Entries from November 2009
Tools Needed: 10, 12, 14 sockets and wrenches. You will also need a Oxygen Sensor removal tool or 22mm wrench or socket to remove the stock Oxygen sensors from the catalytic converter and install them in the new Jackson Racing header. Most of these tools are available at your local hardware or auto parts store.
IF YOU ARE NOT A COMPETENT MECHANIC, DO NOT ATTEMPT THIS INSTALLATION! ALLOW AT LEAST ONE HOUR FOR THE EXHAUST SYSTEM TO COOLBEFORE DOING ANY EXHAUST SYSTEM INSTALLATION WORK.
READ THESE INSTRUCTIONS THOROUGHLY! Follow the instruction STEP-BY-STEP, and your installation will be trouble free. If in doubt, CALL!
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Prepare for the installation.
• If possible, install the SWI-ALP while you are installing the new head unit. Keep in mind you may need to plug in the factory stereo to locate certain wires; therefore do not complete the head unit installation until the SWI-ALP is working properly.
• Plan a general installation location for both the SWI-ALP plug and the control body. Keep in mind that the supplied wire harness is two feet long, and the 1/8″ plug harness is three feet long.
• Use a multimeter or approved measuring device for checking vehicle circuits
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1) Use an adhesive solvent to spray the badge you are removing. Make sure you use an adhesive solvent (such as Xenit Adhesive Remover) that won’t damage the paint.
2) Once the solvent has penetrated the backing of the badge use a length of dental floss and gently work it under the edge of one of the top badge corners. Once you have the floss behind the badge you can use it like a saw in a back and forth motion to gradually ‘cut’ through the backing adhesive and separate the badge from the body of the car. You may need to repeat the procedure from various angles to achieve this.
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Begin by removing the small trim bezel that surrounds the radio. This bezel has four clips that hold it in place in each corner. Carefully use the dash trim panel tool and insert it in behind the bezel in the lower right corner. Note: Be careful not to mar the soft plastic that the bezel is made of when using the dash trim panel tool. Pull back toward you to release the lower right clip. Perform this same action in the other remaining three corners of the bezel. When the bezel is loose set it aside.
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Before installing a big bore kit, you should first install a high volume oil pump. A high volume oil pump will deliver up to 300% more oil to your top end which will only help preserve the life of your engine. To install the big bore kit you will need to:
1. Stuff a CLEAN rag behind the piston to seal off the crankcase.
2. Install a c-clip into one side of the piston. When installing the c-clip, compress the c-clip just enough to get it into the piston. Note the position of the c-clip once it is installed.
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This kit is intended for use on 1993 and newer XR/CRF100’s using CDI ignition. Engine assembly requires special attention to detail. A new BBR Cylinder and piston kit have been supplied. The following measurments are critical to proper installation and performance.
Ring end gap: .012″ - .015″
Valve clearance: Intake: .002″ Exhaust: .003″
Piston to head clearance: .040″
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Remove existing parts
Remove your existing side case cover containing the existing stator and place case on a clean work surface. Unscrew the stock stator and pick-up coil from the case. Pull grommet and wiring free and clear from case. Retain all mounting screws and brackets for installing new stator.
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Take care to follow the above diagram.
There are two leds located on the PCB, a GREEN and YELLOW. Their purpose is to aid the initial installation. A direction change is indicated with the leds. Ensure the wire pairs of the electric motors are correct (in the same direction) or the mirrors will operate opposite to each other (Match mirror connections to same connection on PCB). The unit can be triggered from any momentary normally OPEN contact (actuating trigger voltage 9V - 15V). This can be manually via a switch or electronically such as a car alarm.
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1. Attach the left strake to the side under spoiler using the three self-tapping screws.
2. Remove the three self-tapping screws that fasten the front inner fender to the fenderwell.
3. Remove the four clips that fasten the existing side under spoiler to the side sill, then remove the spoiler by sliding it toward the front.
4. Remove the spring nut from the end of the side under spoiler you just removed.
5. Remove the eight clips from the side sill by turning them 45 degrees.
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This kit is intended for use in applications where a remote mounted idle air control motor is necessary, and an ecu with the ability to control a Honda idle air control motor is being used. These instructions will specifically go over the ecu setup for an AEM EMS, though it can also be used with other systems such as Motec or Haltech.
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