Automotive Manual PDF

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.
(more…)

[Read more →]

REMOVING FACTORYAIR DAM
1. To remove factory Air Dam, use a 6” long flat blade screwdriver. The rivets are accessed through the bottom of the bumper behind the factory Air Dam.
2. It will be necessary to remove the factory driving lights by removing the two bolts that hold the plastic light brackets to the bumper. Also remove the nut clips from the bumper.
3. Insert the screwdriver blade into the rivet head slots and twist screwdriver to force rivet inserts downward. Once rivet inserts are 1/4” to 1/2” down, grab with fingers or pliers and pull down, completely removing inserts.
4. After all rivets and lights are removed, use the screwdriver from the front side of Air Dam and pry down on the Air Dam to remove it from the bumper.
5. Next remove the plastic rivet clips from the bottom of the bumper by squeezing the clips and pulling down.
(more…)

[Read more →]

1. Start by supporting the car on 4 jack stands. The car should be sitting on approximately the same angle as it does on the ground, or slightly lower in front.
2. Remove all the old front suspension components. Note that on the underside of the frame are the two rubber axle snubbers (or the holes for them, if they are missing) directly above the axle. Mark them for later reference.
3. We would recommend that at this point, you tack weld or clamp a temporary brace across the frame rails in front of the old crossmember as shown in Figure 1. This helps to maintain the rail dimension after the old crossmember is removed.
(more…)

[Read more →]

Step 1. Before you remove anything off the truck, measure the pinion on the front and rear axle differential. Make sure to record this measurement as we will want to put each axle back to this angle after the suspension lift kit is installed. This is especially important for the front axle. Putting the front axle back to the same measurement will keep the stock camber and caster.
Step 2. Jack up the truck and place a jack stand under the frame on each side of the truck. Jack the truck up enough so that the front tires are just barely off the ground. Take a motorcycle strap and wrap the strap around the differential and to the frame. This will help keep the axle in the generalproximitywhile the factory suspension is removed and the 4 link is installed.
(more…)

[Read more →]

Mounting the Vacuum Reservoir (10067563)
1. Take out the windshield washer fluid bottle from passenger side by removing the two 10-mm nuts holding it in place.
2. Remove the clutch master cylinder reservoir by popping out the two push clips that attach it to the bracket.
3. The vacuum reservoir is going to be mounted upside-down on the cowl wall with the Amp opening on the top and the Main opening on the bottom.
4. Mount the reservoir using a rivet gun and two 3/16-in rivets, making sure it is not in contact with the hood release or clutch master cylinder reservoir bracket.
5. Replace the clutch master cylinder reservoir by snapping the two push clips back into place.
(more…)

[Read more →]

Remove rear tires, carpet in the rear section and the speakers. Use a plastic drop cloth to seal off behind the seats, so that the cockpit area remains free of fiberglass dust. Locate the “hat” shaped brackets circled in Fig 5. Draw a line straight back from each bracket so they can later be located in the same front-to-back location.
(more…)

[Read more →]

The filter is very compact and uses a one-micron filter element. The quality of the filter is top notch and mounts in the TDI very easily. The nice thing about this installation is it allows you to service the filter without having to get on your back or remove anything! I feel that for the TDI that this is the best bang for the buck. It cost’s a bit more than other bypass filters but provides the same level of filtration and the replacement filters are 1/4 of the cost and includes new o-rings and a filter element.
(more…)

[Read more →]

FRonT SySTem InSTALLATIon
1. Park vehicle on clean, flat, and level surface. Block the rear wheels for safety.
2. Lift front of vehicle with hydraulic jack. Secure frame rails with jack stands. If installing optional long radius arms, make sure there will be clearance for brackets.
3. Remove wheels
4. Disconnect the anti-sway bar (if equipped) from the frame, retain hardware. (Fig 1)
5. Disconnect steering linkage from pitman arm, retain nut. (Fig 2)
(more…)

[Read more →]