Kawasaki Voyager 1700 Hitch Removal both saddlebags and Installation Instructions

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Filed Under (Kawasaki) by admin on 08-05-2012

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Remove the seat. Remove both saddlebags by removing the 3 bolts shown below Remove the plastic liner in the bottom of the trunk by gently pushing in on the center of the plastic clips Once the liner is removed remove the trunk rear light assembly by removing the 4 black screws in side the trunk and 4 on the bottom side of the light assembly. Unplug the light assembly and set it aside. Remove the bolts for the trunk Have a friend hold the trunk up and remove the 4 screws (two on each side) for the side trim Put the bolts back inside the trunk and tighten finger tight to make sure it does not fall. Remove the remaining side trim screws, 5 on each side, and remove the side trim and set it aside Remove 2 bolts from the saddle bag supports. Place the side plate mounting bracket behind the saddlebag supports and replace the two bolts you removed in the previous step. (We recommend using a few drops of Loctite). Do this step for both sides of the bike. Place the side plate behind the mounting bracket and attach the side plates to the mounting brackets with the two bolts supplied with the hitch (We recommend using Loctite on this step) Repeat this step for both sides of the bike

Kawasaki Mule Roof 600, 610 and 4010 Trans Crew, Roof Installation Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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INSTALLTION INSTRUCTIONS – Mule 600/610 (4010 Trans skip to pg 4) 1. Place Roof Panel on top of UTV Roll cage and center front to back, and left to right. 2. Using Figure 1 Below – place UTV Roof Mounting Brackets around roll cage bar and using a marker, mark the position of the holes needed in the roof for each Roof Mounting bracket . Figure 1 Copyright 2007 DiamondBack Automotive Accessories, Inc. Page 3 3. Next, remove the roof from the roll cage and using a drill with 1/4″ bit, drill holes using the marks as a guide. 4. Cut (4) 3″ strips of adhesive foam and apply to roof in where mounting brackets are positioned to prevent roof rattling once mounted. Foam should run in the direction of the roll cage as shown in Figure 1 above. 5. Next, reposition the roof on the roll cage according to step 1. 6. Prior to attaching the roof mount brackets, cut the remaining adhesive foam in half and apply one section to the roof in the center of the roof where roof and each roll cage bar meet as shown in Figures 1 above. If additional tape is required to prevent rattling it can be purchased from any hardware store as window sealant foam tape. 7. Next, attach the roof mount brackets according to Figure 2. Use channel locks or pliers to hold top of carriage bolt and turn nut with 7/16″ socket.

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1996+ HARLEY DAVIDSON FLH INNER AND OUTTER FAIRING MOUNT FOR HONDA VTX 1300 installation

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Filed Under (Tips and Review) by admin on 09-04-2012

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This mount was made to attach the HD FLH assembled fairing to the 4 fork mounting points on the VTX 1300 using the Memphis Shades mounts. This allows use of the MS allen wrench to quickly remove the fairing if needed. You will have to make or buy a headlight extension. Has to be done first. I used a 5″ x 5″ x .5″ piece of aluminum stock and made one to bump the headlight out 4″. There will be some trimming and relocating of brackets. And you’ll have to buy longer bolts to mount everything correctly. Get the headlight squared away first, then do the fairing. Take a length of 1″ aluminum angle stock and cut two 17″ pieces from it. These will be the uprights for the “H” brace. Measure 5.5″ from the bottom of one piece and center punch for a hole. Drill a large enough hole to slip over the MS mounting hardware on the forks. Start at about ½” bit and notch out as necessary. Center of this hole has to be 5.5″ from the absolute bottom of the angle iron. In the same location, drill out another notch for the bottom mounting point. A drill press is handy for these modifications and you can hog out the mounting notches with a file, dremmel, etc., until they fit. Do the same for the other length of 1″ angle stock but make sure it is a mirror image of the first one. Test fit these by mounting them to the MS fork brackets using the MS bracket hardware. Bottom notch goes in first, then the top notch. I epoxied the back “nuts” of the mounting hardware to the fork mounting brackets. It keeps it in place when you’re taking the fairing on and off the bike. On the top mounting points, I epoxied a washer with one side ground flat to the bolt’s mounting ferule. This allowed better contact between the H brace and the fork mounting bracket. Didn’t want that fairing falling off. Adjust as necessary and after the test fit, remove.

HARLEY-DAVIDSON SPORTSTER MID-LENGTH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-04-2012

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1. Find and unplug the O² sensor wires from the wiring harness and remove the ZIPSTRIP holding front O² sensor wires to the frame. Feed the end of the wire through the frame so they are free from the motorcycle. Note: pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear head pipe to gain easier access to the mounting nuts. 3. Remove the two head pipe mounting nuts from the flange at the heads. 4. Remove the clamp bolts that mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffler body where they attach to the stock mounting bracket. Carefully remove the exhaust system from the motorcycle and set aside. 6. Using a 7/8″ wrench, carefully remove the O² sensors from the stock head pipes and save for re-use on your RUSH system. 7. Remove the drive belt cover and remove the bracket off the rear cover bolt, bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T-30 torx socket. 9. Remove the three mounting bolts and washers attaching the exhaust mounting bracket. 10. If equipped with mid-controls, remove right side foot peg before installing your new RUSH system.

Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

1995-2010 HARLEY DAVIDSON TOURING MODELS 3.5" & 4" TRU-POWER CHROME SLIP-ON MUFFLER SET installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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1. Be sure motorcycle is properly secured before you begin. 2. Remove saddlebags and place aside. 3. Begin removing your stock mufflers. Starting on one side of the bike, loosen the clamp securing the muffler to the headpipe. Remove the two bolts securing the muffler to the mounting bracket on the saddlebag support of the bike. Keep these bolts for use with your new slip-on mufflers. 4. Using supplied clamp over new slip-on muffler install over stock headpipe. Align the mount tab with holes in the mounting bracket on the saddlebag support. Note that there is a left and a right side pipe. The clearance dent is on the side closest to the swingarm providing clearance on many models. Secure pipe with stock bolts. Be sure to apply Loctite® to bolts upon re-installation. 5. Securely tighten bolts, and then tighten the clamp securing the slip-on muffler to the headpipe. 6. On the opposite side of the bike, repeat steps 3-5. 7. Reinstall saddlebags. 8. Be sure to check proper alignment and clearances before riding. 9. Every time you perform regular maintenance be sure to re-torque all clamps and fasteners. SUGGESTION: For maximum performance you can purchase our “Tru-Power” Headers and XXX Air Cleaner to truly complement the power that your new “Tru-Power” Slip-Ons provide. DISCLAIMER: This aftermarket exhaust system is designed to replace a stock exhaust system on a motorcycle with its engine, frame, and other components in their stock design configuration and location. Re-mapping or re-jetting may be necessary after installation of these exhaust pipes.

Harley-Davidson MOBILE RADIO & CONTROL UNIT Installation Manual

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Filed Under (Harley Davidson) by admin on 22-03-2012

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Installation of the ORION mobile radio and control unit consists of: •Assembling and installing the weather resistant motorcycle case assembly, including the adapter bracket, case/antenna mounting bracket, and bottom case (previously assembled) to the motorcycle mounting bracket (user supplied). •Installing the radio in the radio mounting bracket located inside the weather-resistant case, •Installing the control unit, microphone, and speaker •Installing the antenna •Routing the power, control, and option cables •Connecting all cables including: power, control, and option cables. •Installing the Headset Option •Operational check All mounting hardware consists of stainless steel screws, locknuts, nuts, and lockwashers to resist corrosion. TOOLS REQUIRED •Socket wrench set U.S./metric with 3″ extender •Open end wrench, adjustable •Wire clippers •TORX BIT set, small metric 13
EQUIPMENT INSTALLATION Assembling & Installing The Weather Resistant Case As- sembly The motorcycle Weather Resistant Case Assembly may be installed on almost any motorcycle. Installation instructions provided here include information for the Harley-Davidson Dyna and Road King models and the Kawasaki K1000. Figure 5 illustrates installation on Harley-Davidson motorcycles while Figure 6 illustrates installation on a Kawasaki K1000. Refer to these diagrams during installation. Installation on other motorcycles is at the discretion of the installer. Harley-Davidson Installation 1. Unpack the weather resistant motorcycle case, remove the key taped to the top cover and open the case. 2. Refer to Figure 5 and verify that all components shown in the diagram are available. 3. Mount the adapter bracket onto the Dyna or Road King radio mounting bracket (user supplied) using the 1/4-20 x 5/8 screws provided

Harley-Davidson FXWG, FXST (all except FXSTS), FXDWG Light Bar INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2012

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1. Put a pair of male and female clamp halves together just above the lower triple-clamp. Squeeze the ends of the clamp together with a pair of pliers. Diagram A. 2. Have an assistant position the Light Bar Assembly so the lightbar bracket is to the outside of the clamp assembly. Make sure the wires from the Light Bar Assembly are below the lower triple clamp. Diagram B. 3. Insert a Screw through the clamp and Light Bar Assembly mounting bracket and thread on an Acorn Nut. 4. Hold the Light Bar Assembly in place in front of the lower triple clamp, assemble and attach the remaining clamps. 5. With all four clamp assemblies in place, tighten the clamping screws and nuts to 15 ft. lbs. (21 Nm). Refer to the service manual to gain access to the wire harness inside the fuel tank tunnel or inside the frame backbone. Also, verify the appropriate color wires for hook-up of the passing lamps and turnsignals and running lights. Route the wires from the Light Bar Assembly, around the lower triple- clamp, and up to the frame backbone. Secure the wires so they cannot become pinched when turning the fork. A. The short black wires from the Light Bar Assembly connect to the wires powering the running lights. B. The short red wires from the Light Bar Assembly connect to the wires powering the turnsignals. C. The long blue wires from the Light Bar Assembly connect to the wire powering the headlight low beam. After the wires are connected, verify the operation of the passing lamps, running lights and turnsignals. Correct any connection problems before reassembling the motorcycle. Reinstall the fuel tank. Check all fasteners used during this installation for tightness

HARLEY-DAVIDSON DRESSER BIG SHOT DUALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2012

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1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. Note: On older model Dressers, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er. 4. Remove the stock muffl ers with sliding hangers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Remove the right hand fl oor board. 6. Remove both passenger fl oor boards. 7. Loosen the heat shield clamps on both front and rear exhaust pipes. 8. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 9. Remove the clamp holding the front head pipe to the transmission housing. 10. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 11. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new mounting bracket (stamped 353-P), and torque to (13-16) ft. lbs. (Figure 1). Make sure the battery ground cable is secure and properly routed. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. Note: Pre 1998 dressers do not come with this mounting post. It can be ordered from your local dealer, Harley part number: 65619-98. 12. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them

HARLEY DAVIDSON MOTORCYCLE SIREN INSTALLATION AND OPERATING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 15-03-2012

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Before attempting installation, insure that the parts shown in the Kit Contents List (paragraph D.) have been included. To install the chassis, proceed as follows: 1. Insert two shock mount grommets into the large holes in each (2) mounting bracket (see figure 1). 2. Secure a mounting bracket to the chassis with two (each) #10 thread forming hex. head screws and #10 flat washers as shown in figure 1. Secure the other mounting bracket with like hardware. 3. Select a mounting location on the radio mounting platform which allows the siren cable to reach the motorcycle wiring harness, maintains the structural integrity of the motorcycle, and will not interfere with the safe operation of the motorcycle or the siren. 4. Using the supplied mounting template, scribe four drill position marks at the selected mounting location. CAUTION To avoid damage when drilling, ensure that both sides of mounting surface are clear of any parts or wires