1990ktm tvcvalve rebuild

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Mikuni Carburetor Rebuild

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

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1.1 (Below) First note the position of both your high and low speed screws (some models also have a midrange screw). Use a screwdriver to lightly set the screw, noting how many turns in it takes. NOTE: Some Sea-Doos may be seated fully (zero turns) to begin with; do not force the screws. After noting the screw positions, remove the screws. 1.2 Remove the center screw, fuel inlet and o-ring. 1.3 (Below) Remove the six screws securing the pump cover and remove it. 1.4 (Below) Remove the check valve diaphragm. 1.5 (Below) Remove the pump body. 1.6 (Below) Remove the regulator cover and clean the gasket off from it.

Motorcycle Carburetor Rebuilding

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Filed Under (Tips and Review) by admin on 22-11-2010

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Experience has shown that when a customer disassembles, it creates a storage issue for us as well as parts are generally missing. The disassembly usually costs us extra hours of work during the rebuild. The only acceptable part to be removed from an assembly is the cable bracket if it is fragile and in danger of breaking during shipping. All other parts should be where they belong. Rebuild Service Prices: If your carburetor type doesn’t appear below or you are not sure, please send a note to our e-mail for pricing details. Military rebates are available to honor our service men and women! Active Duty military, contact us for a rebate. Please include your service, pay grade and current duty station when you contact us.

2003 COBRA PW3 Owners And Service Manual

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Filed Under (Cobra) by admin on 14-11-2010

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Specifications – General Items PW3 Dimensions Wheelbase 35.75″ (908mm) Wheel size 10″ (254mm) Seat height 22″ (559 mm) Stock #TCHO0001 23.9″ (607 mm) Optional #TCHJ0001 Engine Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm Ignition system Digital Electronic Spark plug Champion C53, NGK B11EGV Gap 0.023″ – 0.025″ (0.58 – 0.64 mm) Fuel type Sunoco MO2 X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Injector oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios Fill oil reservoir as required Ignition timing Fixed Carburetion 12 mm Dell’Orto PHVA – PS Main jet 82 Slow (Pilot) jet 42 Float height 5 mm + 0.3mm (0.2″ + 0.012″) Transmission Speed Single Clutch 3 shoe centrifugal Final drive ratio 10/46 T Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 250 ml (8.5oz) 5 Chassis Front tire 2.50 – 10 Pressure 15 psi minimum Rear tire 2.75 – 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Marzocchi 32mm Fork oil type SAE 20 weight Fork oil amount 200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild Fork oil height 70 mm (2.75″) collapsed from top with spring (no spacer) Specifications – Torque Values

1984 KAWASAKI GPz900R Restoration Project

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Filed Under (Kawasaki) by admin on 01-12-2010

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The paint work on the motorcycle is the original “Red & Gun Metal Grey” but is so badly worn with the outer layer of clear missing and hence all body work requires re-painting. The tank has undergone the usual repair on the left hand side since rust has eaten into the bottom corner from water being in the fuel and the paint has been worn of where the riders legs rub.. The rear tail piece is structurally ok but features worn paint. The right hand side cover has a broken stud and the left hand side cover has a heat warp under the tank. The lower fairing is damaged, the middle fairing is missing one decal on the right hand side and the top fairing has small cracks from a possible accident. The wind screen is worn and faded and will require replacement. The seat has been taped together and requires recovering. Figure 1 Body Work in original state. 1984 GPz900R Schedule of Work 4 of 20 1.2.2 Engine The engine has 90,000 klms on it according to the instruments which appear to be original. The engine was sold with a defective starter clutch as it appears to spin but initial attempts to start the engine failed. A replacement starter clutch is in storage and to refit the part requires that the engine be removed, inverted, bottom engine case removed and all assemblies removed until the starter clutch become accessible rather than a total rebuild. The engine was last run in 2005 and appears to be in good external condition. The condition of the carburetors is unknown but will need to be stripped and cleaned as a service exercise. 1.2.3 Suspension and Brakes On arrival a rust spot with a diameter of 5 cm was noted on the left fork and it was determined that the forks must undergo hard chroming to remove the rust and any chips. The fork seals are damaged but replacements have been supplied. An inspection of the disks revealed worn disks front and rear. New disks are available and will be required. The condition of the brakes appears to be poor but for a bike that has had no services performed this is to be expected. The image below shows the state of the motorcycle at time of purchase

DUCATI 999R NITRO POWERED R/ C MOTORBIKE INSTRUCTION MANUAL

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

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FUEL SELECTION 1. Choose a fuel from a reputable, brand name company that is approved for car/truck use. Do not use airplane or boat fuels in your car/truck. Choose methanol based model engine glow fuel that has a nitro content in the range 10%-30% and 5% to 18% caster/synthetic oil content for lubrication. Lower nitro percentages will generally result in a cooler engine running temperature and therefore last longer before needing a rebuild; cooler-running engines also generally produce less power. 20% nitro is the most widely used fuel. 2. Fuel color is for identification purpose only and is not important to performance or durability of your engine. 3. Be careful. If the tank overflows it might get on your radio gear or on your brakes and it may create an unsafe driving situation. Always keep your fuel bottle closed when not in use. 4. Do not dispose of fuel or empty fuel containers in a fire. It may possibly cause fire or explosion. ENGINE 1. For proper engine break-in procedure, please refer to the manual of your engine. 2. Never run your vehicle without the air filter .If the vehicle will be operated in an area with fine dust, use filter oil or caster oil instead of fuel. It is important that the foam is only moist to trap dirt and allow air passage. With the foam too wet, limited air can pass through; therefore, limiting engine performance. 3. The parts around engine could be dangerously hot after operation. Do not touch it without any protection! RADIO OPERATION 1. When turning radio on, first turn on the transmitter and extend the transmitter antenna. 2. Then, turn on the receiver. When turning off, first turn the receiver off, then the transmitter off. FIRST AID 1. If you drink nitro fuel by accident, immediately drink large quantities of water and try to induce vomiting. Consult with physician right after then. 2. If the nitro fuel gets into your eyes, rinse them well with water. Consult with physician right after then. 3. If the fuel gets onto your skin, wash it well with soap and water. WARNING 1. Improper operations may cause personal and/or property damage. Thunder Tiger and its distributor have no control over damage resulting from shipping, improper construction, or improper usage. 2. Thunder Tiger assumes and accepts no responsibility for personal and/or property damages resulting from the use of improper building materials, equipment and operations. By the act of assembling or operating this product, the user accepts all resulting liability. If the buyer is not prepared to accept this liability, then he/she should return this kit in new, unassembled, and unused condition to the place of purchase.

HONDA ATV Carburetor Repair Kits Installation

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Filed Under (Honda) by admin on 21-12-2011

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ATV Carburetor Repair Kits Complete kits to rebuild one OEM carburetor. Each kit contains necessary gaskets/o-rings, needle valve or needle valve set, and jets. Made in Japan. Note: Check all parts before installation. Honda Model Year Order No AT C70 78-85 025-001 AT C90 70-71 025-003 ATC90K1/K2/K3 72-75 025-003 AT C90 76-78 025-003 TRX90 Fourtrax 90 93-98 025-084 ATC110 79-83 025-005 ATC110 84-85 025-061 ATC125M 84-85 025-062 TRX125 Fourtrax 85-86 025-050 TRX125 Fourtrax 87-88 025-063 ATC185 1980 025-009 ATC185S 81-83 025-009 AT C200 81-82 025-008 AT C200 1983 025-009 ATC200E Big Red 82-83 025-064 ATC200ES Big Red 1984 025-064 AT C200M 84-85 025-064 AT C200S 84-86 025-065 AT C200X 83-85 025-012 AT C200X 86-87 025-014 TRX200 Fourtrax 200 90-91 025-066 TRX200D Fourtrax 200 Type II 1991 025-066 TRX200D Fourtrax 200 Type II 92-93 025-067 TRX200D Fourtrax 200 Type II 94-97 025-068 TRX200SX Fourtrax 87-88 025-069 ATC250R 81-82 025-017 ATC250R 83-84 025-018 AT C250R 1985 025-019 ATC250ES Big Red 85-87 025-029 AT C250SX 1985 025-070 TRX250 Fourtrax 250 1985 025-071 TRX250 Fourtrax 250 86-87 025-072 TRX250EX Sportrax 250EX 01-04 025-085 TRX250R Fourtrax 250R 86-87 025-060 TRX250R Fourtrax 250R 1988 025-073 TRX250X 91-92 025-074 TRX300 Fourtrax 300 1988 025-075 TRX300 Fourtrax 300 91-92 025-076 TRX300 Fourtrax 300 93-95 025-078 Honda Model Year Order No TRX300EX Fourtrax 300EX 93-98 025-081 TRX300FW Fourtrax 300 4×4 1988 025-075 TRX300FW Fourtrax 300 4×4 91-92 025-076 TRX300FW Fourtrax 300 4×4 93-95 025-078 AT C350X 1985 025-035 TRX350 Fourtrax 4×4 86-87 025-079 TRX350FE Fourtrax Rancher 4×4 ES 00-03 025-082 TRX350FM Fourtrax Rancher 4×4 00-03 025-082 TRX350TE Fourtrax Rancher ES 00-03 025-082 TRX350TM Fourtrax Rancher 00-03 025-082 TRX350D Fourtrax Foreman 4×4 87-89 025-079 TRX400FW Fourtrax Foreman 95-00 025-080 TRX450ES Fourtrax Foreman ES 98-01 025-083 TRX450FE Fourtrax Foreman ES 02-03 025-083 TRX450FM Fourtrax Foreman S 02-03 025-083 TRX450S Fourtrax Foreman S 98-01 025-083 TRX500FAFourtrax Rubicon 01-04 025-086

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Tacoma Power Steering Pump Improving Power Steering Reservoir modification

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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For my SAS I decided to add hydraulic steering assist as it comes in real handy for rock crawling. I got the Redneck Ram setup from the folks at West Texas Off-road that includes rebuilding an earlier IFS steering box along with drilling and tapping the box for the included ram. One of the down sides of adding a ram is that it slows the steering down because the stock steering pump has to supply the added volume for the hydraulic ram. Another is that it creates a fluid volume change in the system reservoir that needs to be compensated for in some way. After doing some reading on the West Texas site about how to go about modifying a Saginaw pump and reading up on earlier Toyota pump mods for steering assist setups on the Pirate board, I decided to give it whirl and see what I could do about the Tacoma pump. Chuck Gardella was kind enough to supply me with a blown pump that I could rebuild and submit to my endless fiddling and tinkering. I plan to give him my pump in return when I get this one done and installed. You need to do something to allow for more room in the reservoir for the standard hydraulic ram assist setup so I decided to tackle the reservoir first. The reason you need the extra space is because the ram is unbalanced. That is there is a rod on one side of the cylinder and not on the other side so the volume of the fluid has to change in the system to account for the volume of the rod as it travels back and forth. I calculated the volume of the rod that I have at full stroke to be about 2 oz or so. This would equate to plus or minus up to 2 oz. in the pump reservoir. Well first off, it’s no wonder why so many folks boil their steering pumps over with heavy wheeling and have so many other steering problems. The stock power steering reservoir doesn’t even rate pint sized

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KTM EXC Enduro & SX Motocross REPAIR MANUAL

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Filed Under (KTM) by admin on 06-03-2012

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Thanks to a history of competition successes, particularly in off-road racing, KTM motorcycles enjoy a large and loyal following. Established in 1953, KTM (from Kraftfahrzeuge Trunkenpolz Mattighofen where founder, Hans Trunkenpolz, had his engineering works) went through difficult times in the early 1990s. After a takeover, the Austrian company emerged as KTM Sportmotorcycle AG and has gone from strength to strength in recent years. Mainstay of their range are their Enduro and Motocross models, the EXC and SX, and these are covered in the latest new manual from Haynes. Models covered are the 250, 400, 450, 520 and 525 EXC and SX with 4-stroke sohc engines, 2000 to 2007. Information has also been included on the SMR Supermoto versions and MXC/XC derivatives. Haynes Manuals for cars and motorcycles are so popular that 150 million have been sold worldwide. Lay them end-to-end and they would circle the globe at the equator! The new manual begins with essential pre-ride checks, competition prep and routine maintenance tasks before moving on to more major repairs. There are comprehensive, fully illustrated, instructions for overhauling the engine, transmission, brakes, suspension and electrical system. Useful reference pages include colour wiring diagrams, fault-finding charts and a comprehensive section on tools and workshop tips. Because all Haynes Manuals are based on a complete stripdown and rebuild, not only are the procedures written from first-hand experience, but there is information about special tools required for each job, and its complexity, plus Haynes tips for saving time and money. The new Haynes KTM EXC Enduro & SX Motocross Manual is the only complete manual for owners of these motorcycles.