HARLEY DAVIDSON FENDER SUPPORT COVER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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REMOVAL NOTE Complete all removal and installation procedures on one side before performing on the other side. 1. See Figure 1. Remove rear turn signal assembly (2) following the instructions in the service manual. Save all hardware for installation. 2. Remove the upper shock absorber hardware (3) following the instructions in the service manual. Save all hardware for installation. 3. Remove the rear fender support cover (4) following the instructions in the service manual. Save all hardware for installation. INSTALLATION 1. See Figure 1. Install the rear fender support cover (4) with the stock hardware. Tighten finger-tight. 2. Install the rear turn signal assembly (2) following the instructions in the service manual. 3. Install the upper shock absorber hardware (3) following the instructions in the service manual. 4. Remove the rear fender support cover hardware and apply Loctite Threadlocker and Sealant 243 (Blue) to the threads of the screws. Tighten screws to the specifications in the service manual. 5. Thoroughly clean the mounting surface of the fender support cover with an equal mixture of water and isopropyl alcohol. Peel the paper backing from the new reflector and install reflector (1). Press the reflector firmly. Allow AT LEAST 24 hours after applying the reflectors before exposing the areas to vigorous washing, strong water spray or extreme weather

Yamaha Road Star Trike Conversion Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. c. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for re-installation after modification are noted. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model Installation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster

Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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2005-2007 KTM 5018 DCC 5018 SXS 5018 SMR WP SHOCK ABSORBER REPAIR MANUAL

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

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liter fuel consumption is equivalent to approx. 15 operating hours Check the bearing in the shock absorber top / replace if necessary Check the piston rod on scratches / leakage Check the static sag – before riding Check the spring Check the bump rubber Check the O-ring of the spring retainer / replace if necessary Complete maintenance of the shock absorber 10 hours 65 liter 20 hours 130 liter 30 hours 200 liter 40 hours 260 liter 50 hours 325 liter 60 hours 400 liter 70 hours 455 liter 80 hours 520 liter 90 hours 600 liter 100 hours 665 liter Adjusting the position of the compression and rebound damping Rebound damping: -Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: -Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, high speed: -Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Adjusting the spring preload NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. -Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. -Tighten the lock screw on the adjusting nut. Recommended periodic maintenance and inspection of the 5018 SXS/SMR Shock absorber

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HARLEY DAVIDSON SPORTSTER LOW REAR SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION NOTE Internal shock absorber components are not repairable beyond the Service Parts listed on this instruction sheet. Consult your Harley-Davidson dealer if further service is required. The installation procedures for this kit are the same as the original equipment (OE) installation procedures in the Service Manual. Refer to the appropriate Service Manual for the rear suspension system removal and installation procedures. The OE hardware will be re-used in the kit installation. Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) SHOCK PRELOAD (SPRING) ADJUSTMENT Refer to the appropriate Service Manual for spring adjustment. Spanner wrench (94700-52L) is required for spring adjustment. SERVICE PARTS 1 is04854 Figure 1. Service Parts: Sportster Low Rear Suspension Kit Table 1. Service Parts: Sportster Low Rear Suspension Kit Part Number Description (Quantity) Item 54734-04 Rear shock (2)

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HARLEY DAVIDSON TOURING DETACHABLE SISSY BAR UPRIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION NOTE The Detachable Sissy Bar Upright can be installed on either a two-point or four-point Docking Kit. 1. If not already in place, install the Detachable Docking Hardware Kit (either two-point or four-point) to the vehicle per the instructions in that kit. 2. See Figure 2. While standing behind the motorcycle, place the left-side and right-side front upright notches (with bushings in place) onto the docking points (A) inboard of the upper shock absorber mounts. Make sure the notch bushings (9) seat fully into the shock absorber docking points. 3. See Figure 2, arrows (D) and (E), and Figure 1. Position the rotary latches (4) over the rear docking points (3). Check to be sure the upright sides (1) and latches fit into the neck (7) of the rear docking points as shown. This may require some gentle squeezing or spreading of the sissy bar upright sides. NOTE After installing the sissy bar upright, check to be sure the sissy bar is secure. The front and rear docking points must be fully engaged. See Figure 1 for correct engagement. 4. Push the rear of the sissy bar downward and close the latches by pressing the latch lever as far forward as it will go. You will hear a “CLICK” when the latch is in place. If the latch does not easily close, do not force. Check the sissy bar alignment again, as described in steps 2 and 3. 5. To remove the sissy bar upright, press the release button (G) on each side and pull the latch levers back. Carefully lift the rear of the sissy bar up and pull the upright out of the front docking points

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HARLEY DAVIDSON TOURING LOW PROFILE REAR SUSPENSION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION 1. Refer to the Service Manual and follow the instructions given to remove the seat. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) 2. Disconnect the battery cables, negative cable first or remove the main fuse if equipped. 3. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 4. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 5. Fasten the air pump, part number 54630-03A to the rear air suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 6. Using the pressure relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 7. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air hose fittings

HARLEY DAVIDSON SPORTSTER LEATHER SADDLEBAG KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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SADDLEBAG INSTALLATION 1. See Figure 3. Remove the rear shock absorber bolt (Figure 1, Item 1). Position the 0.531 x 0.75 x 0.25 inch spacer (7) and the front saddlebag bracket attachment hole over the rear shock absorber bolt location. Secure with the 1/2- 13 x 3.75 inch screw (5). 2. See Figure 3. Position the 0.325 x 0.75 x 0.25 inch spacer (8) and the rear saddlebag attachment hole over the second hole on the rear of the fender, fender support cover, and relocation pad. From the underside of the fender, insert a 5/16-18 x 3.00 inch screw (6) and secure with locknut (10). Tighten locknut (10) to 24-27 ft-lbs (32.5-36.6 Nm) . 3. Tighten the front screw (5) to 21-27 ft-lbs (28.5-36.6 Nm) . 4. See Figure 3. Assemble an isolator washer (12) onto an isolator bushing (13). Place a screw (15) through the bushing. 5. Place the screw and bushing assembly into the top hole inside the saddlebag back. 6. See Figure 3. Push a saddlebag isolator (14) over bushing with cone shape toward saddlebag. 7. Place saddlebag in position on bracket and insert the new screw (15) into the bracket. Do not tighten. 8. Repeat steps 4 through 7 for remaining holes. With all isolators in place, tighten screws to 96-120 in-lbs (10.8- 13.6 Nm) . 9. Repeat Steps 1 through 8 for the opposite saddlebag. 10. Raise rear wheel until the rear shock absorbers align with shock absorber mounting holes on the swingarm. Support the wheel to prevent it from falling during the following step. 11. See Figure 1. Attach rear shock absorber to swingarm by installing bolt (1), washer (2) and nut (4). Tighten bolt to 45-50 ft-lbs (61.1-67.9 Nm) . Repeat step on opposite side of motorcycle. INSTALL REFLECTORS Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) 1. See Figure 3. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Mark hole location. 2. Using appropriate tool, make two 3/16 in. holes in sad- dlebag. 3. Install reflector mount (3) on saddlebag using two pushnuts (2). 4. Remove adhesive backing from reflector (4) and install on mount. 5. Repeat steps 1 through 4 for the opposite saddlebag. INSTALL SEAT After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1. See Service Manual instruction to install the seat

YAMAHA YBR250 OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 15-12-2010

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Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. To increase the spring preload and thereby harden the suspension, turn the adjusting ring on each shock absorber assembly in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring on each shock absorber assembly in direction (b). Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Spring preload setting: Minimum (soft): 1 Standard: 3 Maximum (hard): 5 EAU36700 Luggage strap holders 1. Luggage strap holder There are four luggage strap holders on the bottom of the seat. To use the strap holders, remove the seat, unhook the straps from the hooks, and then install the seat with the straps hanging out from under the seat. (See page 3-9.) EAU15301 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) EWA10240 The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described

Honda CBR 900 RR Öhlins shock absorber kit Mounting instructions

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Filed Under (Honda) by admin on 14-12-2010

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Put the motorcycle on a stand so the rear wheel is clear of the ground. Make sure it’s steadily fixed so it will not fall over. 2 Remove the seat (2 screws from below) and loosen the six screws (four rear and two front) holding the fuel tank. The tank side covers must be loosened as well. 5 Remove the lower shock absorber mounting bolt from the triangle link. 6 Lower the shock absorber and turn it slightly so that it is possible to remove the horizontal attachment bolt. 7 Lift the rear end of the motorcycle enough to make removal of the shock absorber rearwards possible. 8 Attach the Öhlins shock absorber in reverse or- der. 9 Mount the upper and lower shock absorber bolts. 10 Attach the pre-load adjuster to the rear foot rest bracket on the right side of the motorcycle