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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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DUCATI EVOLUZIONE SLIPPER CLUTCH KIT INSTALLATION INSTRUCTIONS

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

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If installing with Ducati OEM basket you need the washer cod. 0D1SR140C220045 (3mm). – If installing with STM basket (Z12 o Z48) you need the washer cod. 001MG019 (1,5mm). – Insert the correct washer on the gear shaft. – Perform the initial hub group assembly: position the progressive engagement steel plate (003MG015) on the hub (0F3SR140J24001C) , with the step facing up. Be careful to position it correctly into the specific seats, then check that pushing one side, the opposite stand up simultaneously. – Now put the 6 steel balls (001MG025) at the bottom of the grooves using a little bit of grease. Then fix the clutch drum (0F3SR140J24002C) on the clutch hub (0F3SR140J24001C) at rest position, using an M6 screw to help locking the two parts, avoiding in this way any possibility for the steel balls (001MG025) to fall out while inserting the hub pack on the main shaft. – Insert the hub pack on the gear shaft – Insert the clutch discs starting with the sintered one and finishing with the steel guided one; total disc set thickness must be included between 36 and 36,5mm. – Remove the M6 screw from the hub (0F3SR140J24001C). – Put the drum stopper hub (003MG106) on the hub (0F3SR140J24001C). – Verify that the secondary spring support (0F3SR540B140016) is well inserted into its housing on the drum (0F3SR140J24002C). – Insert the secondary spring (0S2085) into its housing on the drum (0F3SR140J24002C). – Mount the pressure plate (003MGP10) on the drum (0F3SR140J24002C) . – Position the Evoluzione spring (0S1090) on the pressure plate (003MGP10), with the convex part facing up (STM logo facing up), making sure previously that the squared section ring (901SE003), which works as primary spring support, is well positioned into the pressure plate itself. – Assemble the complete spring stopper pack: starting from the spring stopper plate (003MG008), with the shaped side facing up as shown in the picture. Insert the ball bearing (003MG007) and finally the spring stopper hub (0F3SR140N220007). Once completed these operations, position the complete spring stopper pack inside the Evoluzione spring (0S1090). – Insert the toothed washer (901RD101) with the convex side facing up, then insert and tighten up the clutch nut (0F30S140C220013); use a dynamometric wrench setting the torque suggested by the bike manufacturer. We suggest to use the specific optional tool (UTL-0020) in order to lock the pressure plate (003MGP10) while performing this operation. – Assemble the complete bearing rest pack: insert the washer (001MG018) in its housing on the bearing rest (0F3SR140N220004). Then put in the same housing the ball bearing and the push rod pin of the original clutch. – Position the complete bearing rest pack in the pressure plate (003MGP10), making sure it fits correctly into the housing grooves. – Manually practise a little pressure on the bearing rest (0F3SR140N220004) in order to release the seat for the tightness circlip (003MG018). – Fit correctly the above mentioned tightness circlip (003MG018). MAKE SURE that it adheres to all the groove perimeter. NB: Once completed the installation, repeatedly operate the clutch lever, checking that the pressure plate performs correctly the opening and closing movements. For a road use of the clutch you have to check clutch plates set every 2000 km. Please verify that the clutch plates set thickness is between 36,5mm and 35,0mm. If it is inferior to 35,0mm please replace a 1,5 steel plate with a 2 mm steel plate. For a racing use of the clutch we suggest to check the clutch plates set thickness frequently. GENERAL SAFETY REGULATIONS – In this sheet are reported the directions to perform correctly the clutch assembly operations. – STM reserves the right – without notice – to introduce any technical change whenever deemed it to be necessary to improve functionality and quality of the products. – Assembly operations must be performed by a skilled technician and must be scrupulously observed. – Before mounting the clutch make a complete inspection of the various parts, in order to verify the possible presence of faults or anomalies on the motorbike. – Make sure that there are no missing/damaged parts in the package . – Some parts of the clutch and its components can have sharp surface: handle with care. – Some components of the clutch, because of their small dimensions can be swallowed: keep away from children. STRADA srl Via Campo Archero 20 10023 Chieri ( TO ) Tel +39 011 9422832 Fax +39 011 9471447 003 MG 018 Tightness circlip

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TOYOTA ALL MODELS IRON PARTICLE CONTAMINATION REPAIR

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Filed Under (Toyota Manuals) by admin on 28-10-2011

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During rail transportation or extended storage near industrial areas, vehicles may occasionally be subjected to contamination by airborne iron particles shed from either railroad tracks, train wheels, etc., or exposure to heavy machinery facilities. These particles can adhere to horizontal painted surfaces of vehicles and quickly corrode when combined with moisture. If not immediately recognized and removed from painted surfaces, they become embedded and cause further paint damage. INSPECTION: This type of contamination can be identified by the presence of small red or brown particles on the paint surfaces. These particles are often difficult to see on dark color paints, but still can be readily felt when brushing a hand or fingernail across horizontal body surfaces such as hood, roof, or decklid. CAUTION: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be attempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. CORRECTIVE ACTION: Washing the affected paint surfaces with an oxalic acid solution is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. ZEP X-20472 “INDUSTRIAL FALLOUT REMOVER” is one of several commercially pre-mixed oxalic acid wash solutions and is very effective in removing iron particle contamination. The correct usage of oxalic acid solutions is described in this bulletin

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Yamaha YZ400F Engine specification

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Filed Under (Yamaha) by admin on 13-11-2010

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During more than 25 years as one of the world’s leading manufacturers of advanced motocross machinery Yamaha has consistently developed and produced exciting and innovative new engine technology. Now Yamaha are about to amaze the off-road world once again with what is surely the most important new powerplant to be produced since our liquid cooled YZ 2-strokes of the early 1980s. Extremely compact and remarkably light, the YZ400F’s 4-stroke powerplant incorporates some of the most sophisticated technology ever seen on a production motocross engine. Displacing 399cc, this 55hp high performance liquid cooled motor features bore and stroke dimensions of 92 x 60.1mm – a free-revving short stroke configuration which allows this ground-breaking motorcycle to produce a wider powerband than today’s 250cc 2-strokes. Short skirt piston runs in a ceramic composite plated cylinder which reduces frictional losses, thereby enhancing throttle response throughout the rpm range. To ensure overall dimensions are kept to a minimum this revolutionary new engine is fitted with an extremely light and compact 5-valve cylinder head. Running a 12.5:1 compression ratio and with a combustion chamber volume of 20.8 cc, this high efficiency 5-valve design runs with lightweight valves, springs and lifters for immediate throttle response and smooth high rpm operation. Feeding the three lightweight inlet valves is a 39mm Keihin flat-slide carburettor which breathes through a large capacity airbox. Special feature on the YZ400F’s intake side is an innovative air valve which is designed to ensure easy starting when the engine is warm. A tube connects the machine’s inlet manifold directly to the airbox, bypassing the FCR39 carburettor. By pulling the air valve’s choke-type knob, air is fed straight from the airbox into the engine for easier warm starting.

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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.

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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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

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1997 Honda CBR 1000 F specifications

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Filed Under (Honda) by admin on 03-11-2010

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Front brakes: Dual disc Rear brakes: Single disc Speed and acceleration Top speed: 255.0 km/h (158.4 mph) Power/weight ratio: 0.5745 HP/kg Other specifications Further information Parts and accessories Check out parts and accessories from our partners. Ask questions Join the 97 Honda CBR 1000 F discussion group Insurance, loans, tests Search the web for dealers, loan and insurance costs, tests, customizing, etc. Related bikes List related bikes for comparison of specs Buying a bike starts at Bikez Get a list of related motorbikes before you buy this Honda. Inspect technical data. Look at photos. Read the riders’ comments at the bike’s discussion group. And check out the bike’s reliability, repair costs, etc. Show any 1997 Honda CBR 1000 F for sale on our Bikez.biz Motorcycle Classifieds. You can also sign up for e-mail notification when such bikes are advertised in the future. And advertise your old MC for sale. Our efficient ads are free. You are also welcome to read and submit motorcycle reviews. Rating sample for this Honda bike Value for money for the 1997 Honda CBR 1000 F: (67.1 out of 100) Click here for complete rating. You can also compare bikes. Pictures, trademarks and logos of third parties are exclusive property of the respective owners. Technical specifications are subject to change without notice. Bikez.com has been developed by low-cost software development company ObjectLabs

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2001-2002 GL1800/ A ORDERING AND REPLACING THE CD CHANGER

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

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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 custome

Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

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