Harley Davidson Softail Drive Side Brake System Installation Manual

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Filed Under (Harley Davidson) by admin on 30-03-2012

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Removing The Stock Components Although the PM Drive Side Brake System can be installed with the swing arm bolted to the frame, we recommend removing it for better access as well as repainting. Begin by removing rear wheel,stock brake components and belt guard from swing arm. Photo #1 Using supplied 3/4 x 2″bolt,position Drive Side BrakeAssembly on swing arm. Slide assembly to center position of tab and axle spans. Making sure brake mounting tabs are flush with swing arm,snug 3/4 x 2″ bolt to hold assembly and mark swing arm area to be ground Photo #2 . Remove entire assembly from swing arm and thoroughly grind paint away from marked areas Photo #3 . Photo #4 Re-mount assembly to swing arm and slide to rear-most position of both axle and brake mounting tabs. Confirm that brake tabs are flush with swing arm and parallel to each other. Snug 3/4 x 2″bolt and 5/16″socket head cap screws in tabs to hold assembly during welding process. Warning Center the motorcycle on the lift so that it will not fall while you are working on it. Photo #6 Photo #5 Photo #7 Photo #9 Welding Tabs to Swing Arm Note PM recommends all welding be done by a certified welder. Photo #5 Tack weld rear of tabs to swing arm. Avoid excessive welding near brake as- sembly as heat can mar finish. Loosen socket head cap screws and 3/4″bolt,Slide entire assembly to forward most position and re tighten bolts Photo #6 (movement should require minimal effort if tabs are aligned properly) and tack front of tabs to swing arm. Remove brake assembly from swing arm. Weld tabs to swing arm.Verify alignment of tabs, as they must remain parallel to each other. Repaint swing arm and re-install on bike to factory torque specs. Installing Brake Assembly Remove primary bracket from tower assembly (this allows bracket to be installed without having to line up caliper on disc) by removing the three 5/16″socket head cap screws (commonly called allen bolts). Photo #7 Mount rear tire and bolt pulley to rear wheel. Place disassembled bracket against pulley using smaller of two supplied spacers between bracket and pulley. Slide wheel/brake assembly into swing arm. Place large spacer on right side and slide axle in. Do not tighten axle at this point . Photo #8 Slide caliper/tower assembly over disc and install 5/16″x 1″socket head cap screw in center hole to position assembly Photo #9 . Snug, but do not tighten bolt at this point.

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Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

Sherco Engine Engine Removal and Case Splitting Manual

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Filed Under (Sherco) by admin on 20-04-2011

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Engine Removal and Case Splitting Preparation 1. Wash the bike and engine thoroughly. 2. Drain transmission oil by removing drain bolt and copper washer with 5mm Allen. 3. Drain coolant by removing 3 bolts of water pump cover and lifting off engine side case.4. Remove: a. rear fender- two bolts plus one long with washer using 4mm Allen b. fuel tank hose from petcock c. fuel tank- one short bolt and washer using 4mm Allen d. chain master link and chain from front sprocket e. kick starter- one large button head bolt and washer f. rear brake- one bolt/washer using 13mm wrench g. rear brake master cylinder- 2 button head bolts h. gear shifter- one bolt i. flywheel cover – 3 bolts j. clutch slave cylinder- two button head bolts using 4mm Allen k. clutch actuating rod by pulling it out of the case l. airbox three 4mm Allen bolts and loosening Phillips head carb hose clamp m. carburetor cap/slide assembly n. carburetor by loosening Phillips head manifold hose clamp o. spark plug cap p. spark plug q. header pipe 2 bolts into cylinder head r. silencer- 3 bolts (one with washer and nut using 10mm wrench) s. cylinder head coolant hose clamp and hose t. rear shock upper bolt u. radiator plastic cover bolt, then lever up the radiator with screwdriver until the radiator “legs” pop out of frame retaining holes 5. Remove flywheel using flywheel puller tool, taking care not to lose the small Woodruff
key by placing it inside of the magnetic flywheel for safe storage. 6. Remove ignition (3 bolts) and slide rubber grommet and ignition wiring assembly out of the case and out of the way, taking special note of the ignition timing marks. 7. Remove front sprocket and 2 retaining circlips. 8. Remove clutch side case and its 10 bolts using 5mm Allen, being careful not to lose to lose the 2 aluminum alignment pins (dowel pins). Insert the dowel pins into their holes within the Right Crankcase

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