1979 shovelhead stator replacement

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2001-2002 HONDA GL1800/A CD Changer Replacement

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Filed Under (Honda) by admin on 03-03-2011

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2001-2002 GL1800/A CD Changer Replacement ORDERING AND REPLACING THE CD CHANGER 1. Before calling the CD Changer Order Desk, have the following information ready: • VIN • Failure Information (i.e., symptom) • Warranty Status 2. To order, call the CD Changer Order Desk toll free: (888) 997-7278 . The CD Changer Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. Part Number: 08A06-MCA-100RM Honda Code: 7097009 3. After calling the CD Changer Order Desk, an exchange CD Changer will be shipped overnight (freight prepaid). 4. Replace the faulty CD Changer with the exchange unit (see REPAIR PROCEDURE ). DO NOT remove the faulty CD Changer until you receive the exchange unit. DO NOT ATTEMPT TO REMOVE ANY STUCK CD’S. CHANGERS DAMAGED IN THIS WAY WILL BE RETURNED TO THE DEALER AND NO CORE CREDIT WILL BE ALLOWED. You will be billed $300.00 for the replacement unit. You must return the faulty CD Changer for a core credit and file a warranty claim to receive your total reimbursement (see TRANSACTION SUMMARY on page 3 for details). REPAIR PROCEDURE 1. Refer to the Installation Instructions included with the replacement CD Changer. 2. NOTE: You MUST remove the shipping bracket from the replacement unit before you complete the installation. If a CD is stuck inside the faulty unit, leave it there : • The vendor needs it for diagnosing and testing. • If you try to remove it, you’ll damage the unit. • The vendor will return the unit if it has been damaged during attempted CD removal. Fill in the customer information on the Audio System Diagnosis and Core Return form. The vendor will remove the CD and mail it back to the customer. IDENTIFICATION No identification is necessary for this repair

Kawasaki KX 80 1992-ON, KX100 IGNITION STATOR Installation instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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Take the ignition cover off. Take note of the wire colors of the original stator wires and disconnect them from the wiring loom. Remove the flywheel using a proper puller tool. Remove the baseplate with the original stator. Remove the screws that secure the coil and take the coil off. Cut the original wires close to the original coil. Take a good look at how the wires are connected to the coil. (at which side of the original coil which wire color goes). Connections: Connect the wire colors accord- ing to the drawing. RED and BLACK/RED Connect the old wires up to the new coil. Put the wires in exactly the same place as on the original. Make sure you have good connections here. Use a soldering iron and rosin core solder (the type used in electrical applications). Mount the coil onto the baseplate, fit the screws using locking compound on the threads and TIGHTEN THE SCREWS SECURELY! Refit the stator baseplate. Ensure the wires CANNOT TOUCH THE FLYWHEEL! (especially on the inside of the flywheel) Refit the flywheel. Tighten the bolt to specified torque

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BMW Motorcycles F 650 GS Dakar fuel tank replacement

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Filed Under (BMW) by admin on 12-11-2010

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Your center has been requested in a recent e-mail, to forward VIN, color Information: and status information on all F 650 GS(A) and Dakar models remaining in your inventory. Fuel tanks, together with the appropriate colored trim pieces, will be forwarded to your center for each bike in your inventory as replacement parts arrive in BMW NA inventory. Warranty Please enter a warranty campaign claim , encompassing the following Reimbursement: Work Package information, when claiming reimbursement for the updates called for in this bulletin. Even though there is no charge for the parts, a sublet of $60.00 will be applied to each claim. This sublet amount is intended as a combination of both the handling and as reimbursement for incidental items that may be required in the replacement of the fuel tank. Work Package #1 is to be used in the replacement of all F 650 GS(A) and Dakar model fuel tanks. Defect Code: 00 00 16 1100 Description: Fuel Tank – Leaking Flat Rate Code: 00 60 059 Description: Remove and reinstall fuel tank (USA only) FRU: 12 FRU Sublet #4: $60.00 Pick up & In the recent Sales and Marketing Bulletin # B23/00 introducing the “Customer Delivery: Demonstration Program”, (e-mailed to your center on September 7, 2000), each BMW motorcycle retailer was asked to arrange to pick up, complete the updates and deliver the motorcycle back to the customer and to offer the use of a demonstrator where appropriate.

VESPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT

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Filed Under (Vespa) by admin on 11-11-2010

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VE SPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT To replace the exhaust manifold, order part number 872659 as spare part following standard proceedings. OPERATION PROCEDURE The above picture references the old exhaust flange and the replacement exhaust flange kit part number 872659. Replacement Old Page 5 of 16 With the complete exhaust system removed from the vehicle remove the lambda sensors. Refer to page 88 and 89 of your Vespa GTS workshop manual for exhaust removal. Loosen the 13 mm bolt to loosen the clamp. Bolt Remove lambda sensor Page 6 of 16 Remove the header pipe from the exhaust box. Remove the exhaust packing and clamp. Remove exhaust manifold Gasket Clamp Page 7 of 16 Once all packing is removed check and make sure all surfaces are clean. This will help the installation of the exhaust gasket. Install the new clamp supplied with the kit, but do not tighten down at this point. Fit the exhaust gasket onto the new manifold. Push the new exhaust gasket in with the manifold until fitted all the way down to the flange. Check surfaces. Manifold Gasket Clamp Flange Page 8 of 16 Replace the lambda sensor and tighten down to 40- 50 Nm (29.5 -36.8 ft lbs. ) .

Pulsar XR 650R ELECTRIC-START KIT INSTALLATION INSTRUCTIONS

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Remove the seat, fuel tank, side panels, muffler, and headers. 2. Disconnect the stator wires from their corresponding mates underneath the seat (trace the wires up from the left side case.) Un-route the stator wiring so it hangs free from the left side case. 3. Remove the stock shift lever and the left side engine case cover. You do not need to drain the oil from the engine. 4. Unbolt and remove the stator and wiring from the stock cover. Do not cut any wires. 5. The stock pulsar coil (small black box hanging from the stator) will have to be modified slightly to clear the ring gear before installation into the new cover. Remove (file or grind) about .030 inches of material from the base of the pulsar coil so that the base is flush with the face of the rest of the coil as shown in Photos 1 and 2. File Here Photo 2 Make flush with this surface Remove material here Photo 1 6. Install the stator and modified pulsar coil into the new engine case cover as shown in Photo 3. Use the three provided Phillips head bolts, split lock-washers, and plastic cable clamps to secure the wiring as shown. You will need to pull about ½” of extra wire through the grommet (Photo 4) to give you enough wire length for the grommet to sit in its case cutout. To do this, remove the electrical tape from the end of the stator wires and pull each wire individually through the grommet. Neither of the stock metal wire guides will be used when reinstalling the stator into the new case (Photo 5). 5/16″ cable clamps 1/8″ cable clamp Photo 3 Photo 5 Not Used Pull extra wire through grommet Photo 4 7. Remove the stock flywheel nut (An air impact tool works best to remove this nut without turning the motor). Remove the flywheel using the flywheel puller provided. 8. Locate the T and F marks on the stock flywheel (Photo 6). The T mark is used to adjust valve clearances and its location needs to be transferred to the ring gear. Scribe a line in the edge of the flywheel in line with the T mark as shown in Photo 7

HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

VICTORY BLACK LIGHT LEAK DETECTOR KIT

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Filed Under (Victory) by admin on 31-10-2010

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AMMCO HONE KIT Rigid hone to correct tapered and out of round cylinders. Range: 47.6 mm – 69.8 mm (1 7/8″ – 2 3/4″). Contains 60 and 220 grit stones, driveshank with depth stop and metal storage box. Oversize stone kits increase range to 92 mm ( 35/8″). Replacement Stone Kits are shown below. All stones shown below are included in the kit including the new PU-49876. 2870304 – REPLACEMENT STONE KIT – 60 Grit (47.6 0 69.8mm) 2870305 – REPLACEMENT STONE KIT – 220 Grit (47.6 – 69.8mm) 2870306 – REPLACEMENT STONE KIT – 60 Grit (69.8-92.8mm) 2870307 – REPLACEMENT STONE KIT – 220 Grit (69.8 0 92.8mm) 2871536 – REPLACEMENT STONE KIT – 69.8 for Ni-Ca-Sil deglazing PU-49876 – 320 GRIT REPLACEMENT STONE SET 2870386 PISTON PIN PULLER Removes 18 mm piston pins from all Polaris pistons. Required for many Polaris puller attachments. Note: Some engines require adapters. Available Adapters: 2871342 2871445 2870390 PISTON SUPPORT BLOCK Safely supports piston while disassembling or assembling engine top end. 2870569 CRANKSHAFT TRUING STAND For holding crankshaft while checking runout for all Polaris engines. 2870588 HONING OIL 12 oz can with dispensing tip. Promotes better finishes, faster cutting and longer stone life. Engine VICTORY 83 PU-46219 OIL EXTRACTOR Used to draw the engine oil from the crankcase. PV-35457 BLACK LIGHT LEAK DETECTOR KIT The Black Light Oil Leak Detector provides an effective time saving method for pinpointing engine oil leaks. Simply add 1 oz. of fluorescent oil additive to the engine crankcase (6 – 1 oz. bottles included). Run the engine for ten minutes to circulate the fluorescent oil additive throughout the engine. Oil leak will fluoresce a bright yellow when illuminated with PV-35457 Black Light. Includes: Fluorescent Black Light PV-28431-6 Oil Additive (6) 1 oz. Bottles (available separately) PV-28431-6 – LEAK DETECTION DYE PV-35667-A CYLINDER LEAKDOWN TESTER PV-35667-A will test for worn piston rings, cylinder walls, valves, gaskets and any other related leakage problems. Uses shop air. M12 x 1.25 Adapter and instructions included. PV-39951-A ENGINE TACHOMETER This digital tachometer accurately measures engine RPM and maximum RPM of 2 or 4-stroke engines. The dual display allows for readings of current RPM alone or current and maximum RPM. Also features two maximum RPM memories for comparison

SUZUKI GSX-R1000K7 IDLE SPEED CONTROL VALVE REPLACEMENT

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Filed Under (Suzuki) by admin on 26-11-2010

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1. Check the repair status by checking the Vehicle History in the Suzuki Connect Service Menu. If the repair needs to be performed to the motorcycle, you will see the message “CAMPAIGN NOT YET PERFORMED” displayed and the ISC valve will need to be replaced. Refer to the replacement procedure in this bulletin. 2. Inspect the right side of the frame head tube for an identification punch mark located at the end of the Vehicle Identification Number. If a punch mark is presentthe recall repair has already been performed. NOTE: A punch mark may already be present at the beginning of the Vehicle Identification Number if the Generator Rotor Replacement campaign (#2M97) has been completed. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT KIT SIREN BOX REMOVAL Read the following instructions and make sure you fully understand them prior to replacing the battery. If the procedure is not within your capabilities, or you do not have the correct tool, have a Harley-Davidson dealer replace the battery. Improper installation could result in damage to this product. (00419b) 1. Refer to the Owner’s Manual and follow the instructions given to disarm the security system. 2. Remove the siren box from the vehicle. Reference the siren installation procedures found in the Siren Kit Instruction Sheet or contact a Harley-Davidson dealer for specific information on locating and removing the siren box from your model. Battery replacement, Smart Siren 1. See Figure 1. Remove the battery cover (2) from the siren box as follows: a. Place the siren on a sturdy, flat surface with the potting (1) and battery cover facing up. b. Using a blunt, stiff blade such as a table knife, insert the blade between the case and cover at a 45 degree angle to the side of the case. Insert the blade until it touches the snaps on the inside face of the cover. Figure 2 shows the four barbed snaps (2). c. Twist the blade slowly so the inserted edge presses against the inside face of the cover. The cover will pop off and can be replaced later using silicone adhesive if necessary

Cobra JR/ OI Radiator with Louvers Replacement

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Filed Under (Cobra) by admin on 10-11-2010

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The 2009 model year radiator for Cobra JR (also remaining OI ) model will be FCCJ0004 which now has provisions for louvers. On the 2009 models these louvers also rely on a feature on the frame down-tube for mounting the plastic louvers. Older models do not have these features on the frame and so it is not possible to utilize the louver mounts on the radiator. Customers with older models JR/CM or OI/P3/PW3 needing a replacement radiator for ECMU0061 or ECMU0225 will be sold a radiator kit FKMU0001 which includes the new style radiator, FCCJ0004C (with louver mounting tabs removed), and all mounting hardware. This will allow the mounting of the new style radiator onto these products without mounting the louvers. As the 2009 frame is now the service replacement frame for JR/CM & OI/PW3/P3 models from 2004 – 2008, the louvers are able to mount on all older models JR/CM & OI/PW3/P3 that have the appropriate mounting provisions. Welding on the highly stressed down-tube frame member is not recommended by Cobra because it can cause premature structural failure to the frame and possible injury to the rider.