Filed Under (Honda) by admin on 10-11-2010
Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh
Filed Under (Harley Davidson) by admin on 04-12-2010
1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect negative Battery Terminal. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Save the Passenger Handrail and two nuts. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove five ¼ – 20 HHCS, ¼ – 20 nyloc nuts, and Aluminum Spacers. 13. Remove Tour Pak from Top Support Tube. 14. Loosen Muffler Clamp on both Mufflers and remove 2 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 15. Remove and discard Muffler Support Plates. 16. Remove both ¼ – 20 HHCS and Front Saddle Bag Brackets. 17. Remove the twelve 5/16 – 18 Torx HCS six 5/16 – 18 nuts, and the Left and Right Saddle Bag Guards. 18. Remove the Air Line Junction from the Rear Fender. 19. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip.
6 20. Remove two 5/16 – 18 Phillips head screws. Remove the Left and Right Frame Covers. 21. Remove two 5/16 – 18 Torx HCS. Remove and save the Top Tour Pak Support Tube Top. 22. Remove four 5/16 – 18 Torx HCS. Remove the Left and Right Rear Saddle Bag Guard Support Bracket. 23. Remove four 5/16 – 18 HHCS. Remove and save the Tour Pak Support Tube Bottom. 24. Remove and discard the Air Valve Assembly Bracket. 25. Remove four ½ – 13 HHCS and washers. Remove and discard both Rear Air Shock Absorbers. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. 26. Drain all Brake Fluid from the Rear Brake System. 27. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 28. Remove the 10 – 24 flanged HHCS and Rear Brake Hose Clamp from the Right Rear Fork Bracket. 29. Remove ¼ – 20 SHCS from Rear Stop Lamp Switch Bracket. 30. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 31. Remove the Spring Clip and nut from the Rear Axle. 32. Remove Rear Axle and Rear Wheel Spacers. 33. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 34. Remove Rear Brake Caliper. 35. Slide Rear Wheel Assembly rearward. Remove one 5/16 – 18 Torx HCS from inside the Rear Fender well. 36. Slide Rear Wheel Assembly forward. Remove two 5/16 – 18 Torx HCS. Remove Rear Fender. 37. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate
Filed Under (Triumph) by admin on 28-10-2010
A.) REAR WHEEL REMOVAL- PAGE 14-16 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 12 mm bolt from rear seat section—if you have a pillion pad remove it first by removing the 8 mm bolt, slide forward and lift free of seat catch. Take a position where you can see what you are doing or you will scratch your painted surface. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-14 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 side allen head mount bolts and 2 12mm hex head top front mount bolts– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-11 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove the 12mm rear tank-mounting bolt. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface. E.) REMOVE SIDE COVERS PAGE 15-10 and 9-15 Triumph Motorcycle Service Manual 1.) Loosen and remove left side cover screws on the air filter facade— lift slightly to disengage top mounts and remove—set aside in a safe place to prevent damage to painted surface. 2.) On right side cover simply and gently pull bayonet fittings from rubber slip mounts. 3.) Secure these rubber mounts and remove for later re-assembly with the Bonneville Performance brackets.
Filed Under (Triumph) by admin on 29-10-2010
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
Filed Under (Harley Davidson) by admin on 29-01-2011
1 2 is 00911 1. Tongue 2. Keyhole Figure 2. Underside of 2-up seat INSTALLATION NOTE If installing the seat with a sissybar/backrest pad present, remove the backrest pad prior to seat installation. This will prevent damage to the pad and/or seat. Reinstall backrest pad after the seat is installed. 1. Models equipped with solo seats: See Figure 1. a. Remove the plastic plug (1) from the rear hole location in the fender (2). Save the plastic plug for installation. b. Move the seat retention nut (4) and lockwasher (5) from the middle location to the rear location, where the plug was just removed. As shown in the inset, a cable strap (6) can be used as an installation aid. Place the retention nut (5) over the cable strap so that the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender, and through the fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. c. With the rib of the retention nut (4) seated into the notch in the fender hole, slide the retension washer (5) into place from the rear. This will lock the retention nut in place. d. Reinstall the plastic plug in the fender hole in the middle location. NOTE The foam cushioning of the seat needs to be compressed as the seat is slid forward to engage the post on the frame when the seat is dropped into place. When properly installed, the front tongue on the underside of the seat should fit snugly in the groove at the fuel tank rear mounting location and the keyhole on the underside of the seat will lock the seat to the post on the frame. 2. All models: See Figure 2. a. Angle the front of the new seat into place so the tongue (1) engages the slot at the rear fuel tank mounting location. b. Push the seat forward and rotate the rear of the seat downward until the seat contacts the frame. Flex the seat slightly in the middle and slide the seat towards the rear so that the keyhole slot (2) on the seat bottom engages with the center seat post on the frame. 3. See Figure 3. Pull up on the center of the seat to verify that it is locked into place. (There will be a small amount of play, but the seat should only come up about a half an inch and then will be held firmly in place by the post on the underside of the seat.) If the seat is not firmly in place, repeat Step 2 until the seat is firmly in place. Reference the Owners Manual for further instruction on seat placement if needed