2005 yamaha roadstar 1700 carburetor

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YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 22-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove both frame covers. Remove the left cover first to access a bolt that holds the right side cover in place. 2. Remove right side floorboard assembly held in place by two bolts (Figure 1). 3. Remove exhaust port Allen nuts. 4. Remove Allen bolts securing rear muffler to exhaust system mounting bracket. 5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required). 6. Check condition of stock exhaust gaskets. Replace if damaged or worn 7. Remove two bolts attaching stock exhaust mounting bracket to frame. 8. Remove hose clamp securing rear brake hose to exhaust mounting bracket. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loop in bracket. 11. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 12. Reconnect brake hose to caliper (without bracket) and torque Banjo bolt to 25 lbs. ft. 13. Brake system must be bled or brake will not operate correctly. Refill reservoir after bleeding 1. Remove exhaust system and heat shields from protective packaging. Place exhaust on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through (Figure 2). 2. Attach brake hose clamp to mounting bracket (stamped 362-P) using one 6x16mm flange bolt and nylock nut (supplied) to tab located on top of bracket (Figure 2). 3. Install mounting bracket using two 10x30mm Allen bolts and lock nuts (supplied)(Figure 3). 4. Carefully slide heat shields onto headers.

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YAMAHA RAPTOR 350 Removing stock carburetor and cables

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Filed Under (Yamaha) by admin on 18-01-2012

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remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Stuff a clean, dry rag into manifold to keep debris out of motor. 4. Remove stock air box. 5. Remove choke cable from handlebars. 6. Remove carb vent line from bike. Carburetor installation 1. Carefully trim the rubber alignment tab off of the face of the manifold with a razor blade or side cutters. 2. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 3. Attach fuel line to carburetor and secure with clamp. 4. Install remote idle cable into tab on top of carburetor. See main manual for this step. NOTE: Nut must be removed from cable before installation 5. Place carburetor into manifold

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YAMAHA V-Star 1100 Carburetor Bowl Screw Repair and Removal After Stripping and Pilot Cap Removal

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Filed Under (Yamaha) by admin on 19-01-2012

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When I first started working on bike many years ago, I learned the danger of stripping the heads of Philips screws when removing or installing them on motorcycles. I remember the two worst screws were the casing side-cover aluminum screws and carburetor bowl screws. I think I tried every method of screw removal after they were stripped. Vice grips, better tipped screwdriver, hammer, drill, and other tools were used. One way I learned to remove stripped screws is to re-make the Philips head into a flathead screw. Cutting a slot in the top of the screw and then use a flat-head screwdriver to remove the screw. On some parts this technique can work, other parts and screws it may not. The Philips screws on the bottom of the V-Star carburetor bowls are VERY prone to stripping. In fact, I will not start a carburetor cleaning without new hex head screws to replace the original Philips bowl screws. Replace the bowl screws for yourself if you keep the bike, or for the next rider that will appreciate the hex-head screws when they clean the carburetors. Not many other parts on a V-Star have screws that are prone to stripping. This documentation is to help riders with motorcycle maintenance. Some riders will find themselves with the problem of removing stripped screws. A carburetor cleaning can quickly double in time when you realize the hardest part of the job is removing bowl screws after they strip. And then realizing you do not have the replacement hex-head screws available and must now go to the hardware store.

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KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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HSR Carburetor Total Kits Installation Instructions

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

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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2004 – 2005 Camry, Highlander, And Solara, 2005 Matrix & Corolla PASSENGER AIRBAG INDICATOR LAMP

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

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passengers weighing approximately less than 100 pounds, depending on their seating position. It is important for the front seat passengers to know that proper operation of the advanced frontal airbag system is highly dependent on the pressure placed on the seat bottom. Situations that add or subtract sensed weight can result in occupant misclassification. To minimize this situation: Check seating posture. Passengers should be seated upright with their back against the seat back and feet on the floor. Check loading conditions. Extra weight from items, such as bags or groceries or toys, hanging on the seat back can add to the sensed weight of the front seat passenger. A rear seat passenger lifting the front seat with their legs, objects placed under the front seat, or the front seatback in contact with the rear seat can subtract from the sensed weight of the front seat passenger. If the passenger airbag indicator lamp continues to switch ON to OFF after checking the above conditions, perform the following repair procedure. NOTE: The safest place for children is in the rear seat. Please note that Toyota recommends that you never install a rear-facing child restraint in the front passenger seat, even if the passenger “Airbag OFF” lamp is illuminated. Please refer to you Owner’s Manual for additional details. 2004 – 2005 model year Camry, Highlander, and Solara vehicles produced BEFORE the Production Change Effective VINs shown on the following page. 2005 model year Matrix and Corolla vehicles produced BEFORE the Production Change Effective VINs shown on the following page

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Yamaha 2005 R1 Bike Tech Sheet

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Filed Under (Yamaha) by admin on 18-01-2012

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Engine: Type: Liquid cooled, four stroke, transverse four cylinder, DOHC, 5 valves per cylinder. Displacement: 1000cc Year: 2005 Horsepower: 180hp Clutch: PM Exhaust: Vance & Hines Race Exhaust Mufflers: Vance & Hines Frame: Type: Stock Year: 2005 Swing Arm: Performance Machine Chromoly +4 Extended Shocks: Race Tech Modifications: Race Tech Tuned and Lowered. Forks: Stock lowered 2.5″ Rim: Performance Machine Contrast Cut Torque Size: 19″ X 3.0″ Finish: Contrast Cut Fender: None Tire: Dunlop Sportmax D208ZR 120/70ZR19 Brake: Dual Performance Machine 4 piston Radial Calipers Wheels Rear: Rim: Performance Machine Contrast Cut Torque Size: 18″ X 8.5″ Brake: Performance Machine 4 piston Radial Caliper Finish: Contrast Cut Tire: Dunlop Elite3 250/40/R18 Other Parts: Handlebars: Stock Foot Controls: Over Racing Seat: Stock Turn Signals F/R: Anything Extra? Mirrors: Performance Machine Torque chrome Mirrors 19″ FRONT WHEEL! Paint, Chrome, and other F/X’s: Colors: yellow/Black Type: Special Paint: AirTrix Industries The Painter: Chris Wood Powder Coating: A to Z Coatings

YAMAHA YFM 350 Removing stock carburetor and cables.

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Filed Under (Yamaha) by admin on 19-01-2012

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Remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Preparing motor for carburetor install 1. Remove stock manifold from cylinder head. 2. Place supplied o’ring into aluminum flange as pictured in figure 1. Figure 1. 3. Install aluminum and rubber flange to motor using supplied bolts. See Figure 2. The shorter 25mm bolt will need to be placed in the bottom hole. IMPORTANT NOTE: Install the aluminum flange with the o’ring towards the motor and the thick side up.

HARLEY DAVIDSON BIG TWIN SPIGET MOUNT CARBURETOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 26-03-2012

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A. BEFORE INSTALLATION OF YOUR NEW ZENITH CARBURETOR, NSPECT THE RUBBER MANIFOLD SEAL FOR NICKS,CRACKS, OR DEBRIS. APPLYING A LIGHT FILM OF PETROLEUM BASED LUBRICANT AROUND THE INSIDE LIP OF THE RUBBER SEAL WILL ALLOW THE CARBURETOR TO SLIP INTO PLACE EASIER. B. BEFORE ACTUAL INSTALLATION OF UNIT INTO MANIFOLD, THROTTLE CABLES SHOULD BE HOOKED TO THETHROTTLEWHEEL.MAKESURETHATTHE PULL CABLE IS LOCATEDPROPERLY TO OPEN THE THROTTLE PLATE (IN SOME APPLICATIONS THROTTLE CABLE SLACK MAY NEED TO BE ADJUSTED FOR PROPER HOOKUP AND OPERATION) SEE FIG. #1 C. AFTER THROTTLE CABLES ARE PROPERLY HOOKED UP,UNITCAN BE INSERTED INTO MANIFOLD. MAKE SURE THAT UNIT IS FULLY SEATED. WITH CARBURETOR SEATED INTO MANIFOLD AND FUEL LINE HOOKED UP TO FUEL INLET, INSTALL CHOKE CABLE AND HOOK TO CHOKE LEVER. PLACE AIR INTAKE GASKET ON END OF CARBURETOR, NEXT PLACE INTAKE ADAPTOR OVER INTAKE GASKET. SEE FIG#2 ZENITH MOD.16P12 SPIGET MOUNT CARBURETOR -HARLEY DAVIDSON ™ BIG TWIN INSTALLATION INSTRUCTIONS FIG. # 1 FIG. # 2 D. WITH ADAPTOR IN PLACE, LOCATE THE STOCK AIR BOX OVER THE ADAPTOR, UTILIZING THE STOCK AIR BOX GASKET (THERESHOULDBENO GAPS BETWEEN ADAPTOR, AIRBOX OR CARBURETOR WHEN PROPERLY INSTALLED) STAND-OFF SPACERS PROVIDED ARE TOBEPLACEDBETWEENAIR BOX& ENGINE HEADS BEFORE INSTALLING THE VENT/RETAINING BOLTS. FOR EVALUATION ENGINES STOCK VENT BOLTS CAN BE USED WITH LARGERI.D. SPACER PROVIDED. SEE FIG#3 E. WITH AIR BOXSECURELY IN PLACE, INSTALL THE AIR FILTER COVER RETAINING BRACKET AND FILTER USING THE STOCKBOLTS, AND REPLACE AIR FILTER COVER AND SECURE WITH STOCK BOLT. SEE FIG#4 F. AFTER INSTALLATION IS COMPLETE AND FUEL FLOW HAS BEEN RE-ESTABLISHED, CHECK FOR ANY LEAKS BEFORE STARTING ENGINE. H. AFTER STARTING ENGINE, SOME ADJUSTMENTS OF IDLE AND MAIN JET MAYBE REQUIRED FOR PROPER OPERATION. AFTER ADJUSTMENTS HAVE BEEN MADE AND WITH ENGINEAT IDLE, TURN WHEEL FULLYTOLEFTANDRIGHT.ANYCHANGEIN IDLE SPEED INDICATES THROTTLE CABLES ARE TOO TIGHT AND MORE SLACK MUST BE PROVIDED.

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2005 Yamaha Royal Star Tour Deluxe speedo Healer Installation Manual

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Filed Under (Yamaha) by admin on 09-11-2010

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The speed sensor is on the left side (looking from the back towards the front of the motorcycle). Just FYI, here is the speed sensor coming off of the drive shaft behind the left saddlebag. The speed sensor connection for the Speedo Healer is behind this red cover. Take off the seat. There are two screws. One pointed out by the arrow and one on the opposite side. Also, remove the screw on the red cover. After removing the screw on the red cover, remove the cover by pulling it straight away from the bike. It is held on by 2 rubber grommets. The arrow points to the speed sensor coupler. Pull the connection apart. There is a little tab holding the connector together that will need to be depressed in order to get it apart.Hook the SH harness into the appropriate connectors. It only goes one way. The Yamaha plug and go kit works perfectly with no splicing required. Here is a close-up of the connection. Run the cable up under the bar towards the battery and hook the wires up to the Speedo Healer unit. The speedo healer fits nicely right behind the battery. You can barely see it next to the intercom. Note, none of the wires in this example have been secured yet. Put the red cover back on. Figure out the error that needs to be adjusted and make the adjustments to the Speed Healer per their instructions. Put the seat back on and you’re good to go. Be sure to verify that your adjustment was correct before believing your speedometer to be accurate. With the right adjustment, it will be, but don’t wait for a cop to tell you that you miscalculated! The electronic cruise control was not affected by the installation of this unit. I ended up setting mine to -7.5% after chasing my wife’s ’03 Vue for a couple of times. I ended up reading 59mph to her 60mph (previously it read 65mph to her 60mph) which is right where I wanted it since her speedometer reads a little fast, too. My back tire is about halfway worn. Your adjustment may vary

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