what stroke does a stock shovelhead have

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Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 14-12-2011

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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. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

Yamaha FZ-1 TiForce exhaust system Installation Instructions (Slip-on)

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Filed Under (Yamaha) by admin on 03-01-2012

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Loosen the clamp where the stock tailpipe connects to the stock collector. 2. Remove the bolt holding the stock muffler assembly to the footpeg/exhaust bracket. 3. Remove the stock tailpipe and exhaust assembly as one piece. 4. Remove the nut securing the right side center stand support bolt. Install the new supplied bracket as shown in (See figure 1) 5. Remove the right rear footpeg assembly complete, bolt the new footpeg mounting bracket in place of the stock one using supplied bolts. 6. Carefully unbolt the footpeg from the bracket (Be careful there are springs and washers that will fall out if you are not careful), bolt the footpeg into the new billet footpeg bracket. Bolt the footpeg bracket to the footpeg- mounting bracket. (See figure 2) 7. Remove the stock exhaust gasket from the stock tailpipe and installthe gasket into the new tailpipe. 8. Slide the supplied clamp over the new tailpipe and slide the new tailpipe onto the stock collector. 9. Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stayarm / hanger G to the end can using the supplied 6mm hardware H. See figure 4. 10. Place the bands approximately 150mm from the edge of the end can. See figure 5. 11. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 12. Attach the supplied springs to connect the tailpipe and muffler assembly. 13. Make sure the exhaust system is free and clear, if necessary jigglethe system to adjust for proper clearance. 14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (figure 5), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure thatthe rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 15. Tighten the supplied clamp to secure the new tailpipe to the factory collector. 16. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 17. Check that all hardware is tightened, then start the motor and check for exhaust leaks.

2000-2010 KTM X2 SWITCH WIRING HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 25-01-2012

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The included 3600-SWHA switch harness is intended for use with offroad models that do not come with a Hi/Low beam switch from the factory. The harness is compatable with stock AC lighting electrical systems as well as high output DC electrical systems. 1. Remove the stock numberplate or headlight. Remove the stock kill switch from handlebars and replace with the 3600-SWHA switch. 2. Remove the gas tank. Route the white and black leads from the 3600-SWHA under the tank following the wires from the stock kill switch. Disconnect the stock kill switch bullet and connect the white wire of the 3600-SWHA to the wiring harness. Disconnect the stock kill switch ring terminal and connect the ring terminal of the 3600-SWHA. Fully remove the stock kill switch. Be sure all the wires are safe from being burned or pinched and re-install the gas tank. 3. Disconnect the two female spade terminals from the stock headlight switch (if present). Connect the terminal with the yellow wire to the red power lead from the switch. Connect the white wire to the blue accessory output from the switch. Be sure the clear silicone sleeves are covering the stock plastic housings. 4. Connect the X2 headlight to the switch headlight plug. Note: The stock headlight plug will not be used for the X2 installation, but is still functional for connecting the stock headlight. The stock plug will turn on and off with the new headlight switch, and will be powered in either of the Low or High Beam positions

2006-2008 Honda TRX 450R SR4 4 Stroke Carbon racing system INSTALLATION

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Filed Under (Honda) by admin on 25-12-2011

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Removal of the stock exhaust, 1. Loosen stock tail pipe clamp (Fig 1) 2. Unbolt and remove stock muffler (Fig 2) 3. Remove stock header pipe (Fig 3) Installation Motoworks exhaust 1. Install Motoworks header pipe using stock nuts, finger tight at this point ( Fig 4) 2. Install Motoworks tailpipe with muffler using bolt and spacer supplied in kit on upper rear mount, use stock nut and bolt on lower mount finger tight at this point. (Fig 5 and 6) 3. Torque header pipe nuts to 1.0 kg-m ( 7.3 lb-ft ) 4. Torque tailpipe mounting bolts to 2.5 kg-m ( 18 lb-ft ) 5. Re-check all your work 6. We recommend that you clean the entire exhaust system with a mild detergent, i.e. glass cleaner prior to starting as any oily residue may cause permanent staining. 1 Instruction sheet 1 Stainless header pipe 50-1002A 1 Tailpipe with SR4 Carbon muffler 51-1002 1 8mmx1.25x65mm flange bolt 70-100-100 1 Aluminum spacer 8mmx7mmx32 SA4 1 Header pipe port flange PF8 1 Spark arrestor 75-100-01 2 Motoworks stickers 07-1002 1340 North Melrose Drive, Vista, CA 92083 Phone 951-587-9222 Fax 760-758-5991 Email: info@motoworks.com
7. Before operating check for proper clearance between Motoworks exhaust and ATV i.e. frame, plastic, brake line, fuel line etc if problems exist re-check work . Note: It is normal for the new exhaust to emit white smoke the first time you start the ATV. This is from the oil used during manufacturing.

Steering Stem Nut Installation Instructions & Owners Manual

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Filed Under (Tips and Review) by admin on 26-11-2010

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Sport Bike Damper Kit Installation Instructions DISCLAIMER: All GPR Sport Bike damper kits are manufactured to be used ONLY w/ the stock top triple clamp and frame. If either is modded, aftermarket or crash damaged, the kit will not install properly and GPR will not be held responsible for the consequences of improper installation due to this or any other improper mounting or modifying. The provided instructions must be followed precisely, as failure to do so can result in the GPR damper kit being installed incorrectly. An improper installation may lead to a variety of undesirable steering problems. Please take your time and carefully follow the installation instructions. As always, give us a call if you have any questions, we’re more than happy to assist you in getting the damper kit mounted on your bike properly 1. Remove the stock Steering Stem Nut (SSN) and washer from the stock top triple clamp steering stem. Carefully set the stock nut aside, as you may be using it later. Bikes requiring a specific GPR SSN to replace the stock SSN are listed at the end of this installation sheet. If your bike is on the chart, throw you stock SSN in the toolbox along w/ the washer, as you may need it at a later date if for any reason you need to remove the GPR kit from your bike. Stock SSN’s that are either ‘domed’ at the top or ‘flanged’ at the bottom will definitely NOT work, may lead to problems and should NOT be reinstalled during the baseplate installation. See #2 below for further instructions about both SSN/Steering stem and arm clearance issues 2. With the stock SSN and washer removed, place the GPR Baseplate over the steering stem on the top triple clamp and reinstall either the stock SSN or the GPR SSN provided. Torque SSN down to the recommended specs as per the owner’s manual for your particular bikes make and model. NEVER reinstall the stock washer that came on the bike! The baseplate is now your new washer. If you do accidentally use the stock washer, the arm on the stabilizer will most likely ‘rub’ on the nut. It will be too high, potentially locking the steering and handlebars, thus making your bike un steerable and unridable. DO NOT ride your bike until all installation steps have been completed and you can visually verify that there is clearance between the arm of the stabilizer and the steering stem and/or SSN. Once the installation is complete, at the #1 setting you

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Honda VTX1800C/ J Left/ Ringht Floor Board Assembly Instruction Manual

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Filed Under (Honda) by admin on 14-11-2010

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Left Side 1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

HARLEY DAVIDSON RONT & REAR HEADPIPE AND HEATSHIELDS INSTALLATION

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Filed Under (Harley Davidson) by admin on 10-11-2010

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1. Remove both left and right saddlebags and set them aside. 2. Remove the right side floorboard from the frame and set aside. 3. Unplug the O 2 sensors on front and rear headpipes from motorcycle wire harnesses. 4. Remove the stock exhaust system. It may be necessary to lubricate the slip joints of the exhaust with WD-40 or similar lubricant to aid in disassembly. The stock muffler slide hangers may be left in place in the rubber mounts for later reinstallation of the mufflers. 5. Remove the stock rear headpipe support-mounting bracket by removing the two starter mounting bolts, this bracket will not be reused. Note: Use caution when removing the bolts so that any tools used do not come in contact with the positive post on the starter. Install the Cobra supplied, exhaust support-mounting bracket, see Figure 1. 6. Remove the stock exhaust flanges, retaining rings and O 2 sensors from the stock headpipes and headpipe support clamp from the front headpipe. Remove the new front headpipe from packaging and install the stock flange, retaining rings and O 2 sensor on to the pipe. 7. On the front headpipe slide the stock headpipe support clamp over it. Install the front headpipe on the motorcycle using the stock flange nuts to secure it to the exhaust port studs, but do not tighten at this time. Slide the headpipe support clamp forward on the headpipe and over the stock exhaust mount on the right side engine case, make sure the clamp’s rectangular hole is on top and the flat part of the clamp is downward, see Figure 2. Install the carriage bolt and nut to secure the tube clamp but do not tighten at this time. 8. Reinstall the muffler onto the front headpipe using one muffler slip clamp. Reinsert two stock 5/16- inch bolts into rear muffler mount, tighten to factory torque specs, do not tighten front muffler slip clamp at this time. (NOTE: On some models equipped with saddlebags the bag rail may need to be adjusted outward to allow proper clearance between muffler body and swing arm / axle nut.) 9. Tighten front headpipe flange nuts then headpipe support clamp to factory torque specifications. 10. Remove front heatshield and hose clamps from packaging. Unscrew the hose clamps and feed the tail end of the clamps through the clips on the inside of the heatshield from the bottom, so the screws are facing toward the bottom and accessible with a screw driver once the heatshield is installed. Install the heatshield over the front headpipe. (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes.) Align heatshield with headpipe and snug clamps but do not tighten .

Honda VTX1800F Left/ Right Floor Board Assembly Installation Manual

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Filed Under (Honda) by admin on 14-11-2010

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1. Unplug the horn wires. 2. Unbolt the left side foot peg bracket assembly and save the hardware, the stock bolts will be used to install your new Cobra floorboards. 3. Remove horn and the shift lever from the stock mount and install onto the new Cobra mount the same way they were on the stock mounts. Install the 8mm acorn nut on the exposed threads from the shift lever bolt. 4. Bolt the Cobra floorboards to the motorcycle using the stock bolts and torque to factory specifications. Note: Make sure shift lever operates properly and that there is adequate clearance. Right Side 1. Remove chrome cover from the top of the rear brake master cylinder by removing the two nuts on top. 2. Remove brake lever return spring and the stop light switch spring. 3. Remove rubber plug from the center of the brake lever pivot bolt then remove the bolt. 4. Remove the two bolts that hold the master cylinder and brake light switch/chrome cover mount. 5. Unbolt the right side foot peg bracket by removing the two stock 10mm bolts and save the hardware, the stock bolts will be used to install your new Cobra floorboards. Note: look at the placement of the large spacers behind the foot peg bracket they will need to be re-installed in the same position. Also note the nut on the inside of frame rail for lower bolt. 6. Install the Cobra floorboard using the stock bolts and spacers removed in previous step. 7. Remount the master cylinder and brake light switch/chrome cover mount removed in step 4 the same way it was on the stock mount bracket, reuse stock hardware. 8. Install the brake lever using the stock pivot bolt & rubber plug that was removed in step 3

Vespa GTS Super Specification

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Filed Under (Vespa) by admin on 11-11-2010

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Gts super 300 ie Gts super 125 ie s 125cc s 50cc Gts 250 ie Gts 125cc LX 125cc LX 50cc 2 stroke Engine Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder LEADER 4 stroke with electronic injection Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder, catalised, LEADER 4 stroke, 4 valve Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Capacity 278cc 124cc 124cc 50cc 249cc 124cc 124cc 49cc Power 16.4 kW / 7500 rpm 10.5 Kw / 9500 rpm 7.65 Kw / 8250 rpm 3.2 Kw / 7500 rpm 15.7 Kw / 8500 rpm 7.65 Kw / 8250 rpm 7.65 Kw / 8250 rpm 2.5 Kw / 8500 rpm Max Torque 22Nm / 6500 rpm 12 Nm / 8000rpm 9.6 Nm / 7250 rpm 4.4 Nm / 6500 rpm 20.1 Nm / 6500 rpm 9.6 Nm / 7250 rpm 9.6 Nm / 7250 rpm 3.3 Nm / 6500 rpm Cooling Liquid Liquid Forced Air Forced Air Liquid Liquid Forced Air Forced Air Starter Electric Electric Electric and kick starter Electric and kick starter Electric Electric Electric and kick starter Electric and kick starter Transmission Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Front Suspension Single arm, dual chamber hydraulic shock absorber with coaxial spring Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Rear Suspension Two dual effect shock absorbers with adjustable preload Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Twin hydraulic shock absorbers with preload adjuster Twin hydraulic shock absorbers with preload adjuster Hydraulic shock absorbers with preload adjuster Hydraulic shock absorber Front Brake ø 220mm disc brake 220mm disc brake ø 200mm disc brake ø 200mm disc brake ø 220mm disc brake ø 220mm disc brake ø 200mm disc brake ø 200mm disc brake Rear Brake ø 220mm disc brake 220mm disc brake ø 110mm drum brake ø 110mm drum brake ø 220mm disc brake ø 220mm disc brake ø 110mm drum brake ø 110mm drum brake Front Tyre Tubeless 120/70-12″ Tubeless 120/70 – 12″ Tubeless 110/70 – 11″ Tubeless 110/70 – 11″ Tubeless 120/70-12″ Tubeless 120/70-12″ Tubeless 110/70 – 11″ Tubeless 110/70-11″ Rear Tyre Tubeless 130/70-12″ Tubeless 130/70 – 12″ Tubeless 120/70 – 10″ Tubeless 120/70 – 10″ Tubeless 130/70-12″ Tubeless 130/70-12″ Tubeless 120/70 – 10″ Tubeless 120/70-10″ Running weight 158kg 158kg 114kg 96kg 151kg 145kg 114kg 96kg Length/Width/Height 2230mm / 755mm / 1170mm 1930mm / 755mm / 1930mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm 1930mm / 755mm / 1170 mm 1940mm / 755mm / 1180 mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm Fuel Tank Capacity 9 litres 9 litres 8.5 litres 8.5 litres 9.2 litres 10 litres 8.5 litres 8.5 litres Emmissions Euro 3 Euro 3 Euro 3 Euro 2 Euro 3 Euro 3 Euro 3 Euro 2 Colours Rosso Dragon Nero Lucido Montebianco Rosso Dragon Nero Lucido Montebianco Taormina Nero Lucido Montebianco Taormina Nero Lucido Montebianco Marrone Terra Di Toscana Bronzo Perseo Nero Vulcano Blu Midnight

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2010 Harley Davidson Touring Model Power Commander Installation manual

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Filed Under (Harley Davidson) by admin on 29-02-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Plug the PCV connectors in-line of the stock ECM and wiring harness (Fig.B). 4 Tuck the PCV to wiring harness connection into the opening in front of the battery box (Fig. C). 5 Using the supplied velcro attach the PCV to the top of the ECM (Fig. C) FIG.A FIG.C Remove Ground wire FIG.B PCV connector PCV connector Stk connector Connection 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 4 6 Remove the right hand saddlebag and sidecover. 7 Locate the stock O2 sensor connections and unplug both connectors (Fig. D) The stock O2 sensors will NOT be connected to anything at this time. The sensors can be removed from the exhaust if you have a way to plug the hole. Unplugging the sensors does NOT cause an engine light but will cause a historic code in the ECM for non-active O2 sensor. This is not causing any issues with the running of the bike. FIG.D Follow these instructions when using the Auto tune kit – part #AT-100B 1 Remove the left hand side cover. 2 Place the Autotune modules in front of the battery as shown in Figure H. If using velcro make sure the velcro does not cover the designation of the unit on the back (AT #1 or AT#2). The modules are coded to the front and rear cylinders. FIG.E 3 Remove the rubber plug for the diagnostic connector. Plug the lead from the Autotune kit into the stock diagnostic connector (Fig. J).This connection is under the LH sidecover. DO NOT connect to the accessory connection in front of the battery. 4 Reinstall the sidecover. FIG.F 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 5 5 Connect the longer harness to the front O2 sensor. Route the harness along the front down tube and along the backbone of the frame to Autotune module AT#1. Wire the harness to the module per Figure G. The harness can be cut to length if desired. 6 Repeat step 4 for the rear cylinder. Wire the harness to Autotune Module AT#2. The harness can be cut to length if desired. If your exhaust does not accept the M18x1.5mm O2 sensor you will need to install the supplied O2 bungs with the Auto tune kit into your exhaust. See Auto tune instructions for more information