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2010 Toyota Motorsports/ TRD USA Contingency Award Program

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Filed Under (Toyota Manuals) by admin on 29-09-2011

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To enroll in the program, complete the registration form included in the enclosed material and mail, fax or e-mail it to TRD per the instructions at the bottom of the form. Contact personnel are listed on the attached 2010 Contingency Award Guidelines sheets. These people are available to assist you throughout the year. Parts Ordering: If you are planning to order Toyota parts during 2010 you must supply us with your Visa or Master Card credit card number at the time you register in the program. There is a line on the registration form for this number. See the attached Parts Ordering Guidelines for detailed information on how to order parts. TRD is looking forward to working with each of you, and we wish you a very successful year with your racing program

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YAMAHA SKULL AIR CLEANER KIT INSTALLATION PROCEDURE

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Filed Under (Yamaha) by admin on 15-11-2010

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STEP 1 Remove the stock air cleaner and components to the point shown in PIC. 1. The stock plastic air box adapter “A” and stock mounting brackets “B” will remain in place. STEP 2 Remove the carburetor according to the section in your factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. Now is a good time to proceed with re-jetting the carburetor. Consult your factory service manual for details of this procedure. We have supplied jets to cover many common configurations. Individual bikes may need additional tuning to achieve maximum performance. If your exact combination is not listed, choose the listing that most closely resembles the configuration of the motorcycle. These recommendations are based on testing done at 700 feet above sea level. COBRA/STOCK EXHAUST V&H STYLE OR OPEN PIPES Main Jet 120 Main Jet 122.5 Pilot Jet 35 Pilot Jet 35 PMS Screw 1-1/2 Turns Out From PMS Screw 1-1/2 Turns Out From Bottom Bottom NOTE Your optimal performance and drivability may require some fine-tuning from these specifications. For instance, the general rule of thumb is one jet size smaller for every 3000-4000 feet of elevation. STEP 3 Insert both flanges of the rubber adapter through the mounting bracket as shown in PIC.2. The hardware components used for installation are placed near their respective mounting points: “A” Socket head cap screw — 30mm long, tapered bolt cap, and two spacers. The spacers are placed between the chrome and the stock mounting brackets. “B” Socket head cap screw — 15mm long, tapered bolt cap “C” Socket head cap screw — 30mm long, tapered bolt cap, two spacers (place between chrome and stock brackets), and flange nut. “D” Mounting holes. STEP 4 Install a Line Fitting Plug into the threaded hole in the back plate labeled as “A” in PIC.3 and tighten snugly. STEP 5 Install a 90 Degree Elbow into the threaded hole on the back plate labeled as “B” in PIC.3. Tighten snugly.

Kawasaki KFX450 Slip On INSTALLATION AND REMOVAL INSTRUCTIONS

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

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Kit includes 1 Mid pipe 1 Silencer 1 Silencer clamp 1 8×20 bolt 1 quiet core Installation instructions Save your stock parts. Some may be used for installation of new pipe! 1. Remove your stock silencer leaving the stock head pipe. 2. install mid pipe sliding it over the end of the stock head pipe. 3. place the Silencer onto the mid pipe. Make sure the clamps are in correct position. Loosely mount the silencer w/ the provided 8×20 bolts. 4. Tighten the silencer bolt (torque to manufactures specs). 5. Make sure the clamps are tightened to the silencer. 6. Install LTE’s Gen 3 TFI that is programmed for optimum performance w/ no tuning. 7. After running this unit for the first 15-20 minutes allow the system to cool and re-check the system for any loose bolts or nuts. It is also good to check the spark plug to see that you are not running to lean or rich. NOTE: TFI Gen 3 specs are for sea level with the airbox lid removed for optimum performance. Check your packing after 20hrs of riding for optimum power and lowest db levels. It is your responsibility to read and understand these instructions.

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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KTM 250/300/380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 19-11-2010

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Carburetor adjustment Basic information on 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 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of 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. Checking the setting of the TVC system The function of the TVC system is checked with the engine running. This test checks the start of advance and the end of advance. -For this, remove the left control cover. -Connect a rev counter (either to the ignition cable or to the blue/white cable in the electronics box, depending on the rev counter design). -Start engine, accelerate gently and observe when the TVC system starts to advance (tooth segment creeps upwards) Bleeding of the hydraulic clutch -Take off cover together with rubber bellows. -At the slave cylinder of the clutch, remove the bleeder nipple 2 . It its place, mount the bleeder syringe 3 which is filled with SAE 10 hydraulic oil

KAWASAKI KLX 140 160cc BORE KIT INSTALLATION INSTRUCTIONS

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

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Engine assembly requires special attention to detail. Your cylinder must be bored to fit this new piston. For long engine life it is very important that the cylinder bore is professionally machined to be very round and without taper. Piston-to-Cylinder Clearance: .002″ Ring End Gap: .007″ – .012″ Once the cylinder is bored to size, installation of this piston kit is identical to OEM installation. Please refer to the Kawasaki shop manual or a qualified mechanic for assistance.The side of the piston marked EX should go toward the exhaust port. Coat both sides of copper gasket with a quality gasket sealer. (Gasgacinch or comparable product) Every effort has been made to insure the quality of this product. Because BBR cannot control the installation or use there is NO warranty or guarantee with this product. Using quality motorcycle oil will help prolong engine life. Be sure to change it often. Recommended main jet: 100 Main (at sea level, 65 degrees) Recommended Fuel: 91-93 octane pump fuel

KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. 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. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on 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 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of 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:

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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.

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.

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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.

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