removing cat converter from 2012 flhx

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HARLEY DAVIDSON AUXILIARY BRAKE/RUN/TURN SIGNAL CONVERTER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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 battery cables, negative side first. 2. Remove the seat according to the procedures in the applicable Service Manual. NOTE Federal regulations require that red turn signal lenses need to be a minimum of 4 inches from the tail or stop lamp, edge to edge. In order to ensure this spacing requirement, new directional stand-offs are provided in kit and must be used to replace the original (stock) directional stand-offs. To install the new directional stand-offs, perform the following. 3. See Figure 1. Insert a small screwdriver into middle hole (1) of license plate light cover assembly (2). Push forward to release tail lamp spring clip. -J03679 1 of 4 2 1 is01493 1. Middle hole 2. License plate lamp assembly Figure 1. Removing Tail/Stop Lamp Assembly 4. See Figure 2. Lift tail lamp assembly upward and disconnect tail lamp connector (1). Disconnect left (2) and right (3) turn signal 2-place connectors. 5. See Figure 3. Remove two left side fender support front socket head screws (1). Save hardware for installation. 6. Remove left fender support capscrew (2) (under fender) near end of support and washer (3). Remove capscrew (4) at approximate midpoint of fender support and washer (5). Save hardware for installation. 7. Remove directional lamp screw (6) and washer (7). NOTE Prior to removing turn signal wires, carefully note routing. In particular, pay close attention to the locations of cable straps which must be replaced. 8. Carefully remove fender support (8), turn signal lamp (9) and directional lamp support (10) along with wiring through elongated hole in fender (11). Discard directional lamp support and cap screw. Save turn signal lamp for installa- tion. 9. Perform Steps 5 through 8 for the right fender support and signal lamp assembly. NOTE At this point, the two turn signal pin terminals must be removed from the two-place connector in order to remove the turn signal and directional stand-off from the fender support. The pin terminals will be re-installed to the connector after routing wiring through new directional stand-off and installing stand-off and turn signal to fender support. Follow the instructions under AMP MULTILOCK CONNECTORS in the applicable Service Manual to remove the pin terminals from the two-place con- nector. 10. See Figure 3. Obtain new directional stand-off and cap- screw from kit. Route wiring from turn signal lamp (9) through new directional lamp support (10) and elongated fender support hole (11). Install capscrew (6) through fender support, new directional lamp support then into turn signal. Tighten capscrew securely. 1 3 2 is 01494 1.4-place tail/stop lamp connector 2. Left turn signal 2-place multi-lock connector 3. Right turn signal 2-place multi-lock connector Figure 2. Disconnect Tail Lamp and turn Signal Connectors 11. Perform step 10 for the right side

Triumph Bonneville America And Speedmaster The Freak Installation Instructions and Parts List

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Filed Under (Triumph) by admin on 29-10-2010

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INSTALLATION In order to install The Freak, the factory air-box must be removed. Because of it’s design, the factory air-box is not an item that is easily removed. There are several parts that must be removed in order to get the air-box out of the bike in one piece. We recommend using the following method to remove your air box without having to cut it into smaller pieces in order to get it out of the frame. 1. PARTS REMOVAL In order to gain access to the air-box, it is necessary to remove certain parts of the motorcycle to gain access to the air-box area of the frame. Removing the following parts should be the first steps you take. A. Seats – Remove both seats starting with the passenger pillion, if applicable. B. Side cover and grommets – Remove the plastic side cover on the right side (throttle side) of your motorcycle. This is the faux oil-tank cover that has the name of your bike on it. Underneath the side cover there are three rubber grommets (1 on the frame tab, and two on the air-box) that support the side cover. Remove the two that are on the air-box and leave the one on the frame. You will attach the two that you removed to the right side bracket in Section 4C . C. Faux air filter covers – On the right side of the bike, remove the chrome faux air filter covers, by removing the one allen head screw that holds it onto the air-box. On the left hand side (clutch side) remove the faux air filter cover in the same manner, you removed the one on the right. D. Plastic shrouds – on the left side, remove the black plastic air-box shroud, by removing the two allen head screws holding it in place. Then remove the plastic shroud covering your fuse box (this is the piece that surrounds your ignition terminal next to the battery). E. Battery – Remove the battery by unscrewing the torx-head bolt that holds the chrome bracket in place. Remove the chrome bracket and the black plastic cap. Tilt the battery out of the box with the top towards you. Disconnect both battery terminal connectors, negative (-) terminal first. Remove the battery. F. Battery box – Remove the two bolts that hold the battery box to the frame. Pull the battery box out as far as you can, then remove the the ignition terminal from the battery box, by removing the two allen screws that hold it in place from the back. Next, remove the fuse box from the battery box, by pushing it out from the back. It is not necessary to disconnect any of the wiring going to the fuse box, or the ignition terminal. G. Rear fender – Remove the rear fender, by first disconnecting the taillight wires. Follow the wires from the tail light assembly on the inside of the rear fender (left side) towards the front of the bike until you come to the box connector. Disconnect the tail light wires at this connector, being careful not to break it. Once the wiring is disconnected, remove the 6 bolts that hold it to the struts. Have someone hold the fender for you while you are removing all of the bolts so that it does not drop once the bolts are removed. Slide the fender out the rear of the bike. 2. PREPARE THE MOTORCYCLE FOR AIR-BOX REMOVAL To remove the factory air-box without damaging it, it is necessary to lift the bike. We recommend the use of a multi-position ATV/motorcycle jack with a minimum lift height of 10″. A. Setting up the lift – Place the lift under your bike and secure your bike to the lift according to the lift manufacturer’s instructions. B. Raise slightly – Lift the motorcycle to the point where the rear springs are without tension, but NOT to where the rear tire is off the ground. C. Remove the rear springs – Take off each of the rear springs by removing the the two bolts on each spring. Once all the bolts are removed gently pull the springs out off of the studs. If they do not pull off easily, you can raise or lower the bike slightly with the lift to ease tension on the spring. Remember, you should not have the rear tire off the ground at this point. The bike should only be raised enough to relax the tension in the springs. D. Remove the mufflers – Remove the mufflers by loosening the clamp at the exhaust header, and by removing the rear foot peg hangers. If the mufflers are not removed, they can become damaged by the axles in Section 2H . E. Disconnect the carburetors – With a small flathead screwdriver, pull the retainer springs out of the channel of the carburetor intake tubes (the two large black tubes coming from the air box into the back of each carburetor), and simply push them towards the air box off of the carbs

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HARLEY DAVIDSON 2008-2009 FLHR, FLHRC, FLHT, FLHTC FLHTCU, FLHX, FLTR 1584CC INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Start the engine with the transmission in neutral or park. Listen for air leaks or odd noises. For air leaks secure hoses and connections. For odd noises, fi nd cause and repair before proceeding. This kit will function identically to the factory system except for being louder and much more responsive. 2. Test drive the vehicle. Listen for odd noises or rattles and fi x as necessary. 3. If road test is fi ne, you can now enjoy the added power and performance from your kit. 4. K&N Engineering, Inc., suggests checking the air fi lter element periodically for excessive dirt build-up. When the element becomes covered in dirt (or once a year), service it according to the instructions on the Recharger® service kit, part number 99-5050 or 99-5000. ROAD TESTING: • 1455 CITRUS ST., P.O. BOX 1329, RIVERSIDE, CA., U.S.A. 92502 • TECH SERVICE 800-858-3333 • FAX 951-826-4001 • e-mail: tech@knfi lters.com® • WWW: http://www.knfi lters.com® 10. Install the provided K&N® air fi lter and secure with the provided hose clamp. A black hose clamp is being supplied with kit. This clamp is intended to clamp the fi lter to the intake tube. NOTE: The K&N® high fl ow intake system is a performance product that can be used safely during mild weather conditions. During harsh and inclement weather conditions, you must install the K&N® Drycharger® onto the air fi lter.

HARLEY DAVIDSON FLHX MIRROR COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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INSTALLATION 1. Remove the outer fairing using service manual instructions. 2. See Figure 1. Remove the mirrors (1) and retain the flange nuts (2) and plastic backing plates (3) securing the mirrors to the inner fairing. Do not heat or bake plastic parts after painting. Applying heat can damage plastic parts. (00615b) NOTE The adhesive will not bond correctly if it is applied at temperatures less than 50° F (10° C). 3. For primed/painted mirror kits: See Figure 2. Install mounting tape to the mirror covers as follows: a. Clean the tape mounting surface of the mirror cover (1) with alcohol pads provided. Allow to dry com- pletely. b. Get the primer tube and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the tape mounting surface of the mirror cover. c. Rub the adhesive backing of the mounting tape (2 or 3) to activate the adhesive then remove the backing. d. Install mounting tape to the mirror cover in the locations shown. Press tape and hold in place for 60 seconds. e. Repeat steps c and d and attach each piece of mounting tape to the mirror cover as shown, then repeat step 3 for the opposite mirror cover. 4. Clean the backside of the mirrors with the alcohol pads provided. Allow to dry completely. 5. Get the primer tube and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back face of the mirror. 6. Rub the adhesive backing on the backside of the mirror cover to activate the adhesive then remove the backing. 7. Place the mirror cover over the backside of the mirror and press into place for a minimum of 60 seconds. 8. Repeat steps 4 through 6 for the opposite mirror. 9. With the mirror post on the outboard side, place the plastic backing plate against the inner fairing engaging two holes in the washer with the threaded stud and index pin. The letters “L” or “R” are stamped on the backing plate posts to differentiate between the left and right side. Repeat for opposite mirror. 10. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 11. Install the outer fairing using the service manual instruc- tions

1996-2004 HONDA XR250R Removing stock carburetor and cables

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Filed Under (Honda) by admin on 26-11-2011

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Install the throttle cables into the supplied throttle housing and place onto clean handlebar end. 2. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or sharp cutters. This should be done with the rag left in the manifold. Be very careful not to damage the manifold or your hands while doing this!! 3. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering
adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 4. Install provided fuel line onto fuel inlet banjo and secure with pinch clamp. 5. Place Edelbrock carburetor into manifold. Do not tighten clamp yet. 6. Remove the cable bracket end from cable bracket using #2 phillips. 7. Install pull cable (see Figure 2) end into
the 4:00 position of the cable wheel and the return cable into the 1:00 position. Secure cables into cable bracket by replacing end piece and phillips screw. See figure 3.

YAMAHA RAPTOR 350 Removing stock carburetor and cables

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Filed Under (Yamaha) by admin on 18-01-2012

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remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Stuff a clean, dry rag into manifold to keep debris out of motor. 4. Remove stock air box. 5. Remove choke cable from handlebars. 6. Remove carb vent line from bike. Carburetor installation 1. Carefully trim the rubber alignment tab off of the face of the manifold with a razor blade or side cutters. 2. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 3. Attach fuel line to carburetor and secure with clamp. 4. Install remote idle cable into tab on top of carburetor. See main manual for this step. NOTE: Nut must be removed from cable before installation 5. Place carburetor into manifold

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HONDA TRX 400EX Removing Stock Carb and Cables INSTRUCTION

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Filed Under (Honda) by admin on 21-12-2011

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Remove seat/fender assembly and fuel tank. 2. Remove throttle cables paying close attention to routing. 3. Remove thumb throttle housing if you are installing a twist throttle. 4. Remove air box and air box intake tube. 5. Remove stock carburetor. 6. Stuff a clean rag into intake manifold to keep debris from entering engine. Preparing machine for carburetor installation 1 . Route the provided throttle cables per manufacturer’s recommended procedure, routing them the same as the stock cables. 2 . Remove the rubber alignment tabs from the manifold using a razor blade or cutters. Be very careful not to damage the intake manifold! 3. Remove air box intake tube from the air box and use a hacksaw to cut approx. 1½” off of the air box intake tube. Your tube should resemble the one shown in Figure 1. Re-assemble the air intake tube into air box and install back onto bike. Don’t forget to tighten clamp around intake tube and reinsert crank vent into the air boot. Figure 1. Thumb Throttle Attach cable into cable wheel with the cable end at the 8: 00 position of the cable wheel, then into bracket. Secure by replacing the cable bracket end and phillips screw. See Figure 2. Figure 2. Twist Throttle 1. Install the pull (see figure 4 for cable identification) , cable end into the 8: 00 position and the idle cable end into the 11: 00 position on the cable wheel. See Figure 3

Bajaj Removing And refitting Automatic Cam Chain Tensioner

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

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1. Remove the 2 Flanged Bolts securing the Tensioner Assembly. 2. Remove Tensioner Assembly from the engine block. 3. Unscrew and remove Lock Bolt. 4. Remove Pushrod, Ball & Retainer, Spring and “O” ring. Clean parts thoroughly and apply grease to the Balls & Retainer. Re-assembly procedure : 1. Place Spring on Pushrod and compress the spring beyond the hole in the Pushrod. 2. Insert a pin or wire into the hole in the Pushrod to hold the Spring in its’ compressed position. 3. Place Balls & Retainer onto Pushrod. 4. Insert Pushrod into the Tensioner body with the small flat on the Pushrod facing, and aligned with, the Locking Bolt hole. 5. Insert the Locking Bolt and tighten it against the small flat on the Pushrod to lock the Pushrod in the compressed position. Remove the pin that’s holding the Spring compressed. 6. Install the Tensioner assembly onto the cylinder block and install and tighten both Flanged Bolts. Be sure that the “O” ring has been installed at the base of the flange. 7.Looosen the Lock Bolt to release the Pushrod, then re-tighten the lock bolt

YAMAHA YFM 350 Removing stock carburetor and cables.

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Filed Under (Yamaha) by admin on 19-01-2012

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Remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Preparing motor for carburetor install 1. Remove stock manifold from cylinder head. 2. Place supplied o’ring into aluminum flange as pictured in figure 1. Figure 1. 3. Install aluminum and rubber flange to motor using supplied bolts. See Figure 2. The shorter 25mm bolt will need to be placed in the bottom hole. IMPORTANT NOTE: Install the aluminum flange with the o’ring towards the motor and the thick side up.

Kawasaki ZX-10 R MXL Strada / Pista Plug and Play kit Isntallation Manual

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

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INSTALLATION STEP # 1 – Removing front transparent fairing and mirrors. The first installation step consists in removing the bike front transparent fairing and the lateral mirrors. The front transparent fairing is fixed to the bike chassis through 6 screws circled in Figure 1 . Please unscrew them and remove the front transparent fairing. Figure 1 : front transparent fairing – screws location It is now necessary to remove both lateral mirrors. First of all, please remove the two internal screws (one of them is circled in Figure 2 while the other is nearby) and remove the lateral mirror. Please repeat this operation for both mirrors. NSTALLATION STEP # 2 – Removing the stock dash. The second installation step consists in removing the stock dash. To do so you need to slacken the lateral fairing. Once removed the lateral mirrors, please remove the central external screw you see circled in Figure 3 . Please repeat this operation for both lateral mirrors. Figure 3: central external screw. Now please slacken the lateral fairings and remove the screw circled in Figure 4 . Please repeat this operation on both sides of the bike. Figure 4: Location of the little internal fairing screws The stock dash is fixed to the bike through three screws that fix the dash to an internal chassis. To remove the stock dash you need to unthread both dash and internal chassis. To do so, please remove the three screws circled in Figure 5 . It is now possible to unthread the chassis and the stock dash