Automotive Manual PDF

Preparation for Installation
1. Make sure that there are no metal chips or other debris inside the manifold. Check that all bolts will run freely into any tapped holes.
2. Note that while this manifold makes provision for all vacuum lines and other brackets or parts that attached to the stock manifold, the vacuum ports originally on the front side of the manifold have been moved to the back for a cleaner appearance. This will require the use of longer vacuum hoses in some cases.
3. Disconnect battery and drain coolant.
4. Mark and identify all hoses and valves.
5. Check the condition of all hoses, gaskets and o-rings. Replace as needed. Use a new intake gasket. Honda #17105-P72-004.
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Heli Bars are designed to safely increase your riding comfort; however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation. If you have any questions about installation call Heli Modified, Inc. at 1­800­859­4642. This installation requires the use of a torque wrench that covers a torque range of 8 ft. lbs. Before stock bars can be removed, it is necessary to rotate the front brake line clockwise at the master cylinders. Loosen the banjo bolt at the front brake master cylinder just enough so the fitting can be rotated. Position the banjo fitting so the hydraulic line rests against the right fork tube. Cover the fairing with a rag as some hydraulic fluid may leak. Retighten the banjo bolt.
NOTE: If this modification is not performed prior to removing the stock bars, it will not be possible to mount the master cylinders to the Heli Bars.
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Install Galfer Brake lines after HeliBars® are installed. Carefully follow their instructions.
A. Before the factory bars are removed:
1. Carefully loosen the clutch hydraulic line banjo bolt at the clutch master cylinder just enough to rotate the steel banjo fitting forward. (See photo A for positioning). Additional fine adjustments may be required after installation of HeliBars. This modification is necessary for the new bar location / hydraulic line clearance.
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Relieving fuel pressure
a) Remove the fuel fill cap.
b) On models equipped with a 6mm service bolt. (illustrated below) If your vehicle is not equipped with a 6mm service bolt, then proceed to step c.
i) Use a box end wrench on the 6mm service bolt on top of the fuel filter or fuel rail, while holding the special banjo bolt with another wrench.
ii) Place a rag or shop towel over the 6mm service bolt.
iii) Slowly loosen the 6mm service bolt one complete turn.
iv) Leave service bolt loose until all pressure has been relieved.
v) Tighten service bolt to 10 lbf-ft.
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Step 1:
Identify the key components that complete our brake line kit: You should have nine (9) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) single bleeder bolt three (3) drawings, and a picture CD. There are also a total of forty (40) washers and two (2) “olive” conic inversors. Thirty six washers will be used, and two olives. The rest are spares.
Step 2:
Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G are installed on the front of the motorcycle, while brake hoses (H and I) are installed on the rear. Each label will reference a different drawing, which will show you the location of the key brake system components.
To ensure no paint damage from a brake fluid spill, completely cover the bike. This process can be messy, and brake fluid WILL drip!
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REAR SETUP (45” hose)
STEP 1: Lift the vehicle off the ground with a jack or on a stand. Remove the stock shock absorber from the vehicle. Install the Elka shock absorbers on the vehicle. The banjo bolt must face towards the front of the vehicle with the hose coming out on the left side. The rebound adjuster located at the bottom of the shock should face the rear of the quad for convenient access. The bottom fork of the shock can be turned 180° clockwise if needed.
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Heli Bars are designed to safely increase your riding comfort, however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation. If you have questions about installation call Heli Modified, Inc. at 1-800-859-4642.

NOTE: Heli Bars for the ST3 and ST4 are designed to utilize the factory bars and replace the stock mounting lugs only. Remove the front brake master cylinder from the right handlebar. It is NOT necessary remove any other controls or grips.
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