Automotive Manual PDF

INSTALLATION INSTRUCTIONS
1. Disconnect the negative terminal on the battery. Jack up the front end of the truck and support the frame rails with jack stands. Remove the front tires. NEVER WORK UNDER AN UNSUPPORTED VEHICLE!
2. Starting on the driver’s side of the truck, remove the nut securing the tie rod end to the spindle. Using a large hammer strike the spindle to break loose the tie rod end. Save the factory hardware. USE CARE TO NOT HIT THE THREADS OF THE TIE ROD END.
3. Locate the inner tie rod end nut were it connects to the center link. Using a large Crescent wrench remove the inner tie rod end from the center link and remove the inner and outer tie rod end from the truck as one piece.
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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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Before Installation:
• Verify that all parts and accessories have been included (see list below).
• Coat all exhaust pipe mating joints with anti-seize compound / lubricant (Finish Line Ti-Prep packet included).
• Read and review these instructions, cautions, diagrams and images prior to starting any work.
1. Remove the lower fairing.
2. Remove the existing exhaust system from the middle of the stock pipe. Save the stock exhaust can mounting bolt and nut for the end can to the passenger footpeg for reuse as well.
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The vehicle must be turned off and the keys MUST NOT be in the ignition during the entire installation. We recommend that you place the keys in your pocket while installing the module. Failure to follow this suggestion may result in damage to your PCM.

Removal of PCM
Begin by disconnecting the negative battery terminal of your car’s battery. Next, locate your car’s PCM. The PCM is held in place by a 7/32” or 5.5mm bolt. Please remove this bolt. Next, remove the wiring harness by use of 10mm socket and ratchet. Slowly and gently pull the PCM out of its location and out of the car.
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This is the process used to install the Turbo Wheel without having to remove the Turbo from your
Engine. It should take a maximum of 5 hours.

Procedure:
• Start by removing the Intake hose
o Remove all of the Intake tubes, exposing the turbo inlet.
o Remove the 2 bolts from the CCV intake mount.
o Move the CCV mount, exposing the 2 Philips screws. Remove the CCV filter from the valve cover. (watch for the O rings)
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Removing stock carburetor and cables.
1. Remove seat, front fenders and gas tank. Make sure fuel petcock is in “ON” or “RES” position. If it is in the “PRI” position it will allow fuel through it.
2. Remove throttle cable, (and housing if installing a twist kit) from throttle housing. Pay close attention to routing when removing cable as the new cables will need too be routed the same.
3. Disconnect choke cable from stock carburetor before disconnecting it from handle bar and remove.
4. Remove stock carburetor.
5. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
6. Remove stock rear head stay from frame and head.
7. Remove plastic vent box from right side of frame along with hoses.
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Removing stock carburetor and cables
1. Remove seat and gas tank. Make sure fuel petcock is in “off” position.
2. Remove throttle cables and throttle housing.
3. Remove voltage regulator from left side of frame to allow carb to come out.
4. Remove stock carburetor.
5. Unplug TPS (throttle position sensor) and tape end off coming from bike.
6. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
7. Remove engine breather lines along with plastic canister on right side of bike.
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