2002 yz125 torque specs

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2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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2008 FLT Police Models Service Manual Supplement

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ITEM SERVICED 14-21 ft-lbs (19.0-28.5 Nm) Drain plug torque Engine oil and filter 4 qt. (3.8 L) Oil capacity Hand tighten 1/2-3/4 turn after gasket contact Filter 63798-99A Chrome filter part number 63731-99A Black filter part number FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity Primary chain lubricant Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml) 14-21 ft-lbs (19.0-28.5 Nm) Primary chaincase drain plug torque 1/2-1 turn Adjuster screw free play Clutch adjustment 72-120 in-lbs (8.1-13.6 Nm) Adjuster screw locknut torque 1/16-1/8 in. (1.6-3.2 mm) Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm) Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads. Lubricant level Transmission lubricant FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity 32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm) Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm) Transmission filler plug/dipstick torque Front: 36 psi (248 kPA) Pressure: solo rider Tire pressure and wear Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread pattern Wear 55 in-lbs (6.2 Nm) minimum Spoke nipple torque Wheel spokes 99953-99A (12 oz.) D.O.T. 4 hydraulic brake fluid part number Brake fluid level Front: 0.20 in. (5.0 mm) Fluid level (from top of master cylinder reservoir) Rear: 0.26 in. (6.5 mm) Front: 7-10 in-lbs (0.8-1.1 Nm) Master cylinder reservoir cover screw torque Rear: 12-15 in-lbs (1.4-1.7 Nm) 0.016 in. (0.4 mm) Minimum brake pad thickness Brake pads and discs 75-102 in-lbs (8.5.-11.5 Nm) Brake caliper pad pin torque Front: 0.18 in. (4.5 mm) Minimum brake disc thickness Rear: 0.25 in. (6.3 mm) 0.008 in. (0.2 mm) Maximum brake disc lateral runout (warpage) 10 lb. (4.5 kg) Upward force applied at midpoint of bottom belt strand Drive belt deflection 3/8-7/16 in. (9.5-11.1 mm) FLHTP 1/4-5/16 in. (6.4-7.9 mm) FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm) Air cleaner cover bracket screw torque Air cleaner 36-60 in-lbs (4.1-6.8 Nm) Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER 243 (BLUE) Air cleaner cover screw Threadlocker Part No. 99642-97 (6 ml) LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.) Lubricant part number Clutch cable 35-45 in-lbs (4.0-5.1 Nm) Handlebar switch housing screw torque

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

INSTRUCTIONS ON HOW TO R & R YOUR Swingarm

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Filed Under (Tips and Review) by admin on 12-12-2010

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• Upgrade Your Pre- 2002 FL Or FXR Rear Fork & Get Rid Of The Crappy & Dangerous (Cleve Blocks) & Replace Them With A Stable System. • R & R your Swing Arm, Belt Drive, Swing Arm Pivot Shaft, and Rear Wheel. The paragraphs below are a photo journey into the replacement of a FL or FXR swing arm. To upgrade the pre 2002 FL, here is a How-To on cheaply replacing the poor parts Harley stuck you with. Now – Let’s Get Er’ Done • Pre- 2002 had weak swing arms and are known to fail. The cleve blocks are the cause of “Rear Steer” or “Rear Fork Deflection”. Harley came up with a patch in 2002, using bearings. Because the pre 2002 transmissions have a 5/8″ mounting hole for the 5/8″ swing arm pivot shaft, a conversion unit has been made. No transmission removal for boring is necessary. Under no circumstances, do I recommend drilling out the transmission case with a hand drill. The drill will “wander” (drift)! • Solution: Go to either a trike shop/manufacturer, e-Bay, or shop and buy a new style swingarm. Harley made an additional upgrade in 2007, try and buy this type 2007 & above). If upgrading to a 2008, Harley use 25mm (smaller than 1″) axles & wheel bearings, you will have to use 25mm bearings. With that said, let’s get on with it. • In the case of a 2007 swingarm; buy and do not pay over $40 for the swing arm and axle. You must use the corresponding axle as a ¾” axle set-up is different (along with wheel bearings & spacers). You positively can not use a pre -2002 HD stock wheel because the wheel bearing spacer will fit into the wheel. Buy 2002 & above style wheels as they (9 spoke) are cheep. • You are going to have to either bore out your stock rear caliper bracket or better still, upgrade your whole rear brake to the new model & sell yours on e-Bay. • I recommend doing the following before hand and have it ready for installation; Remove bearings et al. from the 2002 & later swing arm via press. Bike Work: • Jack up your bike using a center jack. Secure the bike so it will not fall over. You can also use a motorcycle jack. I use a motorcycle dolly

2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

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Yamaha R1 2007-2008 Frame Slider Installation

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Filed Under (Yamaha) by admin on 01-01-2012

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Installation Steps: 1. Remove left and right body panels. 2. Remove the left side engine stud. Mount the left side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the left side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 3. With the offset in the correct position remove body and torque down to OEM torque specs. 4. Using one drop of blue thread locker mount the left side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 5. Remove the right side engine stud. Mount the right side offset using 99-HB-SH10125080 Socket Cap 10 X 1.25 X 80 Main Engine Stud. Tip: Only tighten enough so you can still move the offset by hand. Loosely mount the right side body panel. Adjust the offset so the frame slider when mounted will clear the bodywork. There is also a groove cut in the offset, this is so the body can clear the offset. 6. With the offset in the correct position remove body and torque down to OEM torque specs. 7. Using one drop of blue thread locker mount the right side puck to the offset with 99-HB- SH10150045 Socket Cap 10 X 1.5 X 45 (Holds puck to offset). Torque down to 30 to 32 foot lbs. 8. Mount left and right bodywork

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HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

YAMAHA YZF-R1P YZF-R1PC ASSEMBLY MANUAL

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Filed Under (Yamaha) by admin on 26-02-2011

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PREPARATION To assemble the motorcycle correctly, supplies and working space are required. Supplies oils, greases, shop rags. Workshop The workshop where the motorcycle is assembled should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Product hands and feet by wearing safety gloves or doing. SYMBOLS USED ON CRATE CARTON Contents of the transport package are fragile therefore it shall be handled with care. Indicates correct upright position of the transport package. Transport package shall be kept away from rain. Insertion of the lift arm from this side is prohibited. Lift arm inserting position. -1- UNPACKING 1. Remove the frame cover 1. NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the bolts 2 (upper bracket). 3. Remove the bolt 3 (front tire). 4. Remove the packing frames 4 (upward and sideways). NOTE: Remove the bolts while holding frame. NOTE: Before starting the assembly, check for damaged or missing parts. The parts are contained in the cartan and the motorcycle for damage, scratches and other defects. -2- PARTS LOCATION 1 Carton box -3- 1 Carton box Screw, washer and special nuts (windscreen) Bolt (front master cylinder) Bolt (handle crown and handlebar) Nut (rear view mirror) Nut (front reflector) Front reflector Vinyl bag 1 Plugs (handle crown) Owner’s manual Rear view mirrors Windscreen – -5- 1. Handlebar 1 2 3 4 5 6 1 1 1 1 2 1 Reservoir tank (brake) Hexagon socket bolt Crown nut Hexagon socket bolt Cap Hexagon socket bolt * V * V V * d = 6 (0.24), r= 12 (0.47) d = 6 (0.24), r= 25 (0.98) d = 8 (0.31), r= 30 (1.18) 2. Front reflector A: Tighten the crown nut to specified torque. Tightening torque: 115 Nm (11.5 m • kg, 85.0 ft • lb) B: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 9.4 ft • lb) C: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 4.4 ft • lb) A: Tighten the screws to specified torque. Tightening torque: 40 Nm (4.0 m • kg, 29 ft • lb) 1 2 3 4 5 2 2 2 4 4 Reflector bracket Reflector Nut Washer Caliper bolt * V V * * d = 5 (0.20) d = 10 (0.39) d = 10 (0.39), r= 30 (1.18) 3. Clutch cable 1 Clutch cable 1 * A: Check the clutch lever for smooth action. CAUTION: Proper cable routing is essential to assure safe motorcycle operation. Refer to “CABLE ROUTING

2000-2002 Aprilia Mille INSTALLATION INSTRUCTIONS

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Filed Under (Aprilia) by admin on 26-10-2010

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1) It is a good idea to use Blue Loc-tite on all bolts you are about to remove and replace. 2) This kit has extremely close tolerances and in order for all the parts to clear the triple clamp and gas tank, you will probably have to loosen and align most of the associated bolts. We have tried very hard to make this as compact as possible but we know the factory tolerances vary from bike to bike. Be patient, the results are worth it. 3) Remove both front fuel-tank retaining bolts. You will use the longer bolts provided in our kit. 4) Install the frame bracket (part #22-6036-03) that mounts to your front (2) tank bolts holes. The frame bracket sits on top of the stock tank spacers. The frame bracket is offset. This means it fits correctly only one way, with the offset toward the triple clamp, part numbers facing forward, (see photo below). Due to the tight clearances on this model you’ll want to be sure the frame bracket does not make contact with the tank itself. It’s easier to start the tank bolts if you lift up on the tank slightly, while starting the new bolts into their threaded hole. Tighten the new tank bolts to 6 ft lbs. and use Loc-tite. 5) Remove the large 14mm Allen nut and washer that holds your triple clamp on. You will not re-use either one. 6) Install the new “Triple clamp damper mount” Part # 22-2925-00 into the recess area where the stock Allen head bolt was sitting. There is a machined recess or built-in-washer on the bottom of our mount to match the recess on your triple clamp. The 2 nubs that hang down, should match the rear contour of your triple clamp precisely. Use loc-tite and retighten the new 14mm Allen nut provided to your factory torque specs, usually a minimum of 35 ft lbs. and maximum of 85 ft. lbs. Do not use the stock washer that was under the original 14mm nut. 7) Grease the tower pin and drop it in the tower pin hole portion of the frame bracket. The tower pin is designed to “float” and requires no retaining devices. Keep the tower pin lightly greased! It should not touch the gas tank on the bottom side. 8) Install the stabilizer using the (2) 6×20 Allens with the slot in the link arm matching the tower pin. 9) Since the tank is rubber mounted at the rear, you want to be sure it won’t push forward and rub the frame bracket. After riding the first time, be sure the tank has not shoved forward by your body making contact with it. Remember, under heavy braking your entire body weight is pushing the tank forward. Until you have verified sufficient clearance between the tank and the tower pin, it might be smart to put something between the tank and tower pin to protect the tank. 10) Read your damper manual for initial settings on the controls. The damper is infinitely adjustable and totally up to the user to find their preference. Start with softer (counter clockwise) settings. Normally where we set the unit, at 8 clicks out on the base valve, is a good starting point.

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