Harley Davidson AIR INTAKE SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-04-2012

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1. Preparing Vehicle a. Make sure vehicle is parked on level surface. b. Set parking brake. c. If engine has run in the past two hours, let it cool down. d. Disconnect negative battery terminal. e. Do not discard stock components after removal of the factory system. 2. Removal of stock system a. Stock air box configuration system. b. Release the four clips on the air box. c. Loosen the hose clamp on the turbo inlet pipe. d. Vehicle equipped with MAF sensor. Unplug the mass air flow (MAF) sensor. 4 d) Clamp removal. e. On vehicles equipped with IAT, unplug the IAT sensor and remove from the housing. f. Pull the air filter status meter from the grommet. g. Remove the rear section of the intake system. h. Remove the remaining stock air box system. 5 3. Installation of AEM® intake system. a. When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed to do so. i. Use the supplied torx key to remove the MAF sensor. Save screws for later use. b. Install the supplied coupler as shown. c. Place the aluminum stand in the plastic member as shown.

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1998-2001 HONDA VFR 800 Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 14-12-2011

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Identify the key components that complete our brake line kit: You should have nine (9) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) single bleeder bolt three (3) drawings, and a picture CD. There are also a total of forty (40) washers and two (2) “olive” conic inversors. Thirty six washers will be used, and two olives. The rest are spares.Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G are installed on the front of the motorcycle, while brake hoses (H and I) are installed on the rear. Each label will reference a different drawing, which will show you the location of the key brake system
components.Step 3: To ensure no paint damage from a brake fluid spill, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a couple pictures, in case you need to re-install. Step 4:Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G. Locate lines A. this hose will run from the master cylinder down to the right caliper and across the fender through the C-CLIP down to the left caliper. Line D. will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame female fitting will thread into the male with a (OLIVE) this O.E.M tubing travels to the proportion valve. Line F will run from the left caliper up through the C-CLIP to the left upper frame female fitting and thread to the male with a (OLIVE) this tubing travels to the rear master cylinder. Locate and install line E; this hose will run from the lower delay valve down to the right caliper. locate and install line C& G; line G will travel from the bottom (left) mounting point on the left caliper, to the upper inner mounting point of the left caliper this line joins line C with a double banjo bolt. line C will travel from the inner left caliper through the C-CLIP across the front fender to the inner mounting point of the delay valve

1997-2003 HONDA CBR1100 XX Black Bird Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 05-11-2011

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identify the key components that complete our brake line kit: You should have eleven (11) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) Installation CD. There are also a total of Thirty Six (36) washers and two (2) “olive” conic inversors two (2) c-clips. Thirty Two (32) washers will be used, and two olives. The rest are spares. Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G, H, K, I are installed on the front of the motorcycle, while brake hoses (J and K) are installed on the rear. Each label will reference a different drawing, which will show you the location of each brake line. Step 3: To ensure no paint damage from brake fluid, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a
couple pictures, in case you need to re-install. Step 4: Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G,H,K,I. Locate lline A. this hose will run from the master cylinder down to the Galfer t-block
joining line B to the right caliper upper mounting point. Line C will travel across the fender down to the left caliper upper mounting point. Line D will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE). This O.E.M tubing travels to the rear master cylinder. Line E Travels from the lower delay valve down to the right caliper lower mounting point. Line F will run from the (SECONDARY MASTER CYLINDER) up through the C-CLIP to the left upper frame O.E.M tubing. The female fitting will thread onto the male with a (OLIVE).This tubing travels tothe rear delay vale

2006 2007 Yamaha R6 Front Brake Line Kit INSTALLATION

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Filed Under (Yamaha) by admin on 25-05-2011

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Identify the key components that complete our brake line kit: You should have two (2) hoses, one (1) double banjo bolt, two (2) single banjo bolts, and one (1) zip ties. There are also a total of nine (9) washers. Seven (7) will be used, and two (2) are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. Take note of how the stock system was routed in case you need to re-install it. Please note there is a plastic shield on the lower triple clamp of most models; we took this piece off to ease installation. Step 4: Install the right and left (to your right and left as you sit on the bike) lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Double banjo hex, washer, 40-degree banjo labeled for right line, washer, 20-degree banjo labeled for left line, washer, master cylinder. Please see picture A for reference! Double banjo bolts must be torqued at 12 FT pounds.

2008 Kawasaki ZG1400 Concours ABS Front 3-Line Kit and FK003D625R Single Line Rear INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 29-01-2011

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Step 1: Identify the key components that complete our front brake line kit: You should have three (3) hoses, one (1) double banjo bolt, and two (2) single banjo bolts There are also a total of nine (9) washers and (3) brass conic inversors. Seven (7) washers and two (2) inversors will be used; the rest are spares. If you have purchased a rear kit as well, locate the following additional pieces: One (1) hose with bracket and c-clip attached, one (1) single banjo bolt, two (2) brass inversors and three (3) washers. You will use one (1) “olive” conic inversor and two (2) washers, the rest are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. On the front brake line kit, we are replacing three hoses and their respective blocks (see pictures 1-2 for blocks) . For the rear, we are replacing one hose from the master cylinder to the ABS hard line. Take note of how the stock system was routed, in case you need to reinstall it. Step 4: Locate Line A – This will travel from the master cylinder to the ABS Junction. (See picture 3) You will use a single banjo bolt and two washers at the master cylinder, and an “olive” inversor to thread female end to hard pipe for incoming ABS (right side). * We have replaced the block at the upper triple clamp with a c-clip; please use your stock bolt to thread this in. (See picture 4) Locate Line B – This will travel from the ABS Junction to the right caliper. First, thread the female end to the hard pipe for outgoing ABS (left side). There will be a bolt from the OEM blocks at ABS Junction; please use this to thread c-clips into frame as shown in picture 5 . There is another bolt/OEM block located at the lower triple clamp; please use this to thread the c-clip in as seen in picture 6. Locate Line C – This will cross over the front fender using OEM holders, from right caliper to left caliper. Thread caliper banjos from Line B and C using the following sequence: double banjo hex, washer, 40- degree banjo from Line C, washer, 20-degree banjo from Line B, washer, caliper. Please see pictures 7 and 8 for reference. Thread single banjo bolt into left caliper, using two washers and 40-degree banjo. If applicable, locate rear Line D – this will travel from the rear master cylinder to the hard line for ABS. Thread the hard pipe into female end using a “olive” inversor, and attach bracket to swingarm as seen in picture 9 . Use the bolt from the holder for ABS hose, and sit our bracket on top of the OEM holder. Using the bolt from the OEM ABS hose holder in location shown in picture 10 , attach the c-clip on top of holder and tighten. Finally, thread 30-degree banjo in caliper using the following sequence: single banjo hex, washer, banjo, washer, caliper

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2007 HONDA CBR600RR GALFER Super Bike BRAKE LINES INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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Step 1: Identify the key components that complete our Superbike kit: You should have 2 lines (front kit), 1 double banjo bolt and 2 lower adapters. There are also a total of 7 washers. 5 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. Inspect your brake system after every race. A: Left Caliper (looking at the bike from the front, not seating on it) Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install onto the calipers the Galfer male adapters, the course thread area threads to the caliper with one washer.Torque level is 12 to 13 ft pounds. See Picture C

2008 Suzuki GSXR 600-750 Super bike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 29-01-2011

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Step 1: Identify the key components that complete our SUPERBIKE brake line kit: You should have two (2) hoses, one (1) double banjo bolt, and two (2) male adapters with two 1.55mm thick washers. There are also a total of (7) washers. five (5) will be used, and two (2) are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter with the two thick crush washers provided into the calipers with one washer, and torque at 12 to 13 ft pounds. Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 90 degree banjo from left line, washer, 90 banjo from right line, washer and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. (For positioning see picture A) Make sure that the 90-degree fittings on each caliper are pointing away from the bike just a little bit (see picture B) . Thread each female end into the adapter, and torque to 6 ½ Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, we recommend using (GALFER’S C-CLIP) to bring the lines together about the same level as the lower triple clamp.

2004-2007 HONDA CBR 1000RR Super bike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Make sure to save the nut and bolt that are currently holding the stock lower section of the hoses. (See picture A) Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 40-degree banjo from right line, washer, 40-degree banjo from left line, washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. (For positioning see picture B) . Make sure that the 90-degree fittings on each caliper are pointing straight up (see picture C) . Thread each banjo end onto the adapter, and torque to 6 ½ Ft pounds. Please tighten the “C” clips on the fender using the OEM bolts we asked you to save above. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, using the galfer 2line clip to bring the lines together and mounting it to the triple tree will insure proper clearness and routing. (See picture D) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with Galfer DOT 4- brake fluid is recommended.

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2007 YAMAHA ZX6RR GALFER Super Bike BRAKE LINES INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 29-01-2011

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Step 1: Identify the key components that complete our Super bike KIT, you should have 1 complete 3 line kit (front Kit), 1 single banjo bolt and 2 lower male adapters. There are also a total of 6 washers, 4 will be used, and 2 are spares. The Left hose has a locating clip and there is a new bolt to bolt that on. We ALWAYS strongly suggest having a professional mechanic install these brake lines, all other installations VOID warranty. Inspect your brake system after every race. A: Right Caliper B: Please re-use stock routing clip for right line Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install onto the calipers the Galfer male adapters, the course thread area threads to the caliper with one washer. Torque level is 12 to 13 ft pounds. See Picture C

2006-2008 Yamaha R6 FK002D512GP ( GP Kit ) INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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Step 1: Identify the key components that complete our GP kit: You should have 3-line (front kit), 3 SINGLE banjo bolt and 1 C-CLIP. There are also a total of 8 washers. 6 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines, all other installations VOID warranty. Inspect your brake system after every race. Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the GALFER GP 3-Line starting with the master cylinder line (top line). Torque level is 12 to 13 ft pounds. (See picture A2) Step 5: Install the C-CLIP provided to the lower triple tee top line needs to be held by c-clip [see picture A4&A5] . Lower lines will travel in front of the forks to the calipers; two single banjo bolt (see picture A1) are included for master cylinder to each caliper. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, forty-degree banjo (Top line), and washer. Single banjo bolt torque level is 12 FT Pounds. ( See picture A2 for positioning) Make sure that the [ CALIPER fittings ] on each caliper are positioned [ positioning ] (see picture A6- A7) . Thread banjo bolt into the caliper, and torque bolt to 12 to 13 Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and are clear of any obstructions. Once the lines have been checked for clearance. Proceed to step #6 Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with GALFER DOT 4-brake fluid is recommended.

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