Automotive Manual PDF

PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. Starting on the driver side of the vehicle, locate the two threaded holes toward the front of the frame. Select the driver side Front Mounting Bracket and bolt it to the threaded holes with (2) 10-1.5mm x 30mm Hex Bolts, (2) 10mm Flat Washers and (2) 10mm Lock Washers, (Figure 1). Snug but do not tighten hardware at this time. Repeat this step for the rear Mounting Bracket installation, (Figure 2).
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You will need a portable crane and/or a friend to lift the motor from the crate and on to the boat. Take your time and be careful. Keep fingers clear of pinch points near the mount and swivel.
Uncrating: Remove the handle and mount it to the side of the engine with three, 3/8″ bolts. Be careful not to stretch the handle wires and cables. The washers and nylock nuts installon the inside of the handle mount near the slots. The handle bolts must be snug enough to hold the handle firmly, but yet allow the handle to move up and down freely.
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TO START:
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Unclip and remove the intake hose from the throttle body housing.
3. Carefully lift the air box out of the mounting grommets and remove from the vehicle.
4. Taking the necessary safety precautions raise the front of the vehicle and support it with axle stands.
5. Remove the wheel arch liner from the vehicle by removing the two screws and clips.
6. Remove the original air box intake hose from the vehicle.
7. Unbolt & remove the air box mounting bracket from the vehicle.
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STOCK EXHAUST SYSTEM REMOVAL
1. Remove frame cover.
2. Remove right side footpeg assembly held in place by two bolts (Figure 1).
3. Remove exhaust port nuts.
4. Remove bolts securing rear muffler to exhaust system mounting bracket.
5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required).
6. Check condition of stock exhaust gaskets. Replace if damaged or worn.
7. Remove two bolts attaching stock exhaust mounting bracket to frame.
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This kit provides the SOLUTION for eliminating air conditioning and power steering on motors found in the 02-06 RSX, ITR and CTR while:
-Relocating the alternator to avoid headlight material removal on 1988-1991 Civics & CRXs
-Eliminating pulley-to-hood interferences on 1988-1991 Civics and CRXs with a K20 engine
-Eliminating individual throttle body interference issues
-Offering a compact yet robust design for overall cleanliness and reliable operation.
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1. Place the motorcycle on the centerstand.
2. Remove the left side cover (painted) to expose the battery. Remove the left plastic engine cover (chrome). Remove the lower center fairing cowl or spoiler; there are 2 pull pin rivets and 6 allen screws holding this panel in place. Drop the panel down and slide it out to the right or left.
3. Horns and Mounting Bracket: Attach the large “L” shaped bracket with the split clamp to the engine guards as shown in photo #1. NOTE: Make the screws snug only! Install the horn set onto the “L” bracket using the 2 allen screws provided, tighten securely. Align the horn set to be level and to have clearance between the fairing as shown in photo #2, tighten securely.
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PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
2. Determine driver and passenger Mounting Brackets.
3. Hang the inner side of the driver front Mounting Bracket into position by partially threading (1) 8mm x 30mm Hex Head Bolt, (1) 8mm Lock Washer, and (1) 8mm Flat Washer into factory threaded hole on the frame (Figure 1). NOTE: There are two threaded holes by the front mounting location on the frame, use the one towards the rear of vehicle.
4. Attach the opposite side of the driver front Mounting Bracket to the threaded holes on the floor panel of the vehicle by partially threading (2) 8mm x 30mm Hex Head Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers (Figure 1).
5. Locate and cut out the openings in the driver and passenger side trimming templates with a pair of scissors (Page 3 & 4)
6. Fit the driver’s side template onto its respective side plastic rock shields. Position them using two each of the 8mm bolts that will later be used to mount the side bar brackets. Transfer the openings in the templates onto the plastic cover using a magic marker.
7. Now remove the rock shield from the undercarriage of the car. The three front screws can be removed with a 10MM socket. The plastic retainer plugs can be removed with a flat blade screwdriver.
8. Using a sharp knife or pair of shears, cut out the shields as marked using the templates (Figure 2).
9. Insert the inner side of driver rear Mounting Bracket through previously cut out hole on the plastic cover. Hang Mounting Bracket by partially threading (1) 8mm x 30mm Hex Head Bolt, (1) 8mm Lock Washer, and (1) 8mm Flat Washer into factory threaded hole on the frame (Figure 3). NOTE: There are two threaded holes on the frame, use the one towards the rear of vehicle.
10. Attach the opposite side on the driver rear Mounting Bracket by partially threading (2) 8mm x 30mm Hex Head Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers into factory threaded holes on the floor panel.
11. Position Driver Side Bar onto Mounting Brackets. Attach Side Bar to Mounting Brackets using the included (4) 8mm x 30mm Hex Head Bolts, (4) 8mm Lock Washers, and (4) 8mm Flat Washers (Figure 1). Do not tighten at this time.
12. Level and adjust Side Bar; then tighten all hardware at this time.
13. Re-install the rest of fastener on the rock shield.
14. Repeat steps 2-13 for passenger Side Bar.
15. Do periodic inspections to the installation to make sure that all hardware is secure and tight.

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Installation Instructions:
Disconnect the negative battery cable and then disconnect the positive battery cable.
Disconnect the wiring, remove the belt, and then remove the stock alternator from it’s mounting brackets.
Mount the new alternator to the existing mounting bracket on the engine with the double feet from the alternator on either side of the mounting bracket. It is important to note that the origional alternator bracket has a “slip bushing” in it. If the Mechman alternator bracket will not slide over the bushing then it will need to be tapped back with a hammer( a very small amount of added room is needed). If extra space exist use the supplied spacers as necessary to reduce the extra space between the mounting bracket and the alternator bracket. Install the original long bolt and hand tighten. See the diagram below.
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You have purchased the finest exhaust system available on the market today! Your Hard-Krome exhaust system has been carefully designed and tested in the dyno room and on the road to ensure the best performance possible for your motorcycle. ALL Hard-Krome exhaust systems feature our exclusive, patented Double wall Technology Construction that makes your pipes look as beautiful as the day you purchased them. Because of this technology, you can ride mile after mile without ever worrying about your pipes discoloring or turning blue. These instructions have been carefully prepared to ensure proper installation of your new Hard-Krome exhaust system. Following all the steps listed will ensure correctfit and performance as intended.
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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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