ride height to accommodate changing loads. PRO RACER
The Pro Racer shock features a twin tube design with external compression and rebound adjustments. This design also
incorporates an orifice damping system, one that is unique to Works Performance. This damping system allows an
extremely wide range of adjustments to the high-, medium- and low-speed circuits on compression and rebound. it has
spring pre-load adjustment to change the ride height to accommodate changing loads. (Damping adjustment information
is contained in an additional instruction sheet that comes with the Pro Racer series of shocks.

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)

1999-2010 Yamaha Roadstar 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 14-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n Remove the horn located on the lower left side. Also remove the Remote Adjustable Pre-Load adjuster knob by removing the screw located in the center of the knob, then pull it straight off. n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the opening behind where the horn was located on the left side of the bike – see figures 2 and 3. Do not loosen or attempt to rotate the line between the shock and the adjuster. n Reinstall the adjuster knob, and torque the screw to 50 in/lbs. (5.65 N-m). n Make sure the shock rebound adjustment is at the rear facing the left side of the motorcycle and the pressure valve is facing up. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the stock two drive-belt cover bolts – as shown in figure 4. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. Reinstall horn. To adjust the ride height, simply turn the adjuster knob clockwise (looking at it from the back of the bike) to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height

BMW F650GS Single Shock Supplement

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Filed Under (BMW) by admin on 14-02-2011

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Mount the shock & adjuster as you would your stock shock & adjuster per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the same path as the stock line was routed to the same location. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing forward. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m) as in figure 3. Then mount the bracket and adjuster to the bike in the same location as the stock preload adjuster/bracket using the stock bolts as shown in figure 4. Check banjo-bolt to cylinder clearance and adjust if necessary via tolerances in mounting bracket holes. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. To adjust the ride height, simply turn the adjuster knob clockwise to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height.

Suzuki VZR1800 465 Series Single Shock Supplement

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Filed Under (Suzuki) by admin on 13-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n On the left side of the motorcycle, remove the secondary drive cover, rectifier cover, and rectifier. Also remove the Remote Adjustable Pre-Load adjuster knob by removing the screw located in the center of the knob, then pull it straight off. n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster (knob removed) through opening between the frame and the rear of the motor – just behind & below where the shift-shaft comes out – on the left side of the bike (see figure 3 & 4) . Do not loosen or attempt to rotate the line between the shock and the adjuster. n Reinstall the adjuster knob, and torque the screw to 50 in/lbs (5.65 N-m). n Make sure the shock rebound adjustment is towards the rear and facing down and the pressure valve is towards the front facing up. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the two lower mounting bolt holes for the rectifier bracket as shown in figure 5 – one of which is the lower mounting bolt for the rectifier, which will be replaced with the supplied longer fastener. Reinstall the rectifier, sandwiching the adjuster bracket behind it (see figure 6) . n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. n Reinstall the secondary drive cover and rectifier cover (figure 7) , then proceed to adjust your ride height.

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Yamaha XV-19 Raider 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 13-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster towards the rear (see figure 2) and to the right side of the swingarm (see figure 3) . n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is toward the rear and facing the right side of the motorcycle and the nitrogen pressure valve is facing down. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Locate the EXUP valve servo mounting bracket, specifically the two bolts used to secure it to the frame (see figure 4) . They below the seat on the right hand side of the motorcycle. n Now either mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m), then mount the bracket and adjuster to the bike using two EXUP valve servo mounting bolts (as shown in figure 5) – or – mount the adjuster bracket to the frame using those two bolts, then mount the adjuster to the bracket (may require removal of exhaust stay). n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources.

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KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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Filed Under (KTM) by admin on 12-11-2010

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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Express ATVS -250cc Cobra Setup/ Installation Manual

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

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Unpacking your Cobra Installing the front shock Installing the front tires Installing rear shocks Installing the rear tires Installing seats and harnesses Steering wheel installation Roll cage installation Safety checks / Adjustments General maintenance Unpacking your Cobra First off you should pull the carton off from your new 250 Cobra cart. Inspect the cart thoroughly to make sure that your new Cobra has not been heavily damaged. You will notice that the product has a metal frame holding it in place; you may want to start removing bolts from the shipping steel frame. The next step is to remove the metal frame and lift it off of the cart. Remove any of the metal frame that may afford resistance when working on the cart it self. Be careful the metal frame may be heavy and sharp. Now would also be a good time to inspect your Cobra a little more thoroughly. In the box with the Cobra you should have found a box containing miscellaneous hardware. Installing the front shock Using some of the bolts you found in your box, install the front shocks sliding the bolt through the brackets and tighten the nut down. Next, you will need to place the ball head into the turning arm, then tighten the castle nut and insert a cotter pin so that the castle nut doesn’t loosen and become a hazard. Installing the front tires
Find the front tires and place them on the front hub and place the lug nuts on the studs. Tighten them down. Make sure that all of the lug nuts are on tightly. Installing the rear shocks Moving to the rear of the Cobra you will notice the rear shocks are not inserted. Place the rear shocks into the bracket on the rear of the Cobra. Slide one of the provided bolts through the bracket and shock eyelet and tighten the bolt down. Installing the rear tires Now that the shocks have been placed properly you can install the rear tires, place the tires onto the axle then place the rear rim lined up onto the axle and tighten the provided castle nut down. Place the cotter pin through the axle and bend off to the side. This is so the castle nut does not loosen under load. Installing the seats and harnesses
(The arrow points to an example of where the seat bolts mount) Find the two racing seats shipped in the box with the Cobra. You will need to affix them to the frame by sliding the bolts up through the bottom of the frame. This can be tricky so have patience. Once both seats have been placed in the cart and tightened find the harnesses. Once found the harnesses mount to a bracket behind the seats. Place a bolt through the bracket and bolt the harnesses down tightly. Installing the steering wheel Find the steering wheel and place it onto the steering wheel mount. Grab the six small screws and place them through the steering wheel and mount, tighten them down but also make sure the top of the wheel is facing up. Installing the roll cage

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