Harley Davidson Motorcycles Hot Grips Installation Manuals

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Filed Under (Harley Davidson) by admin on 23-02-2012

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End weights or other need to open the ends: You may drill out the outboard ends of the grips for installation of end weights or other purpose, if you use a fine tooth hole saw and do not go larger than the handlebar’s inside diameter. We have molded in a visual guide on the grip’s ends, and we recommend 7/8″ or at most 1″ diameter and be sure to center drill carefully. DO NOT use a hacksaw or you will destroy the grip, because there are resistance wires molded into the grip outboard of the handlebar diameter. Some Harley throttle sleeves are molded with raised plastic ribs or ridges to help hold the original Harley grip in place, and these will mate up with four (4) of our internal ribs by sliding our heated handgrip over the sleeve. HOWEVER, there are two axial ribs, which go circumferentially around the throttle sleeve as illustrated below, and they may have to be carefully removed with a knife of razor blade. They must be trimmed off with a file or razor knife until the Hot Grips slides over them. Do not force the Hot Grips over the ridges as the grip cannot stretch and will be damaged if forced on. These Hot GripsĀ® have a heat output of 8 watts on “low” and 15 watts on “high” per grip. As a pair they will consume 20 watts of electrical power on “low” and 30 watts on “high”. They consume more than 8 x 2 on “low” because the resistor consumes a little

BULLET & MINI-BULLET TACHOMETERS INSTALLATION MANUALS

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Filed Under (Tips and Review) by admin on 22-02-2012

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UNDER THE HANDLEBAR MOUNTING A: Can the Tach be mounted inverted under the handlebars? A: Yes, if you have enough room to mount under the handlebars for the tach to mount and still be able to turn from lock to lock without hitting the tank or dash. See note in next paragraph for details on how to rotate the face of the Tach for appropriate positioning. BE AWARE: Chances of water intrusion are increased in this position! FACE ROTATION Q: How do I rotate the face of the Tach? A: With the Tach housing removed from the handlebar, unscrew the bezel (counterclockwise) and remove it from the housing, using a 5/32 Allen wrench loosen the the set-screw located inside the clamp area or at the rear of the clamp area. Rotate the face of the Tach to your preferred position, tighten the set screw and replace the bezel. COIL IDENTIFICATION Q: How can I tell positive from negative on my coil? A: Most motorcycles will have two wires going to each of the coils, and each coil will share one common-color wire and have one unique color wire. The common-color is the positive and the unique color is the negative. For example, a Yamaha set-up has a red/black on both coils – that is positive. The other coil wire would be orange or gray – that is the negative side. Hondas set-up is blue/yellow and yellow/blue for the negative, and black/white for the positive. Suzuki has orange/white on both coils as positive and has white or black/yellow as the negative side. COIL SELECION Q: My bike has two (or four) coils – Which one/ones do I use? A: Most multi-cylinder bikes have one coil per cylinder. You only need to connect to one of the coils – choose the one most convenient for wire routing. (Single-fire motorcycles require the Tach adapter we include with each assemble

MPS Sport Bike Auto Shift Installation Manuals

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Filed Under (Suzuki) by admin on 21-02-2012

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The first thing to do is remove the seat, fuel tank, and possibly the front fairing if equipped. You will need plenty of room to work. Electrical Connections – You will need to locate and test a few things on your bike before you start wiring. A good ground, an ignition switched 12 volt power source, the horns, and the ignition coils. We have plug n play style harnesses available for some bikes. Check the web site for specific models. Control Box Wiring Coils – Most four cylinder motorcycles use either a individual firing system or a waste spark system. Waste spark is by far the most common. All four cylinder bikes with only two coils use a waste spark system. Most late model four cylinder sport bikes use waste spark systems even though they have four individual coils. Bikes with a waste spark systems will need the 360 calibrated unit. The 360 calibrated Sport Bike Autoshifts are identified by the 360 engraved into the box below the wire lead exit. The P/N for these boxes has the 360 as a suffix. (P/N 1-0299-360) Some of the newest fuel injected bikes (Hayabusa, GSXR1000, ZX12) that have cam sync sensors are individual firing. These bikes will require 720 calibration and will have no outside identifiers and the P/N 1-0299. The Sport Bike Auto Shift has four brown wire leads that are connected to the negative of each individual coil on a four coil system. You will notice that the connector for the four brown wires has a molded in ridge that marks the brown wire that is used as the rpm sensor. This must be connected to the number one cylinder coil negative wire.

Suzuki M- 109 Front Head Pipe Installation Manuals

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Filed Under (Suzuki) by admin on 18-02-2012

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1. Remove seat (Fig 1) remove right side (Fig 2) panel with allen 6mm bolt and push-pin snap. (Fig 3) Figure 1 Figure 2 Figure 3
- 3 – 2. Remove 6mm bolt on heat shield and remove heat shield. (Fig 4) Figure 4 3. Remove two 8mm bolts on top muffler and remove two 8mm stock bolts on bottom muffler and remove mufflers. (Fig.5 & 6) Figure 5 Figure 6 4. Remove frame cover with stock allen 6mm bolt. (Fig 7) Figure 7 FFF – 4 – 5. Loosen brake pedal bolts to allow more room to remove the exhaust. (Fig 8) Figure 8 6. Remove exhaust system by removing stock 8mm bolts on exhaust flanges. (Fig 9) Figure 9 7. Unplug EXCVA wire connectors. (Fig 10) Figure 10 – 5 – 8. Remove three 8mm stock mufflers mounting brackets bolts as shown. (Fig 11) Figure 11 ffff 9. Remove EXCVA unit from the stock muffler bracket. (Fig 12) Figure 12 10. Remove the stock pulley from the EXCVA actuator unit as shown. (Fig 13)

2003 – 2006 KTM The e-Axle Installation Manuals

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Filed Under (KTM) by admin on 01-02-2012

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Remove the stock wheel spacers from both sides of the wheel hub and install both of the Rekluse wheel spacers. After installing the Rekluse wheel spacers, stow the wheel in a suitable place so that the brake rotor cannot be damaged. See following picture. 5 5. Remove the brake pads by removing the clips and sliding out the pin. See following picture. 6. Remove the leaf spring from the caliper. See following picture. 7. Re-install the brake pads with the included coil spring positioned on the pin between the brake pads. Secure the pin by re-installing the 2 clips. See following picture. Coil Spring on the pin and in between the brake pads 6 8. Coat the center axle in a thin layer of grease to aid in sliding the center axle on and off. Note: Coat the center axle in a thin layer every time it is reinstalled after removing the front wheel for tire maintenance. 9. Position the front wheel back in between the forks so that the brake disk is in place between the brake pads, and so the wheel spacers line up with the hole in the fork fists. 10. Slide the center axle, with 30-mm Bushing attached, through the right-side fork fist and through the wheel spacers in the front hub. Rotate the 30-mm bushing so the set screw is facing up, this will line the “0″ Offset Mark with the fork fist pinch clamp slot. Continue sliding the axle through until the 30-mm bushing is almost flush with the outer edge of the right fork fist. See following picture

YAMAHA RHINO PERFORMER NITROUS SYSTEM INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 14-01-2012

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The nitrous bottle is an aluminum cylinder designed and manufactured to withstand very high internal pressures. The valve on top of the bottle is a high-flow design that allows easy opening and closing which controls the nitrous flow to the engine compartment. Accurate calibration of your nitrous system depends on the bottle remaining at a stable temperature. In vehicles where the bottle must be mounted in an area subject to direct sunlight, it is suggested that the bottle be shielded with a bottle blanket when not in use. Here is the performer bottle valve. Installed on all bottle valves used in Edelbrock Nitrous Systems is a pressure relief device or “PRD”. It is a safety device designed to vent the contents of the bottle into the atmosphere if over-pressurization occurs. Unsafe bottle pressure is caused by over filling or elevated bottle temperatures. It is illegal to tamper with or remove the pressure relief device! Bottle Safety Information 1. Do not attempt to remove the bottle valve. Please return your bottle to Edelbrock if service is required to the siphon tube or the bottle valve itself. 2. Never heat the outside of your nitrous bottle with an open flame such as a torch. 3. Do not strike the surface of your nitrous bottle with a heavy or sharp object. 4. Do not drop your nitrous bottle. 5. Do not attempt to grind off or destroy any imprinted markings on the face of the bottle. 6. Do not remove, modify or otherwise tamper with the pressure relief device on the bottle valve. 7. Do not attempt to use a bottle that has been damaged or tampered with

YAMAHA 1996-2003 Road Star BILLET TACH MOUNT KIT INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 12-01-2012

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Remove and retain the (4) chrome caps from the handlebar clamps. Remove and retain the (4) stock allen head bolts. This hardware will be re-used with the new Billet Tach Mount Kit. Carefully remove the stock handlebar clamps while supporting the handlebars. INSTALLATION: 2. Slide the Electronic Tachometer (#6) into the Billet Tach Mount (#2) and secure with the 10-24 X 1/4″ Socket Set Screw (#10) supplied. Carefully pull the tachometer wire harness through the larger hole in the Billet Tach Cup (#3) and secure the Billet Tach Cup with the 10-24 X 1/8″ Socket Set Screw supplied. (The additional holes in the tach cup are for air circulation). Attach the Billet Tach Mount to the Billet Handlebar Clamp (#1) with the two 10-24 X 1-3/4″ Socket Head Screws (#4) supplied. Install the Billet Tach Mount assembly with the four stock allen head bolts and chrome caps removed in step 1 above. Adjust handlebars to desired height and torque bolts to factory specs. WIRING INSTRUCTIONS: 3. Refer to FIG. #1 . Remove Seat. Disconnect negative cable from battery. Remove fuel tank retaining bolts. Raise fuel tank about 3″-4″ to expose the Left Side Ignition Coil. It is not necessary to completely remove the gas tank on the Road Star. (V-Star 1100 applications use the right front coil and require fuel tank removal.) TIP: Long needle nose pliers are useful in removing and re-installing the coil wires. If desired, tach wire loom may be shortened as necessary. Using an appropriate crimping tool, connect the Tachometer wires in the following manner: Cut Shrink Tubing (#9) into two 1″ pieces

YAMAHA SINGLE SIDED SWINGARM REMOVAL AND INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 27-12-2011

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1. Disconnect Battery 2. Lift and secure bike 3. Remove brake-side floorboard 4. Remove exhaust. 5. Remove rear fender 6. Remove front pulley cover 7. Remove wheel, pulley, and brake assembly simultaneously. Now remove front pulley from transmission. (Keep up with the stock nut and lock washer; these will be used during assembly) 8. Remove Passenger pegs; now remove the plastic covers in the frame that cover the pivot tube bolts. 9. Remove the stock shock bolts ( keep for re-assembly) 10. Remove the pivot tube bolts. 11. Remove the stock swingarmb12. Install “new” belt at this time. 13. Install supplied pivot tube, and bearings in RC swingarm. 14. Install shock bolt with red loctite in RC swingarm. (Do not tighten bolt at this time) 15. Insert supplied pivot bolts with red loctite through frame and supplied bushings into the RC swingarm. (Right side bushing has flats) 16. Torque shock and pivot bolts to factory specs. 17. Install belt adjustment bolts and single side keys into swingarm.