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HONDA ATV FOURTRAX 400EX REPAIR, INSTALLATION MANUAL

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Filed Under (Honda) by admin on 10-12-2011

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Never carry a passenger on an ATV. * Never operate an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. * Never operate an ATV on

Honda 400EX Hub installation instructions

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Filed Under (Honda) by admin on 20-12-2011

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Remove all contents from its packaging and verify that all parts are present and free from damage. You should have the following items: (2) wheel hubs (2) smaller tapered bearings (2) large tapered bearings (2) wheel bearing nuts (2) dust caps (2) inner bearing seals (6) M3 x .5 screws (2) cotter pins (2) inner bearing spacers 2. Completely remove the old hubs from your quad and clean the spindle and the surrounding areas. It is very important to keep the new bearings and seals clean during installation for long life. Be sure to remove the factory inner bearing spacers from the spindle and discard. They will not be used in re-assembly. 3. Pack your new Timken tapered wheel bearings with a liberal amount of high quality wheel bearing grease. A wheel bearing packer works best, however you can accomplish the task by placing the grease in the palm of your hand and manually working it in between the bearing rollers. We also recommend that you pack the area between the bearing races in the hub with grease for additional lubrication and protection against moisture. 4. Place the large wheel bearing (inner) into the hub and install the inner seal. The seal should bottom out against the step in the bore and the face should be flush with the hub. 5. Remove the brake rotors from your old hubs. Re-install the rotors on your new hubs and be sure to use medium strength Loctite on the threads. 6. Apply a light film of grease or oil to the large diameter of the spindle stud. Install the new o-ringed bearing spacer onto the spindle. 7. Apply a thin film of grease to the seal surface on the bearing spacer and the inside diameter of the seal to prevent the seal from running dry. Install the hub onto the spindle and slide the outer bearing over the spindle and install the new bearing nut furnished with your hubs. Do not use the factory nut or washer. 8. SETTING THE BEARING PRELOAD: It is first necessary to seat the bearing before setting the preload. This aligns the rollers and prevents the bearings from loosening after a short period of use. To seat the bearing, tighten the spindle nut while you rotate the hub until the hub becomes difficult to spin. With the bearing now seated, you must set the bearing preload. Preload means placing a small amount of force against the bearings to remove any clearance between the bearing race and the rollers. This is done by backing the nut off completely and re-tightening it with your fingers. Do not rotate the hub while setting the preload . If a hole in the spindle is not accessible for installation of the cotter pin, adjust the nut tighter to bring a hole into alignment. Install the cotter pin and bend the pin around the outside of the nut. Do not attempt to bend the pin toward you (over the end of the spindle) or it may rub on the inside of the dust cap.

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HONDA TRX 400EX Removing Stock Carb and Cables INSTRUCTION

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

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Remove seat/fender assembly and fuel tank. 2. Remove throttle cables paying close attention to routing. 3. Remove thumb throttle housing if you are installing a twist throttle. 4. Remove air box and air box intake tube. 5. Remove stock carburetor. 6. Stuff a clean rag into intake manifold to keep debris from entering engine. Preparing machine for carburetor installation 1 . Route the provided throttle cables per manufacturer’s recommended procedure, routing them the same as the stock cables. 2 . Remove the rubber alignment tabs from the manifold using a razor blade or cutters. Be very careful not to damage the intake manifold! 3. Remove air box intake tube from the air box and use a hacksaw to cut approx. 1½” off of the air box intake tube. Your tube should resemble the one shown in Figure 1. Re-assemble the air intake tube into air box and install back onto bike. Don’t forget to tighten clamp around intake tube and reinsert crank vent into the air boot. Figure 1. Thumb Throttle Attach cable into cable wheel with the cable end at the 8: 00 position of the cable wheel, then into bracket. Secure by replacing the cable bracket end and phillips screw. See Figure 2. Figure 2. Twist Throttle 1. Install the pull (see figure 4 for cable identification) , cable end into the 8: 00 position and the idle cable end into the 11: 00 position on the cable wheel. See Figure 3

Honda TRX 400EX INSTALLATION And REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 14-12-2011

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Quiet cores are supplied with this kit but not installed. To install the quiet cores remove both rear end caps ((turn downs) and install the quiet cores with the tubes facing inward. Re-install the end caps. REMOVAL Remove seat, disconnect attery and remove. Remove front fenders and side skirts. Remove fuel tank (make sure to shut fuel off and drain remaining fuel in the line before removing). Remove stock muffler first, then remove stock headers. Retain the 4 stock header bolts to install on your new exhaust system. Remove the rear bolt from your stock air box. Loosen stock intake clamp at carburetor. Remove stock boost bottle from the side of the boot. Loosen stock snorkel clamp at the air box, remove stock retaining clip at the front of the snorkel. Remove stock air box, intake boot and snorkel together from the ATV. Slide tarter solenoid off of stock mounting prongs. Remove Phillips screws from fuse holder and remove from plastic housing. Remove plastic battery housing from the ATV. Unplug tail light from harness. Unclip harness from the 2 clips above the battery. CARBURATION Now would be a good time to replace your stock main jet, with the supplied 190 main jet and replace your stock pilot jet with the supplied 48 pilot jet. Make certain that all hoses are tight and routed as stock. Be certain carb clamp is tight when re-installed. INTAKE BOOT Remove the intake boot from the stock air box. Take an exacto knife or razor blade and trim off the rubber piece that the hard plastic snorkel slips into. Trim around the intake boot staying the same distance as the rest of the lip. Take a hax saw and cut the groove as the rest of the boot is, being
careful not to cut all the way through (Picture Fig.2).

BLACK POWDER COATED ANTI-VIBRATION PEGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-12-2010

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These pegs, mounts and hardware have a nickel/chrome base coat under the satin black powder coat finish. This is done to prevent any rust or corrosion at the wear points. Its is normal for some of the black powder coating to wear off (exposing the nickel/chrome base) where the pegs pivot on the mounting blocks and on the bolt heads. Again this is normal and they will not rust at these points. If desired the satin black finish can be touched up using a satin black model or spray paint.

Kawasaki Ninja 650R / ER-6F for Cowling Panel Vibration Damper Kit Installation Instructions

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

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Remove the three plastic clips which secure the two halves of the belly pan. First pull the centre pin to it’s out position using a flat blade screwdriver, use a spanner or another screwdriver shaft wrapped in a rag to act as a pivot point. Care should be taken not to damage the surrounding paint. With the centre pin pulled out, the clip can be removed by hand. Remove the two hex screws and clear plastic washers on each side that secure belly pan to the left and right main cowling panels. Note these hex screws are longer than all other hex screws used, take care not to mix. Remove the lower rear hex screw, stepped washer and clear plastic washer on each side and remove the belly pan. The left and right main cowling panels have tangs which locate into their respective belly pan halves

Crankshaft Durability of Rover K-Series Engine: Comparison of ENGDYN Analysis with Dynamic Measurements

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Filed Under (BMW) by admin on 17-11-2010

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The Rover K-Series engine has now been in production for over 10 years, initially of 1.4 L capacity. Since then 1.1L, 1.6L, 1.8L and 1.8L VVC (Variable Valve Control) have been introduced with an accumulative build of two million engines since 1989. The 1.8L engine is also built under official licence for Lotus and Caterham, and also in the MGF motorsport series. The K-Series is an attractive buy due to its reduced cost and low weight, which is a necessity for sport cars. This report aims to validate Ricardo ENGDYN software with respect to Rover K-Series 1.8 Litre VVC crankshaft durability. The software will be used to output the behaviour of the crankshaft under as realistic conditions as possible. The oil film thickness and bearing load characteristics of the crankshaft through the running range of the engine will be compared to results obtained from in-house software. The torsional and bending vibration output from ENGDYN will then be compared with results obtained from dynamic measurements. Finally, the crank stress and durability results from ENGDYN will be compared to strain gauge measurements at comparative points on the crankshaft. ENGDYN is a computer program used for analysing the dynamics of the engine, and in particular the crankshaft and its interaction with the cylinder block. In this analysis the software will be used to predict the time-domain response of the 3-dimensional vibration of the crankshaft coupled to the block by way of a non-linear oil film. When this loading and motion has been calculated the software can perform a fast Fourier transform to break down the time-domain response into its corresponding frequencies. This allows the results to be post-processed in the frequency domain. 2 Method of Analysis 2.1 Engine Specifications Configuration: in-line 4 Fuel: Gasoline Cylinder bore: 80 mm Piston stroke: 89.3 mm Swept volume: 1.8L Crankpin Peak Power: 107 KW @ 7000 rpm Peak Torque: 174 N/m @ 4500 rpm Engine running range: 750-7200 rpm 2.2 Component Modelling 2.2.1 Crankshaft To perform the analysis within ENGDYN two crankshaft models were created. These included a complete stiffness representation of the crank (excluding the crank nose hub and the flywheel), and a detailed model of the crank from main bearing 4 to main bearing 5, with mesh density increased around the fillets. ENGDYN can however perform crank analysis of any portion of the crank as long as the model incorporates at least two main journal bearings. Features such as bolt holes and oil drilling were omitted on both models, which were meshed using solid tetrahedral elements

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YUASA Battery Applications And Specifications

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Filed Under (Tips and Review) by admin on 13-11-2010

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Component Features Benefits Cast Grid Special Grid Design Severe vibration resistance & improved conductivity Active Material Proprietary Formulation Reduced shedding, maximum utilization, & long service life Pasted Plates Specified Thickness Ensures vibration resistance through & Weight precise compression & proper service life through specified active material balance Dried-Charged Tank Formed & Properly dried plates in a sealed battery Plates Dried Plates have a virtually limitless shelf-life, while still retaining 70-80% state of charge when initially filled with acid Top Lead Through-Partition Construction, Shorter current path for increased Connections Large Straps electrical conductivity & higher starting currents, heavier parts for maximum durability Case-Cover Thermal Bonded Plastic Air tight seal to prevent air ingress Seal & acid seepage Terminal- Cover Patented Poly-Seal Eliminates acid seepage, reduces Seal Terminal corrosion, & extends battery life Case & Cover Polypropylene Superior resistance to gasoline & oil, impact resistant in extreme weather conditions Additive Sulfate Stop Sulfate stop added to reduce the solubility (Some models) of lead into the acid, which then reduces battery sulfation potenti

Honda Motorcycle Digital Audio System Owner's Manual

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Filed Under (Honda) by admin on 22-11-2010

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Applicable portable audio unit A commercially available portable audio player with a stereo mini jack terminal can be connected to this accessory. (An attachment kit designed for the model is necessary to connect the portable audio player to this accessory.) American Honda Motor Co., Inc. recommends you use a shock-resistant portable audio player such as a flash-memory player (e.g. MP3, etc.) or an MD player equipped with sound skip prevention function. American Honda Motor Co., Inc. also recommends you always ride your motorcycle safely on paved roads, because sound skip can occur during riding on rough roads. Refer to the following instructions on storage and handling of the portable audio unit. This accessory is not designed to operate the portable audio unit connected to the accessory. Refer to the portable audio unit manufacturer’s Owner’s Manual for how to operate the portable audio unit and operate it accordingly. Note that the warranty of this accessory does not cover function and failure of the portable audio unit connected to the accessory 5 Storage of portable audio unit connected to this accessory After connecting the digital audio system, put the portable audio unit in a stable place where it does not interfere with riding the motorcycle (e.g. in the sold separately front pouch, tank belt pocket, etc.) in a place free from vibration as much as possible. Do not place the portable audio unit in your pockets or clothes while connected to this accessory. The portable audio unit can vibrate and contact other materials while riding, causing a sound skip. To prevent such skips, store the portable audio unit in a suitable place while protecting it from vibration and shock by covering it with cushioning material. (Protect the remote control and peripheral devices as well as the portable audio unit.) Any system failure and damage to the portable audio unit and its peripheral devices are not covered by the warranty of this accessory.

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KAWASAKI ZX1400 A6F/ B6F SPECIFICATIONS

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Filed Under (Kawasaki) by admin on 05-11-2010

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the all new 1352 cm3 engine is the most powerful production engine that Kawasaki has ever built. ! The engine is designed to deliver the perfect balance of power, torque and driveability. ! The torque delivery is very linear, so there is no powerband, as such, but riders will notice an extra push once the rev counter passes 6,000 r/min. ! The sheer amount of torque available makes pulling away in almost any gear possible (at 2,000 r/min the engine produces over 98 N. m of torque) . ! The layout of the engine was carefully designed to maintain a compact engine. The engine width is approximately the same as the ZX-12R. ! Gear driven secondary balancers virtually eliminate vibration for a smooth vibration free engine and aid rider comfort. FUEL SYSTEM ! Idle speed control system contributes to easy starting and ensures the catalysers reach their optimum operating temperature quickly. ! The fuel reservoir is located at the rear of the tank and extends below the seat, contributing to the centralised mass. TRANSMISSION ! Hydraulically operated clutch with a radial mounted clutch master cylinder for smooth clutch operation. CHASSIS ! The next generation aluminium monocoque frame is an advance on Kawasakiís unique ZX-12R frame. The aluminium box section runs over the engine minimising the width of the bike. Lightweight and very stiff, this sophisticated frame gives the bike both responsive handling qualities and incredible stability. ! Already more rigid than a twin spar design, with the engine solidly mounted the monocoqueís torsional rigidity is further increased. Using the engine as a stressed member allows the engineers to make the frame lighter. The air box and battery are housed inside the frame contributing to the compact layout. ! Our engineers made full use of the design freedom given to them by the engineís compact size. The engineís forward position in the frame, the wheelbase and front/rear wheel weight balance were all carefully chosen to achieve both high speed stability and lightweight, responsive handling. The wheelbase is shorter than the ZZR1200 but longer than the ZX-12R. SUSPENSION ! Inverted 43 mm front cartridge forks and Uni-Trak linkage rear suspension complement the highly rigid frame, offering both controllability at speed and superb road holding when sport riding. BRAKE SYSTEM ! Petal disc brakes, radial mounted front calipers and a radial mount front brake master cylinder ensure excellent stopping power and feel.