8 inch harley air cleaner cover

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Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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Filed Under (Victory) by admin on 31-10-2010

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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HARLEY DAVIDSON SCREAMIN' EAGLE VENTILATOR PERFORMANCE AIR CLEANER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the main fuse. Refer to the service manual. 2. Remove the existing air cleaner backplate. Refer to the service manual. Save the original equipment (OE) button head screw that secures the air cleaner cover. Discard the remaining parts. 3. Remove the fuel tank. Refer to the service manual. 4. See Figure 1. Remove and discard the induction module support bracket. is05912 Figure 1. Remove Induction Module Support Bracket INSTALLATION Air Cleaner Installation Use only supplied air cleaner cover. Use of another air cleaner cover could cause element failure and detachment of the air cleaner cover, which could distract the rider and result in death or serious injury. (00596b) NOTE When servicing the air cleaner, apply Loctite 243 – Blue to the threads of all fasteners. 1. See Figure 3. Install two O-rings (1) from the kit in the grooves around the breather bolt holes on the induction module side of the backplate assembly (2). Install the remaining two O-rings in the grooves in the underside of the heads of the breather bolts (5). 2. Remove the liner from the adhesive backing of the gasket (3). Carefully position the adhesive side of the gasket to the backplate, aligning to the equally spaced screw holes, and press the gasket firmly into place. 3. Insert new breather bolts (5) through the backplate. 4. Apply Loctite 243 – Blue to the breather bolt threads and the mating tapped holes in the cylinder head. 5. Thread the bolts into the cylinder head, but do not tighten. 6. Thread the air cleaner mounting studs (4) all the way through the backplate (2) until the screw threads are captured in the induction module. Do not tighten completely at this time. 7. Alternately tighten the two breather bolts to 120-144 in- lbs (13.6-16.3 Nm) . 8. Tighten the three air cleaner studs to 55-60 in-lbs (6.2- 6.8 Nm) . 9. Install the fuel tank. Air Cleaner Element and Cover Installation

HARLEY DAVIDSON EFI INTAKE MANIFOLD COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 1. Remove screw (A) that holds the air cleaner cover (B) and seal (C). 2. Remove three T27 TORX® screws (D) to release the cover bracket (E) from the filter element (F). 3. Remove the filter element, pulling the two breather tubes (G) from hole on the inboard side of element. 4. Remove the two breather tubes (G) from the fittings on the two cylinder head breather bolts (I). 5. Remove the two breather bolts (I) and O-ring seals (K) from the air cleaner backplate (J) with a 7/16 inch deepwell socket. 6. Remove the backplate and gasket (H) from the injection module. 7. Aligning the flat edge of a new cover gasket (2) with the backplate molded tab, install a gasket (2), chrome cover (1) and second gasket, in order, on the air cleaner back- plate. 8. Install the breather bolts through the air cleaner backplate. Re-install O-ring seals onto each breather bolt. Install a washer (3) from the kit on each breather bolt. Apply Loctite 243 to the breather bolts and align holes in the backplate with the holes in the cylinder heads and install the breather bolts. Use a 7/16 inch deepwell socket and alternately tighten the breather bolts to 120-144 in-lbs (13.6-16.3 Nm) . 9. Slide gasket over the sleeve on the inboard side of filter element. 10. Install breather tubes about 1/4 inch (6.4 mm) into holes on inboard side of filter element. 11. Install breather tubes onto fittings of two cylinder head breather bolts. NOTE Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into atmosphere in violation of legal emissions standards. 12. Place the filter element onto backplate, with the flat side down, so that the hole on the inboard side of element fits over the molded boss in the backplate. 13. Align holes in cover bracket with those in filter element and start three screws. Stamp on cover bracket points downwards. Use a T27 TORX drive head, alternately tighten screws to 20-40 in-lbs (2.3-4.5 Nm) . 14. Make sure that the rubber seal is proper seated around perimeter of air cleaner cover and place cover on back- plate. 15. Fit the air cleaner cover onto backplate. Apply Loctite 243 to the threads of air cleaner cover screw. Install screw through cover and tighten to 36-60 in-lbs (4.1-6.8 Nm)

HARLEY DAVIDSON AIR CLEANER COVER MEDALLION KIT INSTALLATION MANUAL

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

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INSTALLATION NOTE All kits except number 29795-02, 29833-06, 29888-06, 29898- 06, and 29929-07 will need to install the medallion onto the insert. Kits 29795-02, 29833-06 and 29888-06 skip to Step 4. 1. See Figure 1. Clean mounting area on insert (2) thoroughly with rubbing alcohol and allow to dry. 2. Remove backing from medallion (3). 3. Carefully place medallion (3) in center of mounting area pressing firmly to activate adhesive. NOTE The medallion will be secure upon contact. Adhesive cures completely in 24 hours. 4. See Figure 1. Carefully press the insert (2)(with medallion installed) and o-ring (1) into the air cleaner cover as shown. SERVICE PARTS 2 A 3 1 is 01866 Figure 1. Service Parts: Air Cleaner Cover Medallion Kit Table 2. Service Parts: Air Cleaner Cover Medallion Kit Part Number Description (Quantity) Item 27226-00 O-ring 1 Not Sold Separately Insert 2 Not Sold Separately Medallion (all kits except 29795- 02, 29833-06, 29888-06, 29898- 06, 29929-07) 3 Items mentioned in text, but not included in kit. Part of Air Cleaner Cover Kit 29745-00A, sold sepa- ratel

HARLEY DAVIDSON NOSTALGIC TWIN CAM 88 AIR CLEANER COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. Remove current air cleaner cover and screw. 2. See Figure 1. Coat threads of screw (1) from kit with Loc- tite® 243 (blue) (Harley-Davidson part number 99642-97). Install new air cleaner cover (2) with screw (1). If this kit will be installed with a Screamin’ Eagle Twin Cam 88 high flow air cleaner kit, place the self adhering gasket (must be purchased separately) inside the cover between the air filter and the cover. Tighten screw to 36-60 in-lbs (4.1- 6.8 Nm)

HARLEY DAVIDSON DERBY COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits are designed for installation on all 1999 and later 1340 Evolution and Twin Cam equipped models.INSTALLATION For models equipped with left side exhaust pipe: 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) NOTE Remove clutch inspection (derby) cover with motorcycle upright, not on side stand. If cover is removed with motorcycle on side stand, primary fluid will leak out of primary chaincase. 1. On models so equipped, remove the left-side passenger footboard. Using a T27 TORX® drive head, remove the derby cover from the primary chaincase. Discard the derby cover and fasteners. NOTE The gasket between the clutch inspection cover and the chaincase cover must be removed and all oil must be wiped from the gasket and groove in chaincase cover each time the cover is removed. 2. Remove the gasket from the groove in the chaincase cover and mounting surface. 3. Inspect gasket for tears or damage. Replace as required with gasket 25416-99C (sold separately). NOTE If installing the Derby cover on a 2006 and later Dyna, 2007 Softail, or 2007 Touring model, the original equipment gasket must be discarded and replaced with Derby Cover Gasket 25416-99C (sold separately). 4. To avoid punching holes in the clutch inspection cover gasket or enlarging the existing holes, install the new derby cover and gasket as follows: a. Align the triangular shaped hole in the gasket with the top hole in the derby cover. Be sure the rubber molding and the words “towards clutch” face the motorcycle. b. See Figure 2. Place a washer (2) from the kit onto the threads of one of the new screws (3). Insert the screw threads through the top hole in the derby cover, and carefully thread it all the way through the triangular shaped hole in the gasket. Do not push the screw through the hole. c. Hang the derby cover on the primary chaincase cover flange by starting the top cover screw. d. Start the remaining four screws and washers. 5. Install gasket (part number 25416-99C) and derby cover (1) on primary chaincase cover using screws and washers from the kit. Tighten screws to 84-108 in-lbs (10-12 Nm) in the sequence shown in Figure 1

HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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HARLEY DAVIDSON SCREAMIN' EAGLE "HEAVY BREATHER" PERFORMANCE AIR CLEANER KIT INSTALLATION INSTRUCTIONS

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

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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. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) Original Equipment (OE) Air Cleaner Removal For carbureted models: Refer to the service manual and check the warm-slow idle speed adjustment before removing the OE air cleaner backplate. For EFI (fuel-injected) models: Have a Harley-Davidson dealer recalibrate the ECM prior to air cleaner installation. 2. Remove the air cleaner backplate following the instructions in the service manual. Retain the two breather screws (A) removed from the backplate (see Figure 1). The remaining parts can be discarded. 3. See Figure 1. Remove and discard induction module bracket (B). “Heavy Breather” Air Cleaner Installation NOTE When servicing the air cleaner, apply Loctite 243 (blue) to all threaded fasteners (both male and female threads). 4. Install the new O-rings (4) in the grooves around the breather screw holes on the carburetor or induction module side of the backplate (1 or 2)

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