Harley Davidson HOGPRO DEUCE 200 TIRE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 18-04-2012

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1. Remove the seat 2. Remove the rear wheel. 3. Drain and remove the primary covers and drive belt. 4. Install the new supplied 13/16″ drive belt. 5. Re-install the primary covers, gasket, seal, and fluid. 6. Remove chrome fender strut covers. 7. Remove the plastic license plate mount and un-plug the turn signals 8. Remove the rear fender 9. Discard the long gold colored wiring covers from both sides of the inner fender. 10. Wash the inside of the fender thoroughly with soap and water. 11. Clean the inner fender along the wiring path with supplied alcohol. 12. Locate the wiring harness at the top right of the fender. 13. Firmly affix the 5 supplied zip holders along the wiring path. 14. Attach the harness using the supplied zip ties. Leave enough slack so that you can adjust the position of the harness once the fender is re-installed. 15. Re-install the fender using the supplied hardware. (The curved fender mounting brackets will be re-installed from the inside out using the 4 thin supplied nyloc nuts and washers. 16. Install the front license plate mount bolts inside out using the 2 supplied nylocs and washers. 17. Tighten the fender. Using a hack saw or cut off wheel, remove the remaining threaded studs flush with the nyloc nut on each of the fender brackets. 18. Re-install your chrome fender struts. 19. Adjust the wiring harness and tighten the zip ties. Cut off the excess zip tie. 20. Install the new Hogpro wheel, pulley, and the 200 tire of your choice. 21. Have Fun!

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Harley Davidson Power Pod Switch Housing Throttle Bracket Installation Instructions

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Filed Under (Harley Davidson) by admin on 19-03-2012

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Attach the “Y” bracket to the Power Pod by using the two Power Pod socket head screws that come in your parts kit. (This bracket may already be attached from the factory. ) 2) Remove the two screws on the Right Hand switch housing on your Harley Davidson motorcycle and reinstall them through the two “Y” bracket open holes and back into the switch housing holes. Tighten snugly. In this mounting position, the heads of the two socket head screws holding the “Y” bracket to the Power Pod should be touching the handlebar; this is necessary as it grounds the unit for proper operation. If the unit is not grounded properly, it will not operate. 3) Run the Power Pod’s 60″ power cord to your battery. Make sure as you hide the cord on the way to the battery, that your handlebars turn freely and that the cord does not come in contact with hot engine parts that may melt the wire over time. 4) At some point, before reaching the battery, attach (using the two butt connectors) the in-line fuse holder. TIP: Keeping the in-line fuse holder in an easy to access place (like under a side panel etc) rather than under the seat, may help you service the fuse easier in case of a blown fuse. In most cases, it’s easier to pull a side panel off than it is to remove a seat! 5) Attach the Power Pod lead wire (with in-line fuse now already attached) directly to the battery for power at anytime without using the key. The hot lead can also be run to the fuse box which will require using the ignition switch to “Accessory” or “ON” in some cases. TIP : Always use the in-line fuse for safety. 6) Insert the 20 amp fuse into the in-line fuse holder. Strap down with zip-ties any loose wires and you’re done!

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Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

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KTM DC CONVERSION HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 06-02-2012

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STEP 3: Install the battery in the battery box. If using the Trail Tech 040-BATT3.7, use the two included 8″ zip ties as shown. If using the Yuasa YTX4l-BS, use a KTM battery strap, STEP 4: Screw the battery box into place on the rear fender. Use the 3 provided screws. The bottom screw hole may not line up on some older models. If so, use alternate opening as shown. STEP 5: Begin installing the wiring harness at the Ground Ring Terminal. Remove the forward coil Bolt (on older models, use the regulator mount), and re-install with ring terminal. Rotate all connectors towards the rear of bike before tightening bolt. Zip- tie the wire harness to the lower frame rail, routing the zip tie through the available slot in the coil mount (as shown). STEP 6: Route the positive(+) battery and tail light connectors under the frame rails, then through the wiring notch in the air- box plastic. If installing a tail light, connect it now

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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Kawasaki KLR-650 465 Series Single Shock Supplement

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Filed Under (Kawasaki) 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 through the opening between the main-frame and sub-frame on the left side of the bike. 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 On 1987-2007 models ONLY , install the supplied 3.5mm thick spacers – one on each side of the shock clevis ( see figure 3 ). Do not install these spacers on 2008-2010 models. 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 two rear footrest mounting bolts – sandwiching the mounting bracket between the rear footrest mount and the frame tabs (as shown in figure 4) . Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. n 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 heigh

GS Ohlins Installation, Adjustment Tips And Tricks

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

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Luckily, I had my dealer install fuel line quick-disconnects when I bought the bike, so removing the tank is a piece of cake. There are two, each one faces the opposite direction, so there is no danger of re-connecting the wrong hose. Put a rag on the cylinder to catch any drops of fuel… 8. Pull breather and overflow hoses out. Put some masking tape or use zip ties on one line (both sides) so you can figure out which one goes where when you put the tank back on.9. Unplug the fuel tank electrical plug. Lift the tank up, back and off. 10. Put the tank on some soft surface out of the way. I put a plastic trash bag underneath the quick disconnects to catch any fuel drips.
11. There’s a whole lotta shit under there! 12. Remove bottom shock bolt using a 15 mm socket and a 14 mm box end wrench

KAWASAKI VULCAN 1600 / NOMAD 1600 INSTALLATION INSTRUCTIONS

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

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Remove seat and fuel tank. Consult service manual for proper removal of tank. 2. Remove left side cover and loosen the four bolts inside. Route the two 6-pin connectors between the side cover and frame as shown by the dotted line. Tighten the four bolts. (Fig 1) 3. Route 6-pin connectors under frame and up left side of engine. (Fig 2) 4. Locate the 6-pin connector next to the ignition coil. Disconnect and connect the Fuelpak 6-pin connectors in-line on the stock connector. (Fig 3) 5. Route single black wire to the front of engine and down to the horn. (Fig 4) 6. Disconnect the factory black/white wire from horn. Plug Fuelpak into horn and plug Fuelpak black/white wire to Fuelpak connector. Be sure Fuelpak connector cannot short to frame or radiator. 7. Route black and green wires to battery negative. 8. Attach Fuelpak to Fuelpak harness and mount in left side cover. (Fig 5a 49 State) (Fig 5b Caliornia Models) 9. Before reassembling the bike, make sure handlebar switch is in the engine off position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the black wire connection on the horn and that it is connected to the correct wire from the factory harness. 10. Use supplied zip ties to hold Fuelpak wire harness away from engine. 11. Follow the service manual to reinstall the gas tank

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