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

HARLEY DAVIDSON TOURING MODEL BASIC SLIP ON'S INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 22-12-2010

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1. Remove both saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. 3. Working with one muffl er at a time, support the muffl er (assistance may be required) while removing the 5/16″ bolts from the saddlebag support and slide muffl er off of the head pipe. 4. Repeat the process for the opposite muffl er. NOTE: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe 1. Install the band clamps (supplied) over the front of each muffl er so that the bolt is to the inside and the nut is facing down (Figure 1). NOTE: New band clamps are supplied, do not use the old clamps. 2. Install muffl er by sliding it on to the head pipe and bolting it to the saddlebag support using the stock 5/16″ bolts. 3. Repeat installation procedure for opposite muffl er. 4. Align muffl ers and tighten hardware, beginning with the 5/16″ bolts on the mounting brackets followed by the Torca band clamp. Torque spec. is 40-45 Ft./Lbs. 5. Replace the saddlebags. 6. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up. 7. Be sure to tighten all hardware before starting your motorcycle

Victory Lowering Kit INSTALLATION INSTRUCTIONS

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Filed Under (Victory) by admin on 04-12-2010

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This kit was designed for use with stock length shocks ONLY! We do not recommend using shorter than stock length shocks with this kit. We highly recommend that your dealer install this kit. If you do not have access to a stand capable of securely supporting/lifting the motorcycle as well as tools capable of removing/replacing the suspension links, please allow your dealer to assist you. INSTALLATION INSTRUCTIONS 1. Support motorcycle securely so that rear wheel is off the ground. 2. Remove #19, #21, #22, & #23. Refer to Fig.1 Secure & support the swing arm before removal of these parts. 3. Re-install #19, #21, & #22 using our kit in place of #23. 4. Torque fasteners to 35 ft. lbs. 5. Check for proper clearance at fender & belt guard. Please note that excessive load or other riding/road conditions could cause the bike to bottom out and potentially cause the tire to come into contact with the rear wiring harness. Adjust the pre-load of the shock per the owner’s manual or relocate the wiring harness as necessary

BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

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Ducati 1098 the antihopping clutch "TITAN" Installation procedure

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

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Please remove your clutch completely (the basket only if it should be exchanged as well), also the black bush on the shaft rear containing an O-ring. Remove the O-ring and push it on the shaft again after it has been cleaned and lightly greased. Afterwards, lightly grease the outside of pos. 1 and push it on the shaft as well. If a new basket is to used as well, now follows the installation of the clutch basket, the screws have to be tightened with a screw locking device and a torque of 30-34 nm. In case of a clutch kit without basket, the original basket must be continued to use, of course. Now, the balls pos. 17 are lightly moistened with grease and placed into the cavities of the adjusting plate pos. 7, then, the kernel pos. 12 is carefully put on so that the kernel can be easily turned clockwise on the balls. This complete unit is now placed on the shaft (none of the balls may be off center), to make this easier 2 springs can be mounted. Then place positions 9 and 4 and finally nut 6 which you should glue in with a screw locking device and tighten with a torque of approx. 190 Nm. Concerning the clutch kit, you have steel plates and clutch plates. The steel plates are available in gage 1.5mm and 2mm as well as curved steel plates with a gage of 1.5mm, to be recognized if you place a straight object flat on the plate.

Ducati 999/ 749 Light weight composite fuel tanks Installation instructions

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Filed Under (Ducati) by admin on 25-10-2010

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INSTALLATION INSTRUCTIONS • Do not paint the inside diameter where the Fuel Pump O-ring seats. Apply a thin film of grease to it prior to installing the pump body and be patient giving time for the o-ring to conform. BE SURE NOT TO SCRATCH O- RING SURFACE WHEN INSTALLING PUMP! •Cap functions as the vent. •Be careful installing nuts and do not over torque the Fuel Pump & Front Mount fasteners. •Use the stock rubber grommet for the rear mount. Use a heat gun to soften the rubber for removal. •Be sure that the tank is not being rubbed at any point by frame or other hard surface, puncture from abrasion can occur in a short amount of time. • WARNING; Composites are not “malleable” like metal, since weight reduction is the main goal of the FuelCel design, rupture of the tank can occur instead of denting. • This Fuel tank is sold without Warranty expressed or implied by the manufacturer and its final suitability for use is determined by the operator of the motorcycle on which it is installed

2004-2006 Suzuki RM-Z250 Kickstand Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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To install your new kickstand: 1. Remove the lower chain roller nut, leave the factory washer installed. Install the included threaded chain roller spacer on the chain roller stud, and tighten. (DO NOT OVER TIGHTEN!) 2. Remove the sub-frame to main-frame mounting bolt. Install the provided subframe bolt spacer into the subframe bolt hole. 3. Install kickstand on the bike using the provided M8X 30mm flat head bolt, in the upper mounting hole. Install the supplied M6X 16mm socket head bolt, in the bottom mounting location. 4. Make sure that you tighten all bolts to the correct torque. 5. Periodically check the kickstand pivot bolt for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride. We recommend using a penetrating lube, such as WD-40. If necessary, you can remove the back cover plate for additional cleaning.

Kawasaki Ultra/ STX-R Billet Head Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove stock head and clean the top surface of the cylinder. 2) Remove the stock water fittings from the stock head and install them in the ADA head in the same order. 3) Install all o’rings in the ADA billet head, use small amounts of grease to hold them in place, do not use super glue or silicone. 4) Apply a small amount of grease to the small (OR020) o’ring at the top of the dome. This will allow the dome to easily slip into the head shell. Be careful when turning the head upside down to install onto the cylinder, as the domes can slide out of the head shell. 5) Make sure all the o’rings are in place and place the head on top of the cylinder with the water outlets on the top side. You must be sure that none of the o’rings slip out of their groove, as this will cause an o’ring to get pinched and a water or compression leak could result. 6) Use the additional 8mm flat washers on the taller studs, along with the stock wash- ers. 7) Torque all of the nuts to 15ft/lbs, in a center-out criss-cross pattern. Now, torque them again to 18ft/lbs. 8) After the 1st time out riding the head should be re-torqued

Kawasaki KFX 700 INSTALLATION and REMOVAL INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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Jetting (see Picture on next page) 1. Remove vacuum slides from carbs. Remove stock needles & spacers, note order of assembly. 2. Install LTE needles on groove # 4 counting from the top down. 3. Remove stock main jets and replace with the supplied main jets. 4. Locate the fuel mixture screws. Using a flat blade screwdriver, turn the mixture screws clockwise until seated, then turn out 2.5 turns.
FINISHING UP Be sure all wires and hoses are zip-tied back so they will not touch the exhaust. QUIET CORES Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. FIRST RIDE Your first ride after installing exhaust should be no longer than 20 to 30 minutes. Let your ATV cool and re torque all of the hardware on your new exhaust. Silencer Packing