2007 HONDA CBR600RR DUAL OUTLET SLIP-ON EXHAUST INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 07-11-2011

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Make sure the motorcycle is cool and place securely on a service lift or stand. 2) Remove the two bolts securing the rider seat to the motorcycle. Remove the seat. See Figure #1 3) Using the key, remove the passenger seat. 4) Remove the bolts and push pin fasteners securing the tail section to the sub frame. Carefully spread the tail section and remove it from the motorcycle. See Figur ) Disconnect the turn signal & tail light plugs on the left side of the sub frame. 6) Remove the four bolts securing the complete rear fender assembly (including the tail light & turn signals) and the rear reflectors to the sub frame. Remove from the motorcycle. See Figure #2 7) Remove the two nuts from the back side of the reflectors and retain to be used elsewhere in Step #38. 8) Remove the two bolts securing the right side passenger peg. Remove the passenger peg. See Figure #4 9) Remove the bolt from the inside of the stock s-bend heat shield located behind the rear brake reservoir. See Figure #5 10)Remove the bolt securing the silver plastic heel cover from the right side rider peg mount. Remove the cover. See Figure #6 11)Remove the bolt securing the rear brake reservoir to the sub frame. Allow the reservoirto dangle

Honda Motorcycle and Offroad Suspension Set-up

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Filed Under (Honda) by admin on 04-11-2011

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Getting your suspension dialled in for your riding style is one of your first priority’s when you take your new bike out on the track. However, it is an on going process. What worked today might not suit the next track conditions you encounter next week. Therefore, you have to take on the role of test rider yourself and learn to identify problem areas. Never stop testing and thinking about what your bike is doing. Here are some practical tips for making your bike as good as it can be, stock or modified. Spring Rates There is again no way a manufacturer can know what you weigh. The “average” target weight for a full size motorcycle is a 75kg rider. Therefore, if you have a MX or current technology enduro bike, chances are the spring rates will be close for you. Of course, you will need to check and adjust your sag to be sure. There are some expectations. If you ride in sand or mud a lot, you might want to do heavier springs. Pro class riders on four strokes will go for stifferrates, as will x-treme jumpers

Fitting new GL1500 Mufflers Installation Manual

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Filed Under (Honda) by admin on 08-04-2011

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The stock mufflers on the GL1500 Goldwing tend to rust after a few years. It doesn’t really matter how much you clean them because the design means that they tend to collect condensation which turns into water, then the dreaded tinworm rots them from the inside out. There is a drain hole in each muffler (near the front) to allow some water out, but the hole is really in the wrong place as the mufflers almost always rot at the ends near where the tailpipe is welded on. Replacing mufflers on the GL1500 Goldwing is easy enough and you really don’t need a tutorial for the task. But I did have a camera handy on the day I did the job so you may as well have the benefit of the images. This is a common sight on a GL1500 Goldwing. The mufflers rot from the inside out and eventually the ends just blow off. Believe it or not, these mufflers are on a 1997 GL1500SE with only 7,700 miles that was always stored in a dry garage! I replaced them in April 2004 and they had been almost as bad as this since 2002, but the owner of the Goldwing wasn’t using it much so he didn’t bother replacing them until 2004

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HARLEY DAVIDSON SOFTAIL DETACHABLE SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Detachable Saddlebag Configurations Table 1 provides a short description of the detachable saddlebag configurations. Table 1. Softail Detachable Saddlebag Configurations Accessory Configuration (Long Description) Short Descrip- tion Kit 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Other Detachable Accessories FL Outer 88237-07 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) Without Other Detachable Accessories FL Inner 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Rigid-Mounted Accessories FL Rigid 2006-Later FX Models (Except FXSTD) With Other Detachable Accessories FX Outer 88238-07 2006-Later FX Models (Except FXSTD) Without Other Detachable Accessories FX Inner 2006-Later FX Models (Except FXSTD) With Rigid-Mounted Accessories FX Rigid 2007-Later FXSTC Models With Stock Passenger Upright FXSTC Stock NOTE Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Install Turn Signal Relocation Kit Refer to instructions included with Turn Signal Relocation Kit 69857-07. Install Docking Hardware Kit(s) Without Other Detachable Accessories: Refer to instructions included with Docking Hardware Kit 53932-03. With Other Detachable Accessories: Refer to instructions included with Docking Hardware Kits 53932-03 and 88256-07. Install Rear Docking Adapter NOTE This procedure only applies to models without detachable accessories. 1. See Figure 1. Insert rear docking adapter (1) into holes in saddlebag bracket and hold in place. 2. Install rear docking adapter using screw (2) and nut (3). Tighten snugly.

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HARLEY DAVIDSON DYNA SPRING SEAT MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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INSTALLATION 1. Refer to service manual and remove the existing seat. 2. See Figure 2. Install the frame cover (9) to the frame and secure with fastener (4). Orient the frame cover to so that it covers the seat pan. 3. Install two springs (2) to the mounting bracket (1), oriented as shown, with screws (3). Tighten screws to 25-30 ft-lbs (34-41 Nm) . 4. Install mounting bracket to frame as follows: a. Remove two screws from the rear of the seat pan area where the spring seat mounting bracket (1) will be mounted. Save washers for later installation. b. Install mounting bracket (1) to the frame over the frame cover. Orient the frame cover so that it will be retained by the mounting bracket when secured. c. Secure the left side of the mounting bracket to the frame with a screw (7), stock washer (B) and spacer (8). Do not tighten. d. Secure the right side of the mounting bracket to the frame with a screw (7) and stock washer (B). e. Tighten mounting bracket screws to 90-108 in-lbs (10-12 Nm) . 5. Install seat pivot bracket (10), washers (15) and screws (5) to the seat. Tighten screws to 48-72 in-lbs (5.5-8.0 Nm) . 6. Remove the rear fuel tank mounting screw, washers, nut and thread protector. Save washers for later installation

HARLEY DAVIDSON SHORT RAIL BACKREST PADS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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These Backrest Pad kits are designed for installation on 1984 and later models equipped with a sissy bar sideplate kit in combination with a Short Rail upright kit, Part No. 52737-94 or 52728-95. The 52513-94 Backrest Pad kit is only for models equipped with Badlander seats and one of the following Mini Rail upright, kits: 52738-94A, 52744-94 or 51512-02. The 52568-01 Backrest Pad Kit is designed for installation on 2001 FXDWG2 model motorcycles and should be used with mini rail upright part number 52744-94 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. The 52901-01 Backrest Pad Kit is designed for installation on 2002 FXDWG3 model motorcycles and should be used with mini rail upright part number 51512-02 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. Kit Contents See Figure 3 and Table 2. There are no Service Parts available with this kit. INSTALLATION NOTE Figures 1 and 2 show pad being mounted on short upright, Part No. 52737-94, before short upright is mounted on side- plates. The pad may be installed before or after short upright is mounted. 1. See Figure 1. Remove protective film from mounting bracket (1) and attach the mounting bracket with the 1/4- 28 x 3/8 in. screw (2) onto short upright, Part No. 52737- 94 or 52728-95; or onto Mini Rail upright, Part No. 52738- 94 or 52744-94. Check that mounting bracket is parallel with upright and tighten screw to 48-60 in-lbs (5.4-6.8 Nm). 2. See Figure 2. Position backrest pad (1) on the upright. Place mounting plate (2) in position and secure with two chrome screws (3) as shown. Tighten screws to 48-60 in- lbs (5.4-6.8 Nm)

HARLEY DAVIDSON DYNA CHROME SWINGARM INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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This kit fits all 2006 and later Dyna model motorcycles. INSTALLATION NOTE Refer to the appropriate Service Manual for detailed information on the following generalized steps. 1. Remove the rear fork. 2. Remove the bearing, spacer and retaining ring from left side pivot bore of the stock swingarm. 3. Install the bearing, spacer and retaining ring removed in the previous step, into the left side pivot bore of the chrome swingarm. 4. Install the dust shield and bushing, from the kit, into right side pivot bore of the chrome swingarm. 5. Install the chrome swingarm kit. SERVICE PARTS

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HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION (2000 THROUGH 2002) Refer to the instructions included with kit 53388-03 for installation on 2000 through 2002 models. INSTALLATION (2003 AND LATER) NOTE To keep the fender aligned, completely install the sideplate on one side of the motorcycle before proceeding to the second side. The sissy bar should be installed last. 1. For models equipped with saddlebags: a. Remove the saddlebag, and retain the mounting hardware for later reinstallation. b. See Figure 1. Remove the bolt (A) and washer (4) that secures the rear fender to the fender brace. Discard the bolt and washer. Remove and retain the two saddlebag mounting studs (C) and nut plate (D) for later use. For models NOT equipped with saddlebags: a. See Figure 1. Remove the two rearmost bolts (A), washers (4) and nut plate that secure the rear fender to the fender brace. Discard the bolts and washers. b. Remove the bolt (B) and washer (4) that secure the fender and brace to the frame. Discard the bolt and washer. 2. See Figure 1. Position the correct sideplate to the outside of the fender brace. 3. With saddlebags: Apply LOCTITE 243 (blue) to the 3/8- 16 threads of the saddlebag mounting studs (C) and reinstall the studs through the sideplate, fender brace, frame and fender, and thread into the stock nut plates (D). Install one chrome 3/8-16 screw (3) and chrome washer (4) from the kit through the rear hole in the sideplate, fender brace and fender, and thread into the stock nut plate (D). Without saddlebags: Install three chrome 3/8-16 screws (3) and chrome washers (4) from the kit through the holes in the side plate, fender brace and fender, and thread into the stock nut plates (D). 4. Repeat steps 1-3 for the opposite side. 5. Install a sissy bar (not included in the kit) into the side- plates. Apply LOCTITE 262 (red) to the threads of the chrome 1/4-20 capscrews (5) and insert them into the sideplate holes. Tighten to 8-10 ft-lbs (11-14 Nm) . 6. Tighten the bolts (3) and/or saddlebag mounting studs to 21-27 ft-lbs (28.5-36.6 Nm) . 7. Reinstall the saddlebags

HARLEY DAVIDSON DETACHABLE LOCK KITS REMOVAL AND INSTALLATION MANUAL

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

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REMOVAL 1. Remove the detachable accessory by pressing the release button on each side and pull the latch levers back. Lift the rear of the accessory up and pull the rack off of the front docking points. 2. See Figure 1. Remove the screw (1) and washer (2) from the latch(es) to be replaced by the new locking latch. Save the screw and washer for installation. INSTALLATION See Figure 8. Depending on the installed detachable, the position of the relief (A) and undercuts (B) will be used as spacers or docking point mounts. Verify that the locking latch is positioned so there is key access for unlocking the latch. NOTES Verify that the locking latch is in the unlocked position before installation. Do not leave the key inserted in the locking latch during assembly. Detachable styles may vary from those shown in the illustra- tions. Outer Right Upright Installation 1. Remove right non-locking latch. 2. See Figure 2. Install stock spring washer (2) on mounting hub. 3. Install flat washer (4) (from kit) on mounting hub. 4. Install latch with relief away from the outer right sideplate. 5. Install stock screw (3) and washer (1). 6. Tighten screw to 30-40 in-lbs (3.4-4.5 Nm)

HARLEY DAVIDSON PUSHBUTTON FUEL CONSOLE DOOR RELEASE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION 1. Open the fuel door. Remove and discard stock lock and nut. 2. See Figure 1. Install pushbutton lock (2) and nut (1) on fuel door. 3. Remove screws (A) and replace the stock hinge mounting clip with the hinge mounting clip (3) from the kit. Install stock screws. Do not over-tighten. 4. Close the fuel door. A small amount pressure will be needed to close the fuel door because it is now spring- loaded. NOTE To keep the pushbutton lock assembly operating smoothly, lightly spray lubricant on the mechanism as needed. SERVICE PARTS 1 2 3 B C A is05361 Figure 1. Service Parts: Console Pushbutton Fuel Door Release Table 1. Service Parts Part Number Description (Quantity) Item 84850-92 Nut, hex 1 Not Sold Separately Fuel release, pushbutton 2 10334 Clip, hinge mounting 3 Items mentioned in text, but not included in kit. Screw (2) A Hinge pin B Fuel door