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HARLEY DAVIDSON DETACHABLE QUARTER FAIRING AND DOCKING HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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Installation The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley- Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE If your motorcycle has directional lights mounted on the upper fork bracket they must be relocated to the bottom fork bracket. Some models have front directional lights equipped with three wires, the third black wire is a ground wire. Check to determine how many wires are connected to the front directional lights and follow the following procedure that applies. Ifdirectional lights are not mounted on the upper fork bracket proceed to “ASSEMBLING FAIRING”. Relocating Two Wire Directional Lights 1. Support motorcycle on a center stand such that front wheel is raised slightly off the ground. 2. Remove fork tube pinch screw from right side of lower bracket. 3. Cut wires connected to right directional light about 2 in. away from directional light body. 4. Remove fork tube pinch screw from right side of upper fork bracket. (This is the screw that secures the right directional light.) 5. Install right directional light on right side of lower fork bracket using pinch screw removed in step 4. Install pinch screw removed in step 2 into right side of upper bracket. Tighten both pinch screws to 30-35 ft-lbs. 6. Repeat steps 1 through 5 to relocate left directional light. NOTE Fork tubes may slide downward within fork brackets. If this occurs, front fork tube extension above front fork upper bracket will have to be readjusted according to appropriate Service Manual procedures. 7. Connect the right directional light as follows: Strip approx. 5/16 in. of insulation from the wires cut in step 3. 8. Crimp solderless connectors from kit on two wires coming from motorcycle. 9. Split one end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 10. Slide a piece of shrink tubing from kit over each of the wire ends stripped in step 9 and crimp the wires into the terminals installed in step 8. Make sure you connect the silver and copper colored wires to like colored wires. NOTE Polarized wire is used in this application to ensure correct wiring. One wire is silver, one is copper colored. Wire colors of spliced wire must match wire color of original directional wire leads. 11. Cut polarized wires to the length required for connection to the wires at the relocated directional light. Make certain you leave enough slack in wires to allow routing the harness along the fork tube. 12. Split remaining end of the 2-conductor polarized wire from kit back about 2 in. and strip 5/16 in. of insulation from wire ends. 13. Slide heat shrink tubes over the two wire end. 14. Strip 5/16 in. of insulation from wires connected to directional light and connect like colored wires at directional light with connectors from kit. 15. Slide heat shrink tubing over connectors installed in steps 10 and 14. Activate shrink tubing with heat gun or hair dryer.

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HARLEY DAVIDSON DASH PANEL EXTENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the seat. 2. See Figure 1. Loosen the two socket head screws on the instrument panel console. Raise the console enough to access the two pushnuts holding the upper end of the leather insert. Remove and discard the pushnuts using pliers or a blade-type screwdriver. 3. Remove and discard the phillips head screw (3) and washer (4) securing the lower portion of the leather insert to the fuel tank. Remove the leather insert and discard it. 4. Obtain the dash panel extension (1) and the dash panel extension trim (2) from kit. Place the dash panel extension on the dash panel extension trim making sure the panel is centered and fits cleanly into the lips on both sides of the trim. 5. Gently lift up on the rear of the instrument panel console and install the dash panel extension with the rubber dash panel extension trim underneath, butting the two together. Make sure the rubber dash panel extension trim is aligned with the dash panel extension. Finger tighten the two socket head screws to hold down the instrument panel temporarily in place. NOTE The console rubber trim from a stock vehicle may need to be trimmed slightly to assure proper fit. NOTE When performing the next step, note that proper alignment is achieved when space is eliminated between the instrument panel console and/or between the dash panel extension trim piece and the fuel tank. Due to variances in fuel tank and instrument panel console fitments, the foam pads are used on “as needed” basis to achieve proper alignment. It may be necessary to experiment a few times using various combinations of pads to achieve the desired alignment. In some cases, pads may not be necessary while in others, it may be necessary to use all with one stacked above another. 6. Observe the overall fitment of the panels over the tank and determine whether the foam pads will be necessary to achieve the desired alignment. 7. If necessary, remove the dash panel extension assembly. Peel the adhesive backing and install the needed foam pads (5) to the raised areas extending from the front of the dash panel extension as shown. Re-install the panel. 8. When the proper alignment between the new kit and the fuel tank is achieved, tighten the rear mounting screw (3) with the washer (4) to the speed nut located on the tab at the rear of the fuel tank. 9. Tighten to 18-24 in-lbs (2.0-2.7 Nm). 10. Tighten the instrument panel console?s two socket head screws to 18-24 in-lbs (2.0-2.7 Nm). 11. Install the seat

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Yamaha V-Star 1100 Custom and Classic cruisers Floorboard/ Footpeg Extension Installation Instructions

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Filed Under (Yamaha) by admin on 09-11-2010

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Start on the right (brake) side. 1) Loosen the nut at the end of the brake rod. This will allow you to unscrew the brake rod from the brake lever clevis later. 2) Pull out the cotter pin and remove the pivot pin. Unscrew the clevis 3) Then using a 14mm socket or box-end wrench, remove the two bolts that hold the brake floorboard/footpeg assembly (whichever your bike has) to the frame. These bolts are torqued to 46 ft lbs, so this may be a bit difficult. 1. Loosen this nut 2. Remove the cotter pin (other side of this pivot pin) remove the pivot pin a unscrew the nut to remove the clevis nd 3. Remove these bolts When you remove the floorboard/footpeg bracket, be careful not to pull the brake switch wires loose. You may wish to cut the cable tie for more room, and then rest the bracket, with the footpeg or floorboard attached, on a short box, or block of wood, to keep it handy. Install the new brake rod, to the end of the existing brake rod. Re-install the pivot pin, and the pivot pin cotter pin. Installing the extension bar: Note that the extension bar is bolted so that it rises up in front. Use the new bolts to mount the floorboard/ footpeg bracket to the threaded holes in front. Install the Extension in the proper orientation (angled holes bolt up to the frame, with front of the bar higher than the rear – see photo) using the stock bolts for the extensions to the frame and the new bolts and washers supplied with the kit, on the forward threaded section to relocate the floorboard or footpeg bracket. The use of LocTite ® Blue here is recommended. At this point the right side Floorboard or Footpeg should be secured tightly and the brake lever hanging loose. Now install the Brake rod extension, threading the male end to the original brake rod. Don’t tighten this end yet Place the clevis over the forward most end of the brake rod extension, and threat the clevis nut onto the end of the rod. Bring the brake rod upright, to meet with the clevis at the end of the brake rod extension and replace the pivot pin. Before reinstalling the cotter pin, check the angle of the brake lever, to insure that you have the brake pedal where you want. If necessary, adjust the extension rod in or out, until you are satisfied, and then reinstall the cotter pin into the pivot pin. Check the Brake switch wire and install a new cable tie if required. Note: Due to utilizing a thicker material, 1/2″ versus 3/8″ from our competitor, the Brake rod is now positioned at a greater angle. Even with the angle, braking performance is not affected, but if you wish to bring the master cylinder in line with the brake rod, do this. Loosen the rear, and remove the front Allen bolt. Then place two washers behind the front bolt, under the bracket, and then re-install the bolts To change the angle of the brake rod, 1) loosen and remove the two master cylinder bracket Allen bolts 2) insert two washers behind the front bolt (front of the bike), behind the master cylinder bracket 3) tighten both bolts. Do not install any washers on the rear mounting hole. This will make the angle of the Brake Rod less aggressive. Step Two – Left Side For the left (Shifter) side, 1) use an open-end 10 mm wrench, to unscrew the two nuts that hold the shift rod in place. PLEASE note that one end of the shift rod has a left hand threaded nut. SAVE the nuts, as you will need them on the new longer Polished Stainless Steel Shift Rod. 2) Remove the stock shift rod. 3) Then using a 14mm socket or box-end wrench, remove the two bolts that hold the shifter floorboard/footpeg assembly (whichever your bike has) to the frame.

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YAMAHA Road Star Fuel Pump Relocation Kit INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)

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V-Star 1100 Floorboard/ Foot peg Extension Kit Installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Take notice of the position of the shift peg positions relative to the floorboard or foot-peg. You will be adjusting it back to these locations upon installation of the extended linkage. 2. Loosen the shifter rod jam nuts and remove the OEM shift linkage. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Remove the jam nuts from the OEM shift linkage and thread them gently on to the new shift linkage. 7. Install the new shift linkage by aligning the control swivel and the shifter swivel and turning the linkage. Be careful not to cross thread the linkage. The linkage will thread into both swivels simultaneously. Adjust to the desired position and tighten the jam nuts that you removed from the OEM linkage. Do not over-tighten or damage will occur to the threads. Right Side Installation: 1. Take notice of the Brake pedal position relative to the floorboard/foot-peg before removal, as it will need to be readjusted upon installation of the kit. 2. Remove the cotter pin from the brake linkage and remove the clevis pin. The brake linkage will now be separate from the brake pedal assembly. Do not discard anything. 3. Loosen the floorboard/foot-peg assembly by removing the mounting bolts (14mm wrench) 4. Install the Extension Bracket using the OEM bolts and torque to 46 ft. lbs. Figure 1 shows how to orient the bracket relative to the front of the motorcycle. 5. Mount the floorboard/foot-peg assembly to the Extension Bracket using the SS hardware provided and torque to 46 ft. lbs. It is always a good idea to apply thread-locking compound such as lock- tite to ensure that the hardware does not vibrate loose while riding. 6. Loosen the jam nut from the brake linkage and remove the linkage bracket. 7. Assemble the threaded brake linkage extension to the coupling nut and tighten using one of the provided jam nuts. Don’t forget the thread locking compound if your using it. 8. Thread the coupling onto the brake cylinder linkage and install the other end of the assembly into the brake pedal end. Tighten the jam nuts. You should be able to adjust the linkage for proper brake pedal location before tightening the jam nuts. 9. Readjust the brake light switch and your ready to roll

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YAMAHA V-Star 650 BIG AIR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 21-01-2012

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Remove fuel tank and air filter assembly per Yamaha service manual procedures. 2. Remove the air silencer box under the tank. 3. Install supplied BA-2410-00 Needle/Jet kit according to the instructions in the jet kit package being sure to use the Jets and Needle Slot setting called out for the external BAK filter assemble. 4. Reinstall the air silencer box under the tank. 5. Remove the rubber boot from the stock air box. It is glued-in from the factory, but will come loose if gently persuaded. See photo #1 Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Barons bears no responsibility on installation costs associated with this product. © 2010 Barons Custom Accessories 7401 Slater Ave. Huntington Beach, CA 92647 (714)274-4065 – Ph. (714)848-0718 – Faxwww.baronscustom.comtech@baronscustom.com Page: 2 BA-2011-00/03/06/07/13/13B BIG AIR KIT – YAMAHA V-Star 650 6. Install the stock rubber boot into your new Baron air filter backing plate with the supplied glue. Squeeze glue liberally into sealing groove in stock rubber boot. See photo #2 Allow glue to set up and dry prior to mounting onto bike

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SR-C400 Motorcycle Security System INSTALLATION MANUAL AND USER'S GUIDE

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Filed Under (Tips and Review) by admin on 29-01-2011

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Routing the Antenna Wire The MCM includes an 18″ antenna wire. The first 12″ is a coaxial wire; the remaining 6″ is the reception antenna wire. When routing, try to avoid running the antenna along or near metal. For best performance, have the antenna wire as vertical as possible and exposed. Wire Connections The system includes one harness (HAR-1a) that connects directly into the MCM. The harness is split into three plugs: one for the GEN-1a connector, one for the optional SN-5 connector and one for the data output for future expansion. Note: Each plug is unique and will only fit the appropriate component one way. Main Harness Note: If the optional factory connector kit is being used, please disregard this section of the instructions and refer to the instructions supplied with the factory connector kit. The main harness consists of two harnesses. One is labeled (HAR-1a) and the second is labeled (GEN-1a). Plug in the white 4 pin connector from the (HAR-1a) into the matching 4 pin connector from the (GEN-1a). The (HAR-1a) also has a waterproof connector that plugs into the MCM. The wires should be connected as follows: HAR-1a Black wire with fuse and ring terminal – To battery Positive (+). GEN-1a Black wire – To ground (-). Orange wire – To tail light wire or any other wire that is hot (+) when ignition is ON (NOTE: this is an input to the alarm this connection is not designed to flash the tail light). Color Codes: Ground (-) Tail Light Honda Green wire Brown wire Kawasaki Black wire Red wire Suzuki Black/White Brown wire Yamaha Black wire Blue wire Harley Davidson Black wire Blue wire

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HARLEY DAVIDSON VRSC BRACKET FOR BILLET HEADLAMP SHELL REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REMOVAL VRSCA Models 1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures. 2. Remove right side cover and maxi-fuse. Refer to MAXI- FUSE in Service Manual. 3. See Figure 1. Disconnect headlamp connector (1) from vehicle wire harness. 4. Remove two screws (2), headlamp mounting bracket (3), and headlamp assembly (4) from upper bracket. 2 3 4 5 1 is03046 1. Connector 2. Screw (2) 3. Bracket 4. Headlamp assembly 5. Screw (2) Figure 1. VRSCA Headlamp Assembly VRSCB Models 1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures. 2. Remove right side cover and maxi-fuse. Refer to MAXI- FUSE in Service Manual. 3. See Figure 2. Disconnect headlamp connector (1) from vehicle wire harness. 4. Remove two screws (2), headlamp assembly (3), and headlamp mounting bracket (4) from upper bracket. 5. Remove nut (5), screw (6), and trim ring (7) from head- lamp. 6. Remove lens assembly (8) from headlamp shell (9). Save lens assembly for Billet Headlamp Shell Kit 67704-03 installation INSTALLATION 2004-Earlier VRSCA and VRSCB Models 1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018. NOTES VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot). Adapter ring from kit (Figure 6, Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018. 2. See Figure 3. Cut the two connectors (1) from existing headlamp wire harness (2). Be sure to cut the wires as close to the back of the connector as possible. 3. See Figure 6. Route new wire harness (2) through the hole in bottom of the billet headlamp shell (A). NOTE Only one 16 AWG wire will fit into pin terminals included in kit. Both black wires (ground) can be joined together, then connected to a single wire, if desired. 4. Tape end of one black wire with electrical tape and secure it to wire harness. 5. See Figure 3 and Figure 6. Install terminal pin (3) and socket housing (4) onto new wire harness (Figure 6, Item 2). Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual for installing socket/pin terminals. 3 4 1 2 is03025 1. Connector (2) 2. Wire harness 3. Terminal pin (4) 4. Socket housing Figure 3. 2004-Earlier VRSCA and VRSCB Headlamp Wire Harness 2005-Later VRSCA and VRSCB Models 1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018. NOTES VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot). Adapter ring from kit (Figure 6, Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018. 2. Disconnect and discard existing wire harness. 3. See Figure 6. Connect new wire harness (2) to billet headlamp shell (A). 4. Route wire harness (2) through hole in bottom of billet headlamp shell (A) before installing socket housing (4) provided in kit

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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

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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

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