Automotive Manual PDF

NOTE: Read all instructions before starting any work.
1. Remove the O.E. front pipe/muffler/tail pipe assembly from the vehicle. Lubricate the rubber isolators with WD-40, or a similar lubricant, to aid in removing the rod hangers. The O.E. system will not come off in one piece. Cut the system between the rear axle and the muffler. Both pieces will then come off easily.
2. Install DynoMax front intermediate pipe 54374. Insert the rod hanger into the rubber isolator on the RH frame. Finger tighten the nuts on the inlet flange connection to the converter pipe.
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VS123.V2 Tool Set comprises the timing pins and specialised tensioner adjustment tools required for timing belt replacement on all the variants of the Rover 2.0 diesel engine fitted in MG-Rover, Land Rover and Honda models.

FLYWHEEL LOCKING PIN - VS170/1
VS170/1 Locking Pin is used to lock the crankshaft in its timed position. The pin is inserted through a hole in the gearbox mounting back plate and engages a corresponding hole in the flywheel.
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Tools Recommended: metric deep socket set, metric & American open end wrench set, 9/64th Allen wrench, Teflon tape, wire cutters, terminal crimpers.
Follow the included diagram exactly. This product uses two different but visually similar threads. 1/8” NPT and 1/8” BSPT may appear to be the same thread, but they are not. Do not assemble any portion of this kit in any way other than described. Doing so will result in stripped threads and oil leaks.
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Congratulations on your purchase of the Honda 750 Ace & Spirit Thunder Air Filter Kit. We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should be installed on bikes with After Market Exhaust Pipes only and jetted, (jet kit not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Honda service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well-ventilated area and clean up any spills immediately. Check for leaks before riding.
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1. Read and understand these instructions before proceeding. If you drop a screw down in some stake pocket holes it is difficult to retrieve. Some installers prefer to apply masking tape around the stake pocket holes to prevent scratches. Remove the tape before tightening the assembly screws.
2. Select the correct stake pocket insert. The flat model is used for the 88-98 Chevy & GMC models. All other trucks use the insert with the bent flanges. The bent flange style should be oriented with the bent wings pointing up like this: [__________]
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Installation Instruction:
1. Verify all the parts from the list above are present and accounted for. Please read instructions completely before starting.
2. Verify passenger and driver side bracket.
3. Locate the round holes on rocker panel for bracket installation. Insert M8 hex nut on the longer end of U-bolt. Insert U-bolt through the first hole and out through the second hole. Install M8 hex nut on shorter end of U-bolt after it comes through second (more…)

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Step Installation: Complete Part One, then find the section for specific instructions for your model vehicle.
Part One: Rear bracket attachment
Step 1) Attach the rear brackets to the step as shown in Figure 1, using a washer, E, and nut, I, on each stud. Tighten each nut.
Step 2) Place the cross member in position as shown in Figure 2, and secure using washers D and F, and one nut, H on each stud. Leave fasteners loose, as the bracket slots will be used to determine exact fit of rear upright bracket.
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• EGR SYSTEM: For EGR applications when using Performer top #3787, you must drill a 7/16″ hole in the manifold base prior to installation (see Figure 2). Be sure to blow chips out of manifold. This procedure is not necessary for non-EGR installations.
• MANIFOLD: This manifold is designed as a two-piece manifold; the base, or lower part, (#3785), bolts directly to the cylinder heads. There are two interchangeable tops to choose from. The Performer 2V top, #3787, accepts the OEM 2-bbl. carburetor and EGR system for use on the street or off-road situations. It comes with linkage, hardware, gaskets and instructions to bolt directly to base #3785. The Performer 4V top, #3789, accepts standard flange carburetors and is not equipped for EGR. This top also comes with link-age, hardware, gaskets, and instructions to bolt directly to the base #3785. See “Carburetor Recommendations” below for both tops.
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Before any tear-down or disassembly begins, it is important to verify which bearing you have. There are two types of “Green Bearings” being supplied by axle manufacturers. Your setup should look like Figure 2 (below left), not the Figure 1 configuration, otherwise this kit will not fit. Furthermore, review the wheel clearance diagram (Figure 3, below right) to verify that there is adequate clearance with the wheels you will be using with this installation.
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PREPERATION
1. Disassemble and clean housing. Use a good grease cutting solvent to remove the lube residue.
Follow this with warm soapy water, such as from the car wash.
a. On “Drop Out” style housings, such as 9” Ford, you must remove the “Drop Out” and then clean the housing as described above. We recommend that you get a used “Drop Out” from a junk yard and use this for your fixture case. This way you will only have minimal work to re-setup your gears. Place the appropriate pucks into the carrier bearing locations. Screw the bearing cap bolts finger tight. Slip the bar through the assembly and then tighten the cap bolts. Remove the shaft.
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