Installation Instructions for Crankcase and Clutch Covers with Cylinder Gasket Kits (2006-2008 Motorcycles)

Tools Required:

1. Socket set (including metric and standard sizes)
2. Torque wrench
3. Screwdrivers (flathead and Phillips)
4. Allen key set
5. Gasket scraper or razor blade
6. Cleaning cloths or shop rags
7. Torque specifications chart (reference for your specific motorcycle model)
8. Oil catch pan
9. Safety goggles and gloves

Installation Steps:

1. Preparation:

   • Ensure the motorcycle is on a stable surface and securely positioned on a stand.
   • Disconnect the battery to prevent any electrical issues during installation.

2. Drain Fluids:

   • Place the oil catch pan under the motorcycle and drain any engine oil from the crankcase.

3. Remove Existing Covers:

   • Use the appropriate socket and screwdriver to remove the bolts securing the crankcase and clutch covers.
   • Carefully lift off the old covers, ensuring no debris falls into the engine.

4. Clean the Surface:

   • Use a gasket scraper or razor blade to remove the old gasket material from both the crankcase and clutch cover surfaces.
   • Wipe the surfaces clean with a rag to ensure no contaminants remain.

5. Install New Gasket:

   • Place the new cylinder gasket onto the crankcase and align it properly.
   • Ensure the gasket is seated correctly without any twists or overlaps.

6. Attach New Covers:

   • Align the crankcase cover and clutch cover over the gaskets.
   • Hand-tighten the bolts in a crisscross pattern to ensure even pressure.

7. Torque Bolts:

   • Using a torque wrench, tighten the bolts to the manufacturer's specifications found in your torque specifications chart.
   • Retighten in a crisscross pattern to ensure even sealing.

8. Reinstall Other Components:

   • If any other parts were removed during the installation, reinstall them as necessary.

9. Refill Fluids:

   • Replace the drain plug and refill the crankcase with the appropriate engine oil.

10. Final Check:

    • Reconnect the battery and check for any leaks around the new installations.
    • Start the engine and allow it to reach operating temperature while observing for any unusual sounds or leaks.

Safety Note: Always wear safety goggles and gloves during installation to protect against debris and sharp edges.

By following these instructions, you should have a successful installation of the Crankcase and Clutch Covers with Cylinder Gasket Kits, ensuring improved performance and stability for your motorcycle. Enjoy your ride!