Yamaha R1 2007-2008 Frame Slider Installation

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Filed Under (Yamaha) by admin on 01-01-2012

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Installation Steps: 1. Remove left and right body panels. 2. Remove the left side engine stud. Mount the left side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the left side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 3. With the offset in the correct position remove body and torque down to OEM torque specs. 4. Using one drop of blue thread locker mount the left side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 5. Remove the right side engine stud. Mount the right side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the right side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 6. With the offset in the correct position remove body and torque down to OEM torque specs. 7. Using one drop of blue thread locker mount the right side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 8. Mount left and right bodywork

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Yamaha Road Star 1600/ 1700 Exhaust kit bill of materials Installation Instructions

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

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1. Remove left side cover, by removing allen bolt as shown (Fig 1). Once bolt is removed, push cover to motor and push back carefully to your upper body. Figure 1 2. Once left side cover is removed, remove 6mm bolt to opposite side cover as shown (Fig. 2). Also remove allen bolt on right side as shown (Fig 3) and remove carefully . Figure 2 Figure 3 . Remove two allen bolts to the muffler bracket, and also loosen hose clamp to bottom head pipe. (Fig 4 & 5) Figure 4 Figure 5 4. Remove bolt next to rear O/2 sensor bracket as shown (Fig 6), also remove Phillips head bolt from O/2 bracket and slide O/2 sensor off bracket as shown (Fig 7). Once bracket is removed mount just bracket on with Phillips head bolt back on. Figure Figure 7 5. Disconnect O/2 by using a pick on inside switch on opposite side of O/2 bracket. With pick on inside push to you and unplug. (Fig 8 & 9) Figure 8 Figure 9 6. Remove two socket cap nuts from rear head pipe flange as shown (Fig 10). Once removed, remove both mufflers and rear head pipe carefully. Slide muffler back and shift rear head pipe to you. (Fig 11) Figure 10 Figure 11 7. Slide wire off bracket from the front O/2 sensor as shown (Fig 12). Also use pick to remove O/2 sensor, push to you and unplug. Figure 12 Figure 13
8. Remove two allen bolts from foot rest/ brake to give you access to head pipe. (Fig 14) Figure 14 9. Remove two allen socket cap nuts off front head flange and remove head pipe. (Fig 15) Figure 15 10. Remove stock muffler bracket by removing two alien bolts as shown (Fig 16). Also remove bolt that holds stock bracket to the brake line (Fig 17). Once that is done remove brake line from caliper and slide though muffler bracket and re-install. Figure 16 Figure 17
Assembly 11. Remove O/2 sensor from stock pipe and install O/2 sensor in Roadhouse front head pipe and mount front head pipe with stock socket cap nuts on bike as shown. (Fig 18 & 19) Figure 18 Figure 19 12. Mount rear head pipe as shown (Fig 20), including stock socket cap nuts. Also mount y-collector with rear head pipe. Y-collector must slide into front head pipe in one. Install Roadhouse O/2 sensor wire lead from hardware kit into y-collector. (Fig 21) Figure 20 Figure 21

Kawasaki Vulcan 1600 Classic Exhaust Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Loosen both top and bottom muffler hose clamps as shown. Remove 10mm bolt with 10mm nut on back side of bracket as shown. 3. Loosen 6mm bolt on passenger foot peg bracket as shown. Once loose remove top muffler 10mm nut and 10mm bolt. Slide bolt out of rubber grommet. . Carefully remove top and bottom stock mufflers, by sliding both mufflers out by rear fender. ( Use Phillips screw driver and remove bolt as shown. Remove side cover carefully by pulling towards your body.figure Figure 9 6. Remove rear head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull rear head pipe away from bike and set aside. (Fig.10)

Kawasaki ZX10R 2008 Frame Slider Installation And Removal Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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installation Steps: 1. Remove right side bolt. Mount right side puck with (99-HB-SH10125060) Socket Cap 10 X 1.25 X 60 Main Engine Stud and torque down. 2. Remove left side mid panel. 3. Locate the left side engine stud and remove bolt. 4. Some photos in this section are used for illustration examples only. It is up to you how you decide to cut your motorcycles bodywork to accept the frame slider there are many different ways customers go through this process. Shogun is not responsible for any part of your motorcycle for any reason. Precisely measure location of cut and if in doubt at any point please call us before the install process has begun. Professional installation is recommended. Always use proper safety measures during the install of this product. Do not try to install this product without proper tools, recently calibrated torque wrench, correct torque specifications from factory service manual, safety goggles and gloves. 5. Body Prep. Use masking tape to completely mask off the area on the body where you will be working. We usually will tape off approximately 6 to 8 inches around the though hole area and any other edges that could get bumped or scratched while working. Tip: In some locations you may want to double up the thickness of the masking take to give extra protection

Kawasaki ZX6R/ RR 2003-2004 Frame Slider Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Locate and remove right engine stud. Tip: Both main engine studs on the ZX6R tend to be very tight from the factory, use a stubby socket to remove stud. Make sure you have good engagement or the head of the bolt can strip. 2. Mount Right side frame slider using 99-HB-SH101250110 Socket Cap 10 X 1.25 X 110 Main Engine Stud and torque down to OEM torque specs. 3. Remove the left side OEM motor mount bolt. 4. Using the 10 X 1.25 X 110 Bolt supplied in the kit: Use the 99-SP-750-4200-L Left Side Bell Type Spacer Black Anodized 5. The small end of the (99-SP-750-4200-L Left Side Bell Type Spacer Black Anodized) goes against the left side of the frame. The longer of the two frame sliders goes on top of the spacer. Using the 10 X 1.25 X 110 Socket Cap mount and torque down to OEM specs

Kawasaki Vulcan 1600 Classic Exhaust Serrated Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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Loosen both top and bottom muffler hose clamps as shown. (Fig.1&2) Figure 1 Figure 2 2. Remove 10mm bolt with 10mm nut on back side of bracket as shown. (Fig. 3&4) Figure 3 Figure 4 3. Loosen 6mm bolt on passenger foot peg bracket as shown. Once loose remove top muffler 10mm nut and 10mm bolt. Slide bolt out of rubber grommet. (Fig.5&6) Figure 5 Figure 4. Carefully remove top and bottom stock mufflers, by sliding both mufflers out by rear fender. (Fig. 7) Figure 7 5. Use Phillips screw driver and remove bolt as shown. Remove side cover carefully by pulling towards your body. (Fig.8&9) Figure 8 Figure 9 6. Remove rear head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull rear head pipe away from bike and set aside. (Fig.10) Figure 107. Remove stock front head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull front head pipe away from the bike and set aside. (Fig.11&12) Figure 11 Figure 12

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