2000-2003 MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 05-02-2012

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1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side anels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees

2000-2003 KTM MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 01-02-2012

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3 4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

HARLEY DAVIDSON FRONT FORK STEM BOLT CHROME COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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INSTALLATION 1. See Figure 1. Remove stock front fork stem bolt and washer (if equipped). 2. Install front fork stem bolt (2) and washer (3) from this kit. Properly adjust fork stem bearings. Improper adjustments affect stability and handling, which could result in death or serious injury. (00301a) 3. Perform the steering head bearing adjustment procedure following the instructions in the service manual. 4. Apply a small amount of LOCTITE 243 Threadlocker and Sealant (Blue) (purchased separately) to the threaded stud inside the chrome cover (1). 5. Install chrome cover to fork stem bolt. Tighten cover hand- tight. Do not over-tighten. SERVICE PARTS 1 2 3 is06245 Figure 1. Service Parts: Upper Fork Bracket Bolt Cover Kit (Typical Bracket Shown) Table 1. Kit Contents Part Number Description (Quantity) Item 45668-90 Cover, front fork stem bolt chrome 1 4453 Bolt, 5/8-18 x 1.0 inch 2 6655 Washer, 5/8 inch

HARLEY DAVIDSON FRONT AND REAR FENDER TIP TRIM INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation GENERAL The original equipment (stock) fender tip lamp assemblies must be removed and the wire(s) must be unplugged or removed as specified in the following instructions. FRONT FENDER TIP REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1994 AND LATER FLT MODELS 1. Refer to the applicable FLT Service Manual. Remove headlamp assembly with housing. 2. Locate the 3-place connector [32 in wiring diagram] through which 12vdc and electrical ground are connected to the fender tip lamp assembly. The connector locations are as follows: FLTC Ultra: Under fuse and circuit breaker block FLHT/C/C-U: On bottom of left outer fairing bracket FLHR: On left front above air suspension valve NOTE Before disassembling the connector in the next step, refer to the applicable wiring diagram and check wire colors and connections to assure that connector [32] has been located. 3. Refer to the “DEUTSCH ELECTRICAL CONNECTOR” section in the FLT Service Manual and remove the leads, connected to the fender tip lamp, from the socket half, connector [32B]. 4. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 5. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wires connected to lamp assembly. 6. Reach under left side of fender and gently pull wires through rear hole in left side of fender and then through clips on left side of fender and finally through front hole and out of trim strip. REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1993 AND EARLIER FLT MODELS, FLSTC AND FLSTN 1. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 2. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wire connected to lamp assembly. 3. Unplug wire connector located about 3 in. from lamp assembly. Cover the socket half of connector (connected to motorcycle wiring) with electrical tape. INSTALLING FRONT FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in fender and guide outer ends of fender tip trim into trim strips on sides of fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs . REAR FENDER TIP REMOVAL OF STOCK REAR FENDER TIP LAMP ON ALL MODELS Follow steps 1 through 3 given above for “1993 AND EARLIER FLT MODELS, FLSTC & FLSTN” INSTALLING REAR FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in rear fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs

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APRILIA RSV MILLE And TUONO 1000 EXHAUST SYSTEM Installation instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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1. Put the motorcycle on a side stand, we recommend a racing stand. Make sure, that surface is solid and flat. 2. Unscrew the bolts from the muffler bracket (Figure 1). Unhook the stock springs and remove the mufflers with welded link- pipes (Figure 2, 3). T-handle 13mm wrench T-handle swiveling 10mm wrench T-handle 4mm swiveling three hexagon key wrench T-handle 4mm three hexagon key wrench T-handle 6mm three hexagon key wrench Combination 10mm wrench Combination 15mm wrench Combination 22mm wrench Spring puller Figure 1 Figure 2 Figure 3 NAV – 332 3 3. Remove the lower parts of the cowling (Figure 4, 5, 6). Unscrew and remove the oil cooler into a position which allows the stock front header tube to be removed; warning: do not disconnect the coolers tubes ; make sure not to damage the cooling fins (Figure 7, 8). Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 NAV – 332 4 4. Unscrew and remove the lambda sensor (Figure 9). Remove the rubber distance cap (Figure 10). Unhook the springs on the collector (collector – header tube joint) (Figure 11). Slightly unscrew the flanges on the stock header tubes (Figure 12, 13). Remove the collector (Figure 14). Completely unscrewthe nuts on the flanges of the stock header tubes and remove the headers (Figure 15). Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 NAV – 332 5 Figure 16 Figure 17 INSTALLATION OF THE AKRAPOVIC EVOLUTION EXHAUST SYSTEM: 1. Tighten the front and rear header tubes (Figure 16, 17). 2. Slide the collector onto the headers and attach the springs (Figure 18, 19).