HONDA XR 250 1996 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 06-12-2011

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, side panels, radiator shrouds, and gas tank.
If you are color blind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 3. Unplug the green and blue taillight wires from the stock wiring harness, remove the taillight lens, and remove the taillight socket and wiring. 4. Unplug the headlight from the stock wiring harness and remove. 5. Remove the kill switch. Unplug the black/white wire and the black wire from the connector near the base of the odometer. AC Regulator Unplug taillight here Photo 1 6. Locate the AC voltage regulator found mounted on the front top edge of the airbox as shown in Photo 1. Unplug the regulator from the wiring harness and remove regulator (Leave the U-bolt
attached to the airbox and save the bolt for a later step)

HARLEY DAVIDSON PUSHROD COVER RETAINER INSTALLATION AND REMOVAL TOOL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Figure 1. Pushrod Cover Retainer Installation and Removal Tool There are no Service Parts available with this kit. REMOVAL 1. See Figure 2. Insert the pin of the pushrod cover retainer tool into the retainer loop with the back of the tool towards the cylinder fins. Rotate the tool towards the cylinder to remove the pushrod cover retainer. INSTALLATION 2. See Figure 3. Load the pushrod cover retainer into the tool as shown in figure 3. Place the top edge of pushrod cover against top edge of push rod. 3. See Figure 4. Place the tool on top of the spring cover. Pivot the tool upward to install the pushrod cover retainer is05892a Figure 2. Removing Pushrod Cover Retainer is05895a Figure 3. Loading Pushrod Cover Retainer in Tool is05893a Figure 4. Pushrod Cover Retainer Installation

HARLEY DAVIDSON KING TOUR-PAK WRAP AROUND LIGHT UNIT INSTALLATION MANUAL

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

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the negative battery cable (-) following the instructions in the owner’s manual. 2. Locate the two-sided template (part number 50002-01) printed on a 11 x 17 inch sheet of poster board. Cut out the template as indicated. 3. If the motorcycle is radio equipped, separate the antenna cable from terminal at antenna base. Remove the nut, lockwasher and ground ring terminal from antenna terminal. Remove phillips head screw threaded into antenna base. Remove mast and antenna base. Detach mast from antenna base by turning counterclockwise with adjustable wrench across flats. 4. See Figure 10. Shield threads of antenna terminal stud with strip of light cardboard. Remove terminal with pliers across cardboard strip. Save terminal and mast for later installation. 5. See Figure 1. Open Tour-Pak top and remove all loose contents. Remove Tour-Pak. Align the template as follows: a. Place center line template (4) along rear top edge of Tour-Pak (1) with curved end against one corner. b. Mark centerline at top edge of Tour-Pak. c. Reverse center line template and mark center with curved end against opposite corner. d. If centerlines overlap, mark center one half the distance between the two lines. e. Place a square against lip at top of Tour-Pak and draw a 3 in (76 mm) line down from the center mark

HARLEY DAVIDSON PREMIUM SUSPENSION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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REMOVAL Front Fork Assembly 1. Refer to the XR model section of the service manual and remove the front forks. INSTALLATION Front Fork Assembly 1. Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. 2. See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85- 11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). is06083a Figure 1. Fork Installation Height Measurement. NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. 3. Install pinch screws to upper and lower fork brackets. 4. Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). 5. Tighten pinch screws to 30-35 ft-lbs ( (40.7-47.5 Nm)) See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. 6. Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. REMOVAL OEM Rear Shock Absorbers 1. Refer to the XR model section of the service manual and remove the rear shock absorbers. INSTALLATION Rear Shock Absorbers 1. See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. is06142 Figure 3. Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c) Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a) NOTES Damping is set at the factory for the average solo rider under normal riding conditions. The rider may make adjustments to compensate for individual riding styles and varying road conditions. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully. The front and rear preload setting will need to be adjusted for the rider’s weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). If the preload adjustment is correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload. The following tools are needed to make suspension adjust- ments. • 5 mm hex key (front fork preload adjustment tool). • Spanner wrench with extension handle (shock absorber preload adjustment). • Screw driver (front fork damping adjustment). 1. Front fork preload adjustment: a. See Figure 4 and Table 1. Using the 5 mm hex key, turn the preload adjuster counterclockwise until it stops. This is the minimum preload setting. b. Turn the preload adjuster clockwise the recommended amount specified for the rider weight

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HARLEY DAVIDSON ADVANCED AUDIO REAR SPEAKER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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This kit fits 2006 and later FLHT (Electra Glide®), FLHTC (Electra Glide Classic), FLHX (Street GlideTM) and FLTR (Road Glide®) model motorcycles. INSTALLATION 1. Have a Harley-Davidson dealer perform the speaker software flash to the previously installed AM/ FM/ CD Radio. 2. Refer to the Service Manual and follow the instructions given to remove the seat and the left-side saddlebag. The right-side saddlebag does not need to be removed, but you may choose to do so in order to prevent damage during the installation of this kit. 3. Follow the instructions in the Service Manual to remove the maxi-fuse. NOTE The Tour-Pak does not have to be removed from the vehicle to perform this installation. 4. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 5. Models with rubber mat: Remove the mat. Models with molded liner: Open the map pocket and remove the acorn nuts with flat washers. Remove the map pocket and liner. 6. Obtain the left-side (3) and right-side (4) drilling templates from the kit. is 00439 Figure 1. Template Positioning (Right Side Shown) 7. See Figure 1. Position the the right-side template flat onto the right front corner of the Tour-Pak. a. Fit the notched corner on the left side of the template to the Tour-Pak latch. b. Align the top of the template just under the top edge of the Tour-Pak. c. Apply tape to the locations indicated on the template to hold the template in place

YAMAHA V-STAR 650 EXHAUST SYSTEM REMOVAL AND INSTALLATION

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Filed Under (Yamaha) by admin on 18-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the right hand frame cover to avoid scratching it. 2. Remove the nuts that mount the rear header to the cylinder head. 3. Loosen the pinch clamp on the inlet end of the lower muffler. 4. Remove the two bolts that mount the mufflers to the muffler bracket, located between the two mufflers. Save the hardware for reuse. 5. Pull the rear head pipe out of the exhaust port. Slide the muffler assembly with the rear head pipe attached, rearward, disconnecting it from the front head pipe. Set the assembly aside. Note: Keep the front head pipe attached to the motorcycle, it will integrated with the new exhaust system. 6. Remove the muffler mounting bracket from the frame and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the V&H muffler mounting bracket (stamped 272) to the frame using the stock hardware and mounting location. Refer to figure 1 2. Slip the T-bolt band clamp (supplied) over the straight pipe that is welded to the front muffler. 3. Slip the front muffler assembly over the stock head pipe. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 4. Install the rear header assembly to the exhaust port using the stock 8mm nuts, but leave them loose at this time. 5. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the rear muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 6. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of both heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 7. Align the mufflers so they are parallel when viewing from the right side of the bike, and tighten the 5/16″ flange bolts on the back side of both mufflers. 8. Tighten the two header flange nuts on the rear head pipe. 9. Tighten the T-bolt clamp at the slip joint of the front muffler. 10. Rotate the hose clamps on both heat shields so they are accessible with a screw driver and tighten each of them evenly. Note: The edge of the heat shield should just cover the weld on the inlet of each muffler, if not, adjust the heat shield for correct alignment