This Service Repair Manual Model Cover: Johnson Evinrude Outboard 60 Hp, 1987 1988 1989 1990 1991 Johnson Evinrude Outboard 65 Hp. Type of catalogue: repair manual: Make: Freightliner: Region: WorldWide: Inclusive languages: English: Amount of disks: 1 CD, PDF file, 2354 pages: OS: Windows XP 32. Motorcycles Repair Manual Download and Reviewsdownload. Remove mid and lower body panels Left and Right.
There is a small plastic cover that is mounted over the main engine stud location on the left side. This cover requires a small notch to be cut out of the cover to clear the small end of the left side offset. Remove stock stud and mount the left side offset (with 1. X 1. 2. 5 X 6. 0). Using a pencil, trace out the notch that you need to remove to clear the small end of the offset. We used a Dremel tool with a sanding roll and cleaned it up with an exacto knife. We removed a small amount of material at a time checking for clearance each time. The notch will not be visible after the body has been mounted. See photos below: 2. Once you have notched the small left side panel, mount the left side offset but only hand tight. You need to be able to move the offset by hand to its proper location. Mount the left side bodywork and align the offset to the opening in the body. Mount the left side slider on the offset to ensure correct location. There is a flat notch in the slider so the body will clear. Remove the slider and body and torque down the offset to OEM specifications. Mount the left side panel. Install the slider using one drop of blue thread locker and torque down to 3. Attach the top two feet of the winch using two 5/1. Note: The winch has floating nuts in its feet. Remove the tail cover by removing the two bolts. 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. Remove the fuel tank. Remove the air box lid by removing the 8 screws around the outer edge (Fig. Remove the bolts shown in Fig. This will allow you to remove the air box. C i. 21. 2- 4. 11 2. Kawasaki ZX1. 0R – PCIII USB – 2 i. Remove these bolts Remove screws Remove bolts 7. Locate the Throttle Position Sensor connector. This is a white 3 pin connector. Plug the white connectors from the PCIII in- line of the stock TPS connector (Fig. Locate the fuel rail connector behind the injector bodies (Fig. 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. 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. Filed Under (Kawasaki) by admin on 0. Tags: access 2, billet aluminum, bolt and nut, exhaust gaskets, exhaust system, flange nuts, head pipes, mounting bolt, oil cooler, pipe flange, radiator, rubber bands, stainless steel bandsdownload. Remove the lower fairing. Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. Remove the existing exhaust system and save the flange nuts for reuse. Inspect the exhaust gaskets. Assemble the head pipes 1 (blue), 2 (red), 3 (yellow), and 4 (green) by matching the joints of the same color to the pair of front Y- pipes. ONLY!!! Place a billet aluminum exhaust port centering flange Z on each Ti. Force headpipe - see figure 3 for details. Attachthe assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Install the S- Bend to the front section of the headpipes and two Y- pipes. Go back and retighten the head pipe flange nuts per factory specifications - make sure the headpipes and flanges Z are centered in each port (’0. ONLY!!! Slide the Ti. Force end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. Place the bands approximately 1. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 1. H and the stock mounting bolt hardware. STEP #2 Route wires starting at the battery end and finishing at the bracket. STEP #3 Connect the wires to the socket. STEP #4 Mount the bracket on the horn bracket located under the gas tank. STEP #5 Fasten ty- wraps. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 - Remove the seat exposing the battery. STEP #2 – Remove negative battery lead. STEP #3 – Finish routing the wire under the tank and up to the horn bracket. Apply either dielectric grease or Vaseline to the spade terminals. Connect the red wire to the positive spade terminal & the black wire to the negative terminal. STEP #4 – On the left side of the bike, under the gas tank, locate the horn and bracket. Attach the Powerlet bracket utilizing the supplied chrome & rubber washers (if necessary). STEP #5 – Apply the three ty- wraps. The Stage IV controller can be mounted in numerous places. Placement depends on personal preferences. Only mount in locations where no damage may occur from sharp or hot objects. With a proper install, you should see lights going from side to side on the controller. After lights have stopped going side to side, you will notice a great light on the left side of the controller. You are now ready to ride! Basic Tuning Adjustments 1. Modes 1,2, & 3 are allowing adjustments to increase and decrease the amount of fuel the engine needs. To help understand how these modes work, you can think of them as if you were working with a carburetor. Looking at the controller you will see eight lights with numbers under them, this is what you need to look at when changing settings. Remove saddlebags if any. Remove rear riders pegs. Attach front of bracket A (left side) and bracket B (right side) between rear footpeg motorcycle bracket and rear footpeg. Attach rear of brackets A and B to BOTTOM of hitch arms 8) Tighten all bolts. Receiver hitch diagram Leveling stand screw jack installation After hitch is installed, install leveling stand screw jacks to hold motorcycle in an upright and level position in order to install or remove Insta. Trike. 1) Thread right side screw jack into leveling stand bracket on bracket B and adjust leveling jack bolt out until motorcycle will be level against it. Push motorcycle over from left side until right screw jack is touching floor. Remove plastic center cap on steering wheel by prying off with a small screwdriver. Remove steering wheel nut and remove steering wheel by pulling up on wheel. If wheel is tight have a partner tap on the shaft while pulling up on wheel. Note: Do not mushroom threads on shaft. Remove all screws that retain dash to body of vehicle. Disconnect all electrical connections at back of dash. Mark all wires to ensure easy install. Remove lower steering shaft bolt at rack and pinion. Remove upper bolt at base of steering column. Remove the 2 bolts that retain the steering column to the frame and remove the column and the shaft assembly. Remove lower u- joint on steering column shaft & replace it with supplied u- joint. There is a welded wire retainer on the lower dash tube where the electric motor will sit. You will need to grind off this piece and smooth. Remove the master cylinder bolt closest to the driver side and discard bolt. Your motor and module has been shipped together bolted to the bracket. It is important to follow the install sequence to ensure a proper installation. The lower shaft on the steering motor is marked on the shaft and on the motor. These marks must not be changed. If you remove the shaft it needs to be installed back in the same spot. Hot start lever (2. SX- F) If you pull the red hot start lever . The result is a . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off- road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button (EXC) Pushing the black starter button . Emergency OFF switch (EXC Australia) The red emergency- OFF switch . In this position, the E- starter is operational and the engine can be started. In this position, the E- starter and ignition circuits are interrupted. The E- starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button . Indicator lamps The green control lamp . The blue control lamp.
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