INSTALL FLYWHEEL
1. Drain 20% of the oil from the bike first.
2. Shut the gas supply off on the bike, then lay it over on its side. A small amount of gas will leak from the overflow tubes when the bike is first laid down.
3. Remove shifter.
4. Remove bolts holding the side cover on (no need to remove one of the oil filter bolts).
5. Remove oil fill cap.
6. Disconnect clutch cable and lay cable out of the way.
7. Remove side case and lay it next to the main case to avoid removing any wires. TAKE CARE - do not allow the two alignment pins to come loose from the side case. They CAN stay in the side case or in the main case, but you don’t want them to fall out and get lost; or, even worse, dropped in the oil for later consumption by the motor!!
8. Use a 17mm deep socket and impact ratchet to remove the flywheel retaining nut. If an air ratchet is not available, hold the rear wheel while removing the 17mm flywheel nut. Note: If a Deep socket is not used damage to the crankshaft oiler may occur.
9. Use flywheel puller to remove the flywheel. Remember to install protective nut on to crankshaft to avoid damage to end of flywheel. Note: there is a small hole on the shaft that allows for oil flow to the crankshaft - using the correct flywheel puller will protect this hole.
10. Install new flywheel and torque flywheel bolt to manufactureer specification. Do not use thread locking compound. Use the woodruff key on the crank to line up the keyway on the flywheel with the crankshaft.
11. For ease of assembly, connect clutch cable before installing bolts.
12. Replace the side case. Use a new gasket if necessary. Torque side case bolts to 7 foot pounds. Do not overtighten these bolts! Replace the shifter. Make sure the bolt threads in smoothly - cross threading is easy. You will need a Honda CRF flywheel puller (TT part# 6600-P02) for this installation. An impact ratchet is also highly recommended.
Note: Trail Tech CRF450X flywheel is provided with one M6×25MM BHCS to replace the timing chain guide bolt (A), and a M6×12 BHCS to replace the guide retainer bolt (B). These bolts allow for the flange on the exterior of the flywheel to clear the fasteners. Trail Tech is not liable for any damage due to the improper installation or lack of installation of these bolts. Contact Trail Tech Tech-Support for further questions.
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Showing posts with label side. Show all posts
Showing posts with label side. Show all posts
Tuesday, May 11, 2010
Sunday, May 9, 2010
2010 Insight Body Side Molding Installation Instructions
The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures should not be attempted by “do-it-yourselfers.
NOTE:
• Be careful not to damage the body paint finish.
• Body side moldings should only be installed if the ambient air temperature is 15°C (60°F) or above.
• To allow the adhesive to cure, do not wash the vehicle for 24 hours. Please advise the customer.
• These installation instructions show the left body side moldings being installed. The same procedure applies to installing the right body side moldings.
1. Using one alcohol swab, clean the area where the left body side molding will attach.
2. Align the front template to the left front door and attach the template to the door using strips of masking tape.
3. Place the left front body side molding against the template to verify the installation position on the left front door. Remove the body side molding.
4. Peel back approximately 1½ to 2 inches of adhesive backing from each adhesive tape, and tape the ends to the front surface of the body side molding. Remove the small end pieces of the adhesive backing.
5. Align the left front body side molding with the front template, and attach it to the left front door. If the vehicle has door edge film installed, align the end with the door edge film.
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NOTE:
• Be careful not to damage the body paint finish.
• Body side moldings should only be installed if the ambient air temperature is 15°C (60°F) or above.
• To allow the adhesive to cure, do not wash the vehicle for 24 hours. Please advise the customer.
• These installation instructions show the left body side moldings being installed. The same procedure applies to installing the right body side moldings.
1. Using one alcohol swab, clean the area where the left body side molding will attach.
2. Align the front template to the left front door and attach the template to the door using strips of masking tape.
3. Place the left front body side molding against the template to verify the installation position on the left front door. Remove the body side molding.
4. Peel back approximately 1½ to 2 inches of adhesive backing from each adhesive tape, and tape the ends to the front surface of the body side molding. Remove the small end pieces of the adhesive backing.
5. Align the left front body side molding with the front template, and attach it to the left front door. If the vehicle has door edge film installed, align the end with the door edge film.
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Sunday, May 2, 2010
VW Jetta, Golf, New Beetle 1.9L TDi Unichip PnP Installation Instructions
Although the PnP kits and ECU’s are identical, the New Beetle’s EC’s location is different than the Jetta/Golf; therefore these instructions are split – the first section describes Golf/Jetta installation and the second section describes Beetle installation.
(2) The ECU connectors lock and unlock by pulling the “T-handle” located at the connector’s edge. Look at the locking handles on the PnP harness and familiarize yourself with the mechanism before trying to remove the OEM plugs.
(3) When trying to remove the OEM Plugs from the ECU, getting your fingers into the T-handles can be difficult. You can gently pry the T-handles back using a screw driver.
(4) The Golf/Jetta OEM ECU bracket will not reinstall with the Unichip PnP harness in place without modification. You can easily modify your bracket as outlined below or can by a modified bracket from UNA (UNA Part # 9950001).
Installation Procedures - Golf/Jetta
1. Using the 10mm wrench, disconnect the car’s battery at the negative terminal in the engine compartment behind the driver’s side headlight.
2. (Photo 1) Remove the Windshield Wiper Arms
Note: Installing the wiper arms in the incorrect position may result in damage when they are actuated.
a. Using the pick, pry off the windshield wiper drive spindle covers.
b. Record the arm position on the drive spindle with a marking pen to assist correct reinstallation.
c. Using the 13mm socket, remove the nut securing each wiper arm blade, and remove the arms.
3. (Photo 2) Remove the plastic Rain Tray Cover
a. Remove the rubber seal along the top of the firewall
b. Slip your fingers between the windshield and the tray at the mid-span point and gently work towards one side unplugging the securing tabs. DO NOT USE ANY TOOLS as they may damage the tray, tray tabs, or windshield. Repeat towards the opposite side and remove the tray.
c. Remove the cover; the cover extends underneath the cowl on the passanger’s side. Remove it by pulling it forward into the engine compartment.
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(2) The ECU connectors lock and unlock by pulling the “T-handle” located at the connector’s edge. Look at the locking handles on the PnP harness and familiarize yourself with the mechanism before trying to remove the OEM plugs.
(3) When trying to remove the OEM Plugs from the ECU, getting your fingers into the T-handles can be difficult. You can gently pry the T-handles back using a screw driver.
(4) The Golf/Jetta OEM ECU bracket will not reinstall with the Unichip PnP harness in place without modification. You can easily modify your bracket as outlined below or can by a modified bracket from UNA (UNA Part # 9950001).
Installation Procedures - Golf/Jetta
1. Using the 10mm wrench, disconnect the car’s battery at the negative terminal in the engine compartment behind the driver’s side headlight.
2. (Photo 1) Remove the Windshield Wiper Arms
Note: Installing the wiper arms in the incorrect position may result in damage when they are actuated.
a. Using the pick, pry off the windshield wiper drive spindle covers.
b. Record the arm position on the drive spindle with a marking pen to assist correct reinstallation.
c. Using the 13mm socket, remove the nut securing each wiper arm blade, and remove the arms.
3. (Photo 2) Remove the plastic Rain Tray Cover
a. Remove the rubber seal along the top of the firewall
b. Slip your fingers between the windshield and the tray at the mid-span point and gently work towards one side unplugging the securing tabs. DO NOT USE ANY TOOLS as they may damage the tray, tray tabs, or windshield. Repeat towards the opposite side and remove the tray.
c. Remove the cover; the cover extends underneath the cowl on the passanger’s side. Remove it by pulling it forward into the engine compartment.
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Wednesday, April 28, 2010
HyperDrive Startup Guide
Remove the handle and mount it to the side of the engine with three, 3/8″ bolts. Be careful not to stretch the handle wires and cables. The washers and nylock nuts installon the inside of the handle mount near the slots. The handle bolts must be snug enough to hold the handle firmly, but yet allow the handle to move up and down freely.
Unscrew the mounting clamps wide enough to easily slip over your transom. Do not use tools to tighten the clamp handles.
Mounting: When you mount the motor, it will be 1″ off center, away from the operator side of the boat, or to the left when standing near the transom facing the bow. (the Hyper propeller runs on the surface and pulls slightly to the left. By offsetting the engine, this helps reduce prop torque.) Place a mark at that point to facilitate quick mounting. When you run the Hyper, if it still pulls, you can bend the lower skeg (which is already prebent). Only do this after you have run the motor an hour or so and get accustomed to the tilt and trim adjustment. If the engine is trimmed up too far, it will also pull to one side.
- Carefully lift the motor and set it on the transom. Again, being careful not to jar or tweak the handle mounting cups. When in place, snug up the mounting clamps hand tight. If you have an older boat with a worn or a weak transom, you can add a piece of plywood or metal plate between the boat and mounting clamps. Two mounting bracket holes are provided in the mount face if you want to add 3/8″ bolts to the mount. They help hold the engine in place and deter theft.
- Connect the battery cables to the battery. We provided a group 24 size battery box. We recommend a group 24 marine cranking battery with 550 cranking amps or more. Red to (+) and black to ( -). Rotate the engine back and forth to ensure the cables travel freely.
- Electric Tilt and Trim: Read the cautions for its use on the control panel. Most importantly, don’t force the drive up or down with the handle while the actuator is running. Do not rock the actuator control back and forth causing the motor to forward and then in reverse while running. This can cause premature failure. Engine Oil: Add oil to your engine. Use a good grade of synthetic 10W-30 oil. Check the dipstick with the engine in the level position. You can use a synthetic or synthetic blend.
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Unscrew the mounting clamps wide enough to easily slip over your transom. Do not use tools to tighten the clamp handles.
Mounting: When you mount the motor, it will be 1″ off center, away from the operator side of the boat, or to the left when standing near the transom facing the bow. (the Hyper propeller runs on the surface and pulls slightly to the left. By offsetting the engine, this helps reduce prop torque.) Place a mark at that point to facilitate quick mounting. When you run the Hyper, if it still pulls, you can bend the lower skeg (which is already prebent). Only do this after you have run the motor an hour or so and get accustomed to the tilt and trim adjustment. If the engine is trimmed up too far, it will also pull to one side.
- Carefully lift the motor and set it on the transom. Again, being careful not to jar or tweak the handle mounting cups. When in place, snug up the mounting clamps hand tight. If you have an older boat with a worn or a weak transom, you can add a piece of plywood or metal plate between the boat and mounting clamps. Two mounting bracket holes are provided in the mount face if you want to add 3/8″ bolts to the mount. They help hold the engine in place and deter theft.
- Connect the battery cables to the battery. We provided a group 24 size battery box. We recommend a group 24 marine cranking battery with 550 cranking amps or more. Red to (+) and black to ( -). Rotate the engine back and forth to ensure the cables travel freely.
- Electric Tilt and Trim: Read the cautions for its use on the control panel. Most importantly, don’t force the drive up or down with the handle while the actuator is running. Do not rock the actuator control back and forth causing the motor to forward and then in reverse while running. This can cause premature failure. Engine Oil: Add oil to your engine. Use a good grade of synthetic 10W-30 oil. Check the dipstick with the engine in the level position. You can use a synthetic or synthetic blend.
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Tuesday, April 27, 2010
03-Up Honda Pilot Step Bar Assemblies Installation Instructions
1. Remove contents and check for damage. Verify all parts are present. Read instructions completely before installation.
2. Locate driver side mounting locations on vehicle (See Figure 1and 2). Repeat for passenger side.
3. Attach driver side front and rear mounting brackets to underside of rocker panel as shown using M8 hex bolts, 5/16” flat washer and 5/16” lock washer. Hand tighten only (See Figure 1 and 2). Repeat for passenger side.
4. Place driver side step bar on saddles with Logo facing outwards. Assemble with 3/8” hardware. Hand tighten (See Figure 3 and 4). Repeat for passenger side.
5. Check step bars and brackets for proper alignment. Tighten and torque 3/8” hardware to 32 ft-lbs and M8 hex bolts to 25 ft-lbs.
Finish protection - Westin products have a high quality finish that must be cared for like any other exposed finish on the vehicle. Protect the finish with a non-abrasive automotive wax (pure carnauba, for example) on a regular basis. The use of cleaner wax or any compound which contains an abrasive is detrimental, as the compounds scratch the finish and open it to corrosion.
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2. Locate driver side mounting locations on vehicle (See Figure 1and 2). Repeat for passenger side.
3. Attach driver side front and rear mounting brackets to underside of rocker panel as shown using M8 hex bolts, 5/16” flat washer and 5/16” lock washer. Hand tighten only (See Figure 1 and 2). Repeat for passenger side.
4. Place driver side step bar on saddles with Logo facing outwards. Assemble with 3/8” hardware. Hand tighten (See Figure 3 and 4). Repeat for passenger side.
5. Check step bars and brackets for proper alignment. Tighten and torque 3/8” hardware to 32 ft-lbs and M8 hex bolts to 25 ft-lbs.
Finish protection - Westin products have a high quality finish that must be cared for like any other exposed finish on the vehicle. Protect the finish with a non-abrasive automotive wax (pure carnauba, for example) on a regular basis. The use of cleaner wax or any compound which contains an abrasive is detrimental, as the compounds scratch the finish and open it to corrosion.
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