2004 Kawasaki ZX10R Power Commander Installation Instructions

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

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Remove the main seat and the passenger seat 2. Remove the tail cover by removing the two bolts. 3 Place the Power Commander in the tail section and route the wiring harness on the inside of the tail section towards the front of the bike (Fig. A). 4. Remove the fuel tank. 5. Remove the air box lid by removing the 8 screws around the outer edge (Fig. B). 6. Remove the bolts shown in Fig. C. This will allow you to remove the air box. Fig. A Fig. B Fig. C i212-411 2004-2005 Kawasaki ZX10R – PCIII USB – 2 i212-411 www.powercommander.com Remove these bolts Remove screws Remove bolts 7. Locate the Throttle Position Sensor connector. This connector is located above the left hand side of the engine. This is a white 3 pin connector. Unplug this connector (Fig. D). 8. Plug the white connectors from the PCIII in-line of the stock TPS connector (Fig. E). 9. Locate the fuel rail connector behind the injector bodies (Fig. F). This connector is brown in color

KAWASAKI Undertail Installation AND Removal instructions

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Filed Under (Kawasaki) by admin on 26-04-2012

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1- MASKING TAPE 2- DRILL 3- PHILLIPS SCREWDRIVER 4- HAND SAW BLADE OR DREMMEL 5- DRILL BIT # 3/16 (TABS – AREA NEAR LENSES ) 6- DRILL BIT # 15/64 (NYLON SCREW RIVETS FOR THE BACK) 7- ELECTRIC TAPE WHAT COMES WITH THIS UNDERTAIL? 2 RED LED BULBS 2 SCREWS REMOVE THE REAR SECTION OF THE BODY There are plastic body connectors as well as bolts inside the tail in addition to the Allen-head bolts on the outside surface. NOTE: KEEP YOUR STOCK RIVETS FOR LATER USE. REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT REMOVE THE TAIL SECTION & SEAT

HARLEY DAVIDSON UNIVERSAL VISTA INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-03-2012

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1. Turn Harley Davidson thumb screw control all the way off. 2. Remove screw (A) from the motorcycle throttle housing. Position the mounting bracket, as shown in drawing. Replace throttle housing screw through the hole in the foot of the mounting bracket and into the throttle housing. Loosely tighten screw. 3. Slide the cruise control’s slip ring assembly over the end of the throttle grip up to the switch housing. NOTE: Metal band on slip ring assembly is next to switch housing not set screws. Insert correct size rubber filler between slip ring assembly and grip with “joint” of filler on bottom side, midway between two set screws. Tighten all set screws into rubber filler until tight or flush. 4. Place thumb lever slot over eye bolt. Depress spring to line up holes, and insert socket head screw. 5. Insert thumb lever screw into the hole in the head of mounting bracket that keep screw parallel to grip. Install the washer then the locknut on the thumb lever screw. Tighten locknut until mounting bracket and thumb lever are snug BUT loose enough to let thumb lever move freely up and down. 6. Secularly tighten the throttle housing screw (A) in step 1. 7. Twist throttle back and forth to insure there is no binding, slip ring is “SQUARE” with switch housing and thumb lever operates smoothly between “ON” and “OFF”. 8. CRUISE CONTROL ADJUSTMENTS – Twist throttle to half position and push thumb lever down to “SET” position. Throttle should hold snugly in this position. Flipping thumb lever to “OFF” position, releases cruise control hold, throttle should return to “OFF” position. Tightening acorn nut (B) will increase cruise control hold. Loosening acorn nut will decrease cruise control hold. Always check to make sure that throttle can be rotated both ways in “SET” position after adjustments.

Harley Davidson Electra Glides, Ultra Vent (model LV-2,3,4) Installation Manual

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Filed Under (Harley Davidson) by admin on 07-03-2012

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Remove the fairing lower from the engine guard using the procedure provided in your Harley-Davidson user/service manual. Do not remove the glove box from the fairing. Vent Placement, Hole Drilling and Cut-Out: Caution: Place cloth or cushion underneath fairing lower to protect it from getting scratched during the following procedures. LV-2,3,4 Installation Copyright 2003-2004 2 3. Working inside the fairing and using the bottom of the glove box as a guide, position a closed vent parallel to and no more than 1/16″ from the rear edge of the fairing. Position the assembly so that the vent side tabs are no more than 1/8″ below the bottom of the glove box. (You want the vent assembly as close as possible to the glove box but with enough room so that the side tabs do not touch the glove box when the vent is closed! ) Mark the back two holes with a pencil then remove the vent and replace it with the cutting template in the exact same location. See photo to the right to assist in judging the cutting template orientation. 4. Lift out the glove box, steady the template with one hand and using an 11/64″ drill bit carefully drill 1 hole near the back edge of the fairing through the bottom corner hole of the cutting template. Install one screw and nut and tighten slightly to stabilize the template’s location. On the other corner (same edge) , drill the second hole. (You cannot drill the remaining holes from inside the fairing because the front edge of the fairing lower is in the way. ) 5. Remove the screw and nut and re-position the cutting template on the outside of the fairing with the three hole side of the template towards the front of the fairing (away from the edge of the fairing) . Install two screws and nuts into the open holes. Drill the remaining two corner holes and install two screws and nuts. Change drill bit size to 1/8″ to drill the final center latch hole. Next skip down to one of the two following procedures to make the vent opening using either A) Dremel tool/RotoZip router or B) coping saw/frameless hacksaw

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Harley Davidson Road King Lightbar installation manual

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Filed Under (Harley Davidson) by admin on 06-03-2012

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This product is designed to mount in the lowest, visible section of the motorcycle windshield. 1. Install the 3 housing edge seals (1 long seal and 2 short seals) onto the lightbar as shown (Fig. 1). Make sure that the seal is oriented so that the lip curls inward (Fig 2). 2. Remove the 3 screws shown from the upper section of the windscreen (Fig. 3.). CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’SWHILE THEY ARE ON. MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT! IMPORTANT WARNING! WARNING! All customer supplied W ires that connect to the positive terminal of the battery must be sized to supply at least 125% of the maximum operating current and FUSED at the battery to carry that load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT! Fig. 1 Fig. 4 Fig. 3 Fig. 2 3. Position the lightbar into its mounting position behind the windscreen. When properly positioned, the holes in the lightbar mounting tabs will be aligned with the vacant holes through the windscreen. 4. Using the mounting hardware included with the lightbar, secure the lightbar to the windscreen assembly. 5. Route the wires to their respective destinations (Fig. 4). It is left to the installation technician’s discretion to select a path for these wires that will both protect them from possible damage and not interfere with the operation of any other vehicle components or equipment

KTM 3V TURBO DRIVE MODEL 9808T KNEE FEED Installation and Removal Manual

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Filed Under (KTM) by admin on 28-01-2012

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Gather together the following items that you will need to complete this installation. a) lathe b) 3/8″ electric hand drill c) 9/32″ diameter transfer punch SERVO Turbo Drive Model 9808T Page 2 d) .4375 drill, 3/16″ drill, #7 drill e) 1/4-20 tap f) 3/4″ socket wrench g) set of inch hex wrenches h) clean shop rag Step 2: Clean the power feed mounting area completely. Step 3: Remove the drive clutch nut and the drive clutch from the elevating jack shaft. Step 4: Remove the dial nut, dial, and dial carrier. Keep the dial for reuse later. Step 5: Remove the existing bearing retainer. Keep the screws for reuse later. Step 6: Pull jack shaft out of knee. Hold inboard end up while removing to avoid damage to the pinion gear. Step 7: Press the bearing off the jack shaft. Step 8: Drill and ream the end of the jack shaft .4375″ diameter by 13/16″ deep. The .4375″ dia. must be concentric to the shaft O.D. within .002″ T.I.R. Chamfer 1/32″ x 1/2″ diameter. For best results, machining should be done in a lathe. Step 9: Place the shaft extension #6975 into the end of the jack shaft. Finish drill 3/16″ diameter through the shaft and pin the extension with the 3/16″ diameter x 5/8″ long roll pin. File smooth. Step 10: Reassemble and replace the jack shaft in the machine. Step 11: Replace the existing bearing retainer with #57904 retainer provided. Secure using existing screws. Step 12: Slip spacer #5426 and bearing race #1616 onto the jack shaft. Slide the adaptor #0771 over the bearing race and locate against front of the knee.

KTM EXC / MXC DUAL SPORT KIT REMOVAL AND INSTALLATION

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

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Using a small phillips head screwdriver, loosen the locking screw ( B ) on the kill switch ( C ). Remove any cable ties and unplug kill switch from existing wiring. Step 2 Loosen clutch cable perch ( D ) and move inboard about 1/2 inch. Important Note Regarding Magura Brakes The KTM uses the Magura hydraulic brake, which may cause potential interference between the turn switch and the lever adjuster. Make sure you have enough clearance between the parts. You can either move the grip out slightly, or take a file and sand away a small notch in the turn switch where it may rub. Install Turn Switch Step 1 Open and wrap the new turn switch ( E ) around handlebar and securely fasten with two screws ( F ) as shown. Make sure you have clearance between the grip, the switch and the lever! Step 2 Route turn switch wiring down and along handle bar behind Dakar headlight unit and in through frame cable guide. Secure switch wiring to handlebars with one cable tie. For more information, please refer to the Cable Routing Diagram

YAMAHA ROYAL STAR VENTURE CENTERSTAND REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 31-12-2011

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Stand Installation. Locate the four mounting holes on the frame that correspond with the holes in the centerstand. Slide the front of the centerstand up into the frame and align the large bolt holes with those in the frame. Install the (2) 7/16″ x 1″ bolts with washers thru the frame and centerstand. Install the (2) 7/16″ nuts and make finger tight. (on California models the fuel tank vent canister must be removed and the hoses bypassed see note below) Pivot the rear of the centerstand up to align the (2) smaller holes in the stand with those in the frame. Insert a phillips screwdriver into one of the (2) remaining mounting holes and pry the other hole into alignment. Install one of the ¼” x ¾” bolt with a washer from the top down thru the frame and centerstand. Install the lock nut finger tight. Remove the screwdriver and install the remaining ¼”x¾” bolt washer and nut. Tighten the ¼ ” bolts securely 10-12 ft. lbs., then tighten the 7/16″ bolts securely 20-24 ft. lbs. 2. Stop Bumper Installation. Next install the centerstand-stop bumper and bracket onto the frame. Locate the bolt “A” in photo #1. Notice there is another 10 mm bolt just below it. Remove the lower bolt. Attach the bumper bracket to this hole using the longer bolt and washer supplied. The leg of the bracket with the bumper should face inward towards the center of the motorcycle. Adjust the height of the bracket to keep the pedal arm 3/8″ to ½” from the bottom of the exhaust pipe. Tighten securely. 3. Emissions Valve Relocation. You will notice that the right leg of the stand near the foot comes in contact with the emissions valve. The valve needs to be moved outward or to the right as you are sitting on the motorcycle approximately ¾”. This is done as follows: Remove the (2) 10 mm bolts holding the emission valve and bracket to the frame. See photo #2. With the hoses still attached pull the valve down to gain access to the (3) allen screws. Remove the (3) allen screws and (2) nuts holding the bracket to the valve, turn the bracket over and re-assemble the valve onto the bracket as shown in photo #3. Re-install the valve onto the frame. You may need to rotate the hose clamp clips out of the way and/or bend the entire valve bracket assembly outward slightly to gain clearance between the centerstand leg and foot. 4. Using Your New Centerstand. To put the motorcycle up onto the centerstand, hold the left handle bar and saddlebag guard rail. Using the ball of your right foot, lower the stand to the ground. Rock the motorcycle from side to side slightly until you feel both feet of the stand touching the ground. Now, put all of your weight on to the centerstand pedal (stand on it). Pull up and back on the grab rail using a rocking motion to rock the motorcycle up on to the stand. Remember it is a matter of using your body weight and leverage not lifting! 5. Getting the Bike Down off the Centerstand. Holding the left handle bar and saddlebag guardrail, firmly rock the motorcycle off the centerstand. You can also rock it off while sitting on the motorcycle.

Honda V4 Cam-Chain Tensioner Installation and Removal

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Filed Under (Honda) by admin on 03-12-2011

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Stay Organized – Misplaced and mismatched screws can be an expensive nightmare on many levels. Spend a couple bucks on organizing bins of various sizes and keep your uninstalled parts together in a logical sequence. 10 seconds now will save you 10 hours later. • Two wire coat hangers • Full metric socket Set w/ medium and long extensions • Various sizes of flat-head screwdrivers
• Safety wire (optional) • Sharpie pen (optional) • Plenty of towels and rags to wipe hands and surfaces • An extra set of hands
2) Keep records – If a job is complicated it’s easy to get confused with what went where before you took it apart. If you have a small digital camera handy and are unsure about your mechanical skills, snap pictures along the way to record how things looked. 3) Don’t get frustrated – If you start feeling frustrated and let yourself continue, you’ll probably cause more problems and damage than you’ll solve or fix. Take a break

2003 Honda Shadow Spirit 750 VT 750DC Custom speedometer dial installation

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Filed Under (Honda) by admin on 06-11-2011

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DO NOT REMOVE THE 3 PHILLIP SCREWS ON THE BACK OF THE SPEEDOMETER. This will unscrew the circuit board and the main components inside the speedometer, and possibly damage it. Just leave those 3 screws alone. They won’t make your customization any easier if they are removed. This is the hard part. Turn the speedometer face down on a soft towel on a sturdy table, bench, etc. I used a regular flat screwdriver to do this step. There is a chrome metal ring holding the glass on the speedometer. It is factory sealed. On the bottom side of this ring start prying with a flat screwdriver under the bottom lip of the metal ring. This will be a slow process (patience, patience, patience) so don’t get in a hurry and ruin the wife’s kitchen table like I did. Go around the metal ring with a flat screwdriver prying it up as straight as you can. It’s easier doing this every millimeter or two. I had to do this about 3 times all the way around the ring. After you pry the lip of the ring up all the way around enough to loosen it up considerably, gently pull the ring off of the speedometer. The glass should come off with it. Put the glass with the chrome ring aside for later. You might want to use a soft lint free towel to rest it on

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