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HONDA ATV Carburetor Repair Kits Installation

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

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ATV Carburetor Repair Kits Complete kits to rebuild one OEM carburetor. Each kit contains necessary gaskets/o-rings, needle valve or needle valve set, and jets. Made in Japan. Note: Check all parts before installation. Honda Model Year Order No AT C70 78-85 025-001 AT C90 70-71 025-003 ATC90K1/K2/K3 72-75 025-003 AT C90 76-78 025-003 TRX90 Fourtrax 90 93-98 025-084 ATC110 79-83 025-005 ATC110 84-85 025-061 ATC125M 84-85 025-062 TRX125 Fourtrax 85-86 025-050 TRX125 Fourtrax 87-88 025-063 ATC185 1980 025-009 ATC185S 81-83 025-009 AT C200 81-82 025-008 AT C200 1983 025-009 ATC200E Big Red 82-83 025-064 ATC200ES Big Red 1984 025-064 AT C200M 84-85 025-064 AT C200S 84-86 025-065 AT C200X 83-85 025-012 AT C200X 86-87 025-014 TRX200 Fourtrax 200 90-91 025-066 TRX200D Fourtrax 200 Type II 1991 025-066 TRX200D Fourtrax 200 Type II 92-93 025-067 TRX200D Fourtrax 200 Type II 94-97 025-068 TRX200SX Fourtrax 87-88 025-069 ATC250R 81-82 025-017 ATC250R 83-84 025-018 AT C250R 1985 025-019 ATC250ES Big Red 85-87 025-029 AT C250SX 1985 025-070 TRX250 Fourtrax 250 1985 025-071 TRX250 Fourtrax 250 86-87 025-072 TRX250EX Sportrax 250EX 01-04 025-085 TRX250R Fourtrax 250R 86-87 025-060 TRX250R Fourtrax 250R 1988 025-073 TRX250X 91-92 025-074 TRX300 Fourtrax 300 1988 025-075 TRX300 Fourtrax 300 91-92 025-076 TRX300 Fourtrax 300 93-95 025-078 Honda Model Year Order No TRX300EX Fourtrax 300EX 93-98 025-081 TRX300FW Fourtrax 300 4×4 1988 025-075 TRX300FW Fourtrax 300 4×4 91-92 025-076 TRX300FW Fourtrax 300 4×4 93-95 025-078 AT C350X 1985 025-035 TRX350 Fourtrax 4×4 86-87 025-079 TRX350FE Fourtrax Rancher 4×4 ES 00-03 025-082 TRX350FM Fourtrax Rancher 4×4 00-03 025-082 TRX350TE Fourtrax Rancher ES 00-03 025-082 TRX350TM Fourtrax Rancher 00-03 025-082 TRX350D Fourtrax Foreman 4×4 87-89 025-079 TRX400FW Fourtrax Foreman 95-00 025-080 TRX450ES Fourtrax Foreman ES 98-01 025-083 TRX450FE Fourtrax Foreman ES 02-03 025-083 TRX450FM Fourtrax Foreman S 02-03 025-083 TRX450S Fourtrax Foreman S 98-01 025-083 TRX500FAFourtrax Rubicon 01-04 025-086

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DUCATI CLUTCH INSTALLATION INSTRUCTIONS

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

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When a vehicle is so equipped, the pilot must be replaced. The pilot is located in either the engine’s crankshaft or in the center of the flywheel. To remove a flywheel-fit pilot, remove the flywheel from the engine and drive or press out the pilot from the backside of the flywheel. Press or gently tap new pilot into flywheel after flywheel has been machined (where applicable). For crankshaft-fit pilots, an effective means for removal is to select a drift punch or wooden dowel that fits snugly into the old pilot. Then, pack the old pilot tightly with grease. Using the drift punch (or dowel) and a hammer, drive the grease toward the engine. The grease will not compress and will in turn push the old pilot out of the crankshaft. Install the new pilot carefully using a bearing driver. NOTE: Do not grease new pilots. New pilot bearings come pre-greased (often with special synthetic grease). Bronze pilot bushings have oil in the pores of the material that grease will clog. For bushings, a few drops of 30W oil can be used if desired. PRESSURE PLATE AND DISC Install flywheel (refer to flywheel section above) . Always tighten flywheel to crankshaft bolts in a star pattern to manufacturer’s torque specification. Before installing the disc, make sure that it slides smoothly on the transmission input shaft. Apply a thin coat of high temperature grease (such as wheel bearing grease) to the splines of the input shaft. DO NOT USE ANTI-SEIZE! It does not cling to rotating parts. Slide the disc back and forth on the input shaft and remove any extra grease that squishes out of the splines of the disc. Do not get grease or oil on the disc facing. Any grease or oil on a disc facing can be removed with alcohol or brake cleaner if done quickly. Lay the disc on the flywheel noting the flywheel side of the disc and hold it in place with the alignment tool. Clean the pressure ring of the pressure plate with brake cleaner to remove the rust inhibiting coating. Do not spray the entire pressure plate with brake cleaner as lube for internal parts will be removed. Set the pressure plate on the flywheel dowel pins (if equipped) and hand tighten the hold-down bolts. With hand tools, tighten pressure plate bolts ½ turn at a time in a star pattern until the manufacturer’s torque specification is met. Remove the alignment tool. NOTE: Different brands of the same pressure plate may have a difference in appearance and uninstalled lever height. These are not issues. Appearance can vary greatly and the installed lever height will be the same.

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HONDA VTX 1300 AND 1800 TRIKE CONVERSION KIT Owner's Maintenance Notes

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Filed Under (Honda) by admin on 17-02-2011

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 20-25 psi. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with 1 quart of SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. Check the oil level every 10,000 miles, or sooner if you experience leaks, and refill as necessary. Do not fill higher than the fill-hole. Change the differential oil every 30,000 – 35,000 miles. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Pads are Volkswagen Part # D101P. 6. Drive Train . If your driveshaft U-joint and/or spline are fitted with grease fittings, pump the fittings with wheel- bearing, graphite or high-pressure grease every 3000 to 5,000 miles. If yours does not have grease fittings then lubrication is not required. 7. Suspension System : The suspension system is designed to give you the best ride with a load of no more than 500 pounds (passengers plus cargo plus trailer tongue weight)

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HONDA GOLD WING GL1500 AND GL1800 TRIKE CONVERSION KIT Owner's Maintenance Notes

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Filed Under (Honda) by admin on 16-02-2011

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 20-25 psi. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with 1 quart of SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. Check the oil level every 10,000 miles, or sooner if you experience leaks, and refill as necessary. Do not fill higher than the fill-hole. Change the differential oil every 30,000 – 35,000 miles. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Pads are Volkswagen Part # D101P. 6. Drive Train . If your driveshaft U-joint and/or splines are fitted with grease fittings, pump the fittings with wheel-bearing, graphite or high-pressure grease every 3000 to 5,000 miles. If yours does not have grease fittings then lubrication is not required. 7. Suspension System : The suspension system is designed to give you the best ride with a load of no more than 500 pounds (passengers plus cargo plus trailer tongue weight): GL1500: The OEM adjustable air shock is used in conjunction with two (2) new Progressive 416 air shocks. The three shocks should be pressurized to about 20 psig, but to no more than 70 psig; GL1800: You can still use your OEM mono-shock pre-load adjustment. Your two (2) new coil-over shocks do not have an air system connection. However, there is a pre-load adjuster ring on each new shock that is factory-set at the “lowest” setting, for the softest ride. Changing this setting will result in a stiffer ride. 8. EZ-Steer (rake kit) : If your trike is equipped with Champion’s EZ-Steer, the bearings are a wear item. You should follow your motorcycle manufacturer’s recommended front-end triple-tree maintenance requirements. Generally these call for an initial service at 1,000 miles followed by periodic maintenance at 10,000 mile intervals. 9. Electrical : Your trike is pre-wired for a trailer connection. The harness is just below the trunk door on the underside of the body.

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HONDA GOLD WING GL1800 Independent Suspension Owner's Maintenance Notes

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Filed Under (Honda) by admin on 16-02-2011

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 23-27psig. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. If you want to check the oil level, do so by removing the fill plug on the top of the differential housing (Remove seat) and by using a suitable measuring device, the oil level should be 5 1/4″ inch down from the top of the differential housing. Refill as necessary. Change the differential oil every 30,000 – 35,000 miles by draining it and refill with 2 quarts of above gear oil.. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Rear brake pads are Volkswagen Part # D101P. 6. Drive Train . The rear driveshaft U-joint and slip yoke spline are fitted with grease fittings, pump the fittings with wheel-bearing, graphite or high-pressure grease every 3,000 to 5,000 miles. The front u-joint does not have grease fittings. 7. Suspension System : The suspension is a Double A-arm Independent suspension with a standard single setting anti-roll bar or an optional Variable Sway Control (VSC) which can be adjustment for optimal ride, handling characteristics and performance. The A- arms are equiped with bushings that does not require servicing. The suspension system is designed to give you the best ride with a load of no more than 600 pounds (passengers plus cargo plus trailer tongue weight): 8. EZ-Steer (rake kit) : If your trike is equipped with Champion’s EZ-Steer, the bearings are a wear item. You should follow your motorcycle manufacturer’s recommended front-end triple-tree maintenance requirements. Generally these call for an initial service at 1,000 miles followed by periodic maintenance at 10,000 mile intervals

YAMAHA ROAD STAR WARRIOR OIL COOLER KIT INSTALLATION MANUAL

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

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INSTALLATION: 1. See FIG. F: Apply a thin film of oil to O-RING (#9) on OIL COOLER MOUNT ADAPTER (#2). Install the OIL COOLER MOUNT ADAPTER with OIL COOLER SUMP STUD (#6). Note that o-ring on adapter is mounted against oil filter sump. TIP: Only tighten “finger tight” at this point so adapter can move as needed to adjust oil lines. 2. See FIG. G: Install OIL LINES (#3 & #4) to OIL COOLER and OIL COOLER MOUNT ADAPTER as shown. Do not tighten fittings yet. NOTE: The shorter 9-3/4″ OIL LINE will be on the TOP fitting on the ADAPTER. 3. See FIG. H :Install OIL COOLER to frame with the BILLET OIL COOLER CLAMP (#7). Adjust OIL COOLER to desired position and tighten the three 10-24 X 1/2 SOCKET HEAD SCREWS (#8) securely. Rotate the OIL COOLER MOUNT ADAPTER as necessary to align the Oil Lines properly. WARNING: Make sure OIL COOLER is moved outward far enough so that it does not contact the Front Fender when the fender goes through its full range of motion! 5. See FIG. I & J: Tighten the AN fittings on the OIL COOLER MOUNT ADAPTER as shown with an 11/16″ open end wrench. Tighten the AN fittings on the OIL COOLER with an 11/16″ open end wrench. TIP: To prevent the OIL COOLER from turning when the fittings are tightened, place a thin screw driver or long allen wrench between the fittings as shown. NOTE: DO NOT USE ANY SEALANT ON AN FITTINGS! 6. See FIG. K : Tighten OIL COOLER SUMP STUD (#6). Re-install oil filter. Start the engine and check for leaks. Check oil level and top-off as necessary. MAINTENANCE:

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

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harley davidson oil filter cooler installation instructions

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Filed Under (Harley Davidson) by admin on 10-04-2012

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2000 cH ROME 99 – 07 SOFTAIL MODELS #2001 CHROME 99 – 07 DYNA MODELS #2002 CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2005 black CHROME 99 – 07 SOFTAIL MODELS #2006 BLACK CHROME 99 – 07 DYNA MODELS #2007 black CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2020 REPLACEMENT OIL FILTER #’S: 2000, 2001, 2002, 2005, 2006, 2007 1. See Figure 1 to verify all Feuling components and the proper mounting bracket for your model 2. Wash, clean and inspect all new Feuling hardware, Including – off-set sandwich oil filter adapter, filter cooler housing and oil lines, use compressed air to blow dry the oil lines, fittings, threads and bolt holes. Use a tap and die if needed to clean threads. (On installation use lubrication on all fasteners and fittings) 3. Refer to the proper service manual for your model motorcycle & engine, for removal of engine oil and spin-on oil filter. Dispose of these items properly. 4. Clean engine case oil filter spigot and sealing surface thoroughly. 5. Install the clean Feuling off set oil filter sandwich adapter; both O-ring and gasket need to be assembled dry. 6. First install the inside half of the off-set oil filter adapter, O-ring side towards engine case filter mount. We recommend using a dab loctite on the 1″ lock nut. (See figure 2) It is recommend to mock up the sandwich adapter before torquing nuts and bolts to obtain desired orientation and proper clearance to engine case and frame rails. 7. Install the fittings and oil lines onto the outer half of sandwich adapter torque fittings to proper specs using thread sealant on the 1/8 NPT threads and engine oil on the -4 AN oil line fittings. 8. Complete installation of sandwich adapter, including the inner gasket. Finger tight the allen head bolts in an alternating sequence on both sides before final torque. Re-Torque the allen head bolts after the first heat cycle after installation and during every oil change.

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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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HARLEY DAVIDSON BRAIDED OIL HOSES INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery negative cable. 2. Drain engine oil according to Service Manual instructions. 3. Removing the rear exhaust pipe may aid in giving access to the oil lines and fittings. If necessary, remove the rear exhaust pipe according to Service Manual instructions. 4. See Figure 5 and Figure 1 for description and location of the three oil hoses that are replaced with the braided hoses in this kit. Remove the original equipment oil feed, return and vent lines. 5. See Figure 2. Remove and discard the original hex threaded quick disconnect fittings (1), (2) and (3) at the engine for each of the hoses removed in Step 4. To remove the fittings, turn the hex in a counterclockwise direction until free. 6. See Figure 5. Install the threaded adapter from the kit onto the corresponding oil line. The adapters for the return and vent lines are the same size. The adapter for the feed line is larger in size. Coat the male threads of the adapters with Loctite 565 thread sealant. NOTE Be sure to install hoses on the correct fittings. If you mix up the hoses, you will change the direction of the engine oil flow, causing severe engine damage. 2 3 1 is04165 1. Oil Return Hose 2. Oil Feed Hose 3. Oil Vent Hose Figure 1. Installed Oil Hoses

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