HARLEY DAVIDSON DYNA SPROCKET KIT INSTALLATION MANUAL

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

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1991-1992 Dyna models: Screw (5) 3739A 1993-1995 FXDL, 1995 FXD and FXDS, all 1997-1999 Dyna models: Screw (5) 3730A 1993-1995 FXDWG and all 1996 Dyna models: Screw (5) 3769 1991-2005 Dyna models: Washer (5) 6516HW 2000-2006 Dyna models: Screw, with lock patch (5) 3737A 2006 Dyna models: Screw, with lock patch (5) 3873 2007 and later Dyna models: Screw, with lock patch (5) 3109 The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) Kit Contents There are no Service Parts available with this kit. INSTALLATION NOTES The cotter pin or spring clip for the rear axle nut must be replaced during assembly and is available for purchase from a Harley-Davidson dealer. The five sprocket mounting screws must be replaced when replacing the sprocket. Remove existing sprocket according to service manual instructions. Remove all residual threadlocking agent from fastener holes using an appropriate thread chasing device and compressed air.

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HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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HARLEY DAVIDSON HANDLEBAR POLYURETHANE RISER BUSHING KIT INSTALLATION MANUAL

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

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INSTALLATION NOTES • Cover fuel tank with blanket or towels to keep paint from being scratched. • See the Touring Service Manual for the Fairing Removal procedure in order to gain access to the handlebar assembly. 1. For Touring Models: See Figure 1. Remove and save the the existing capscrews (C). Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard cup washers (D), rubber bushings (E) and spacers (F). Install the new bushings. For All Models Except Touring: Remove and save the two capscrews (C) from underneath the upper fork bracket that hold the existing lower clamps (risers) (B) in place. Remove the handlebar assembly (A) and carefully allow gauges and handlebar to rest on motorcycle. Remove and discard the existing cup washers (D), rubber bushings (E) and spacers (F). NOTE The upper bushing and lower bushing must be oriented with flat side opposite from each other as shown. 2. Install the new polyurethane riser bushings (1) in place of the removed cup washers, bushings, and spacers. 3. Align components as shown in Figure 1. 4. Secure components with two hex head capscrews removed in Step 1. Insert the capscrews, from the bottom, thru the upper fork bracket, thru the bushings (1) and into the clamps (risers). See the service manual for the torque specification. 5. See the service manual and install the handlebars

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The New Kawasaki ZX-6R Trading in gets easier and easier

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Filed Under (Kawasaki) by admin on 18-02-2011

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didn’t go to my local Kawasaki shop expecting to trade in the 2004 636 I’d been happily riding. I honestly didn’t expect there to be anything on the floor that would motivate me to bring the bike in. Some of you reading this may be able to relate to what I am saying, the day you don’t look for something is the day that you find exactly what you didn’t know you need. That was the day I decided I needed to take home the new ZX-6R. The reworking of the new ZX-6R is more than just about looking good. According to KMC the engine has been redesigned from the crankcase up for the first time in ten years. Racing technology built into the new bike is a close-ratio cassette transmission that can be removed without the needing to split the main crankcases in case you needed to make repairs or adjustments at the track. They also tell us that the fuel injection system has shorter throttle bodies with a smaller diameter bore which claim to give this new smaller sized engine more torque in the mid-range. It also comes with a GPS – Gear Position Sensor. The new ZX-6R comes stock with a slipper clutch which is one difference between the 2004 and 2007. My 2004′s rear wheel would hop if I geared down before a corner and my engine rpms were too high. The slipper clutch allows quicker downshifts. To experience the gains of a slipper clutch you don’t have to buy a 2007 Kawasaki – it was introduced to the 636 in 2005. A quick glance at the exhaust might leave the impression that the ZX-6R comes stock with stacked twin small diameter exhaust cans but if you look closely you will see it is a single oval pipe with a shotgun styled end cap. The titanium pipe has the pre-chamber and catalyser located below the engine to keep the weight on the bike low and centered and the temperature of the under seat silencer reduced. Looking at the new Kawasaki with its fairing removed, I wonder how much more it would have cost the consumer to have an exhaust system that not only works wonders but would be worth showing off? Even if some of the systems of the new 600 look better hidden by plastic the bike does have a cohesive look and every year the fit and finish of Kawasaki’s bikes seem to get better. You can look at this bike from almost any angle and nothing jumps out at you – unless you are on the right side of the bike looking at the rear brake reservoir. It seems odd to me that they would leave the rear brake reservoir exposed. Another design feature of the smooth body of the 2007 ZX-6R is the lack of tie down points for any luggage. It can be argued that this is a bike intended for Sunday morning canyon rides or track days on weekends but if you want to take the 600 out for a weekend away then there is aftermarket solution. Ventura Racks allow you go on vacation with your bike. A Ventura Rack provides you with a frame that you attach to your bike that you can secure luggage to. There is no drilling of body work and the Ventura rack I got fit onto the bike perfectly the first try. One of the things I really like about the Ventura Rack is that you can easily attach bags that you may already have or you have the option of buying the Ventura luggage system. Just give yourself time before a motorcycle trip to pack

Yamaha Road Star EZ-Steer Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Champion Yamaha Road Star EZ-Steer Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamp of your Yamaha Road Star Motorcycle. Much of the OEM hardware is retained and reused. It is assumed that the installer has advanced and/or professional skills in motorcycle servicing. We recommend that you use an OEM service manual and follow the prescribed disassembly, installation and torque specifications for the upper and lower clamp assembly. Recommended Procedures • Remove headlight, windscreen (if so equipped) and brackets from motorcycle. • The wheel and fork assembly can be removed as one complete unit. Disconnect the master cylinder brake line from the tee fitting below the lower triple clamp. The caliper brake lines may be left in place on the tee fitting. • Install supplied extensions to fork tubes the supplied o-rings. Apply lubricant to o-rings and extensions prior to installing to fork tubes. • Install the lower fork tube covers to the lower clamp prior to installation to motorcycle using the longer screws supplied. The two longest screws are used in the outboard holes. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 30 lb. ft. • Slide fork tubes up through bottom of lower clamp approximately 6-8 inches. Install the OEM gaskets, washers and upper fork tube covers. Do not reinstall brake line holders at this time. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of extension is flush with top surface of clamp. • Torque dome nut to 85 lb. ft. • Ensure that fork tube extensions are flush with top of upper clamp. Torque upper and lower clamp bolts to 35lb. ft. • Install handle bars to upper clamp using OEM bolt with supplied flat washers. One washer on top, two on bottom, both sides. • Reinstall brake line holders to the bottom of the lower triple clamp using the supplied M6 NyLoc nuts. • Reinstall all other OEM parts as removed. • Bleed brakes. EZ-Steer Maintenance

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YAMAHA ROADSTAR TRIKE Removal of Clear Taillights and installation of Red Taillights

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Filed Under (Yamaha) by admin on 16-02-2011

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1 Installation of Lights 1.1 Support the trike on jack stands and remove the wheels. 1.2 Remove the clear lights from the inside of the wheel wells by unscrewing the three (3) screws from the light. 1.3 Unplug the wires and remove the lights. 1.4 Remove the chrome bezels and rubber gaskets from the clear lights and install on the red lights (5 screws). 1.5 Re-connect the wire plugs and install the red lights to the trike body using the same three screws. 1.6 Replace the wheels and torque the lug nuts to 75 lb.ft. 2 Wire modification inside trunk 2.1 From the inside of the trunk pull back the carpet on both the left and right hand sides to expose the wire harnesses coming from the wheel wells. 2.2 Locate the resistors in the harness, 2.5″ x 0.5″ x 0.5″, and covered by black shrink wrap. 2.3 Cut the shrink wrap to expose the resistors and cut wire on both side of the resistors. Remove and discard resistors. 2.4 Splice in the supplied 5″ green wires (WITHOUT the diodes) with 2 blue scotchlock connectors per side to reconnect the cut wires. 2.5 Do not glue in carpet until lights are tested. 3 Change to pigtail from Trike to Motorcycle. 3.1 Remove driver’s sear 3.2 Unplug pigtail from motorcycle (MC) wiring and trike body wiring. 3.3 Cut heat shrink on the MC plug side of the pigtail and pull expansion sleeve back to expose the wires. Figure 1 3.4 Cut Green and Yellow turn signal wires and about 3″ from the MC plug and splice in Green and Yellow wires from the supplied resistors with the supplied hest shrink solder connectors (heat to be applied) – (three wires in one connection) Figure 1 3.5 Cut the Red (Brake) and Brown (Running lights) wires and splice in the supplied diodes with the supplied heat shrink solder connectors. Red side of the diode wire facing the Trike plug. Figure 1 3.6 Connect eye lug on the black wire from the resistors to the negative terminal of the battery. Figure 2 3.7 Plug pigtail back into the Trike body and the MC

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HARLEY DAVIDSON CHROME SPROCKET HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION For 1991 through 1996 XL with Laced Wheels For 1993 through 1996 Softail with Laced Wheels For 1993 through 1997 Dyna with Laced Wheels 1. Remove the rear wheel. Refer to REAR WHEEL REMOVAL in the Service Manual. 2. Remove all stock sprocket mounting screws, washers and locknuts. 3. Place a new chrome washer onto the threads of each new chrome screw from the kit. Install the sprocket onto the wheel. 4. See Figure 1. Obtain new original equipment locknuts and install on the screws. See Figure 2. Tighten all screws in the sequence shown to 45-55 ft-lbs (61-75 Nm). 5. Install the rear wheel. See REAR WHEEL INSTALLATION in the service manual. Verify the correct axle alignment and check belt deflection per service manual instructions INSTALLATION For 1997 and Later XL with Laced Wheels For 1997 through 1999 Softail with Laced Wheels For 1998 through 1999 Dyna with Laced Wheels For ALL Models with Cast Wheels 1. Remove the rear wheel. Refer to REAR WHEEL REMOVAL in the Service Manual. 2. Remove all stock sprocket mounting screws and washers. 3. Place a new chrome washer onto the threads of each new chrome screw from the kit. Apply 2-3 drops of Loctite 262 (red) to the screw threads, and install the sprocket onto the wheel. Tighten all sprocket screws finger-tight. 4. See Figure 3. Tighten the bolts in the sequence shown to 23 ft-lbs (31.2 Nm). NOTE If 23 ft-lbs (31.2 Nm) is reached before screw is fully seated, remove screw and examine screw and wheel for thread damage. Replace screw or wheel if threads are damaged. 5. After all screws have been tightened to 23 ft-lbs (31.2 Nm), mark a straight line, with a grease pencil, on all sprocket screw heads continuing the line over onto the sprocket. 1 4 2 5 3 30 is04009 Figure 3. Tightening Sequence (Later Laced Wheels and All Cast Wheels) 6. Mark a second line at 30° clockwise from the lines on the sprocket at each screw. NOTE For best results, use Snap-on Torque Angle Gauge TA360 or equivalent. 7. Using the marks as a guide, and using the tightening sequence shown in Figure 3+, turn each screw an additional 1/12 turn or 30° clockwise. 8. Install the rear wheel. See REAR WHEEL INSTALLATION in the service manual. Verify the correct axle alignment and check belt deflection per service manual instructions

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1999-2010 Yamaha Roadstar 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 14-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n Remove the horn located on the lower left side. Also remove the Remote Adjustable Pre-Load adjuster knob by removing the screw located in the center of the knob, then pull it straight off. n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the opening behind where the horn was located on the left side of the bike – see figures 2 and 3. Do not loosen or attempt to rotate the line between the shock and the adjuster. n Reinstall the adjuster knob, and torque the screw to 50 in/lbs. (5.65 N-m). n Make sure the shock rebound adjustment is at the rear facing the left side of the motorcycle and the pressure valve is facing up. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the stock two drive-belt cover bolts – as shown in figure 4. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. Reinstall horn. To adjust the ride height, simply turn the adjuster knob clockwise (looking at it from the back of the bike) to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height

BMW F650GS Single Shock Supplement

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Filed Under (BMW) by admin on 14-02-2011

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Mount the shock & adjuster as you would your stock shock & adjuster per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the same path as the stock line was routed to the same location. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing forward. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m) as in figure 3. Then mount the bracket and adjuster to the bike in the same location as the stock preload adjuster/bracket using the stock bolts as shown in figure 4. Check banjo-bolt to cylinder clearance and adjust if necessary via tolerances in mounting bracket holes. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. To adjust the ride height, simply turn the adjuster knob clockwise to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height.

Yamaha XV-19 Raider 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 13-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster towards the rear (see figure 2) and to the right side of the swingarm (see figure 3) . n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is toward the rear and facing the right side of the motorcycle and the nitrogen pressure valve is facing down. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Locate the EXUP valve servo mounting bracket, specifically the two bolts used to secure it to the frame (see figure 4) . They below the seat on the right hand side of the motorcycle. n Now either mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m), then mount the bracket and adjuster to the bike using two EXUP valve servo mounting bolts (as shown in figure 5) – or – mount the adjuster bracket to the frame using those two bolts, then mount the adjuster to the bracket (may require removal of exhaust stay). n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources.

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