adjust the choke on a suzuki 800 intuder

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Adjusting the Pekar K68 for Dnepr or Ural

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

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1. Make sure the ignition timing is correct 2. Adjust the valves as necessary to ensure proper operation 3. Run the engine to warm it up a bit 4. Adjust the float setting. To do this, remove the carburetors (leave the throttle cables attached), remove the bowl and turn the carburetor upside down (fuel will spill). The float should look like this: Adjust as necessary by bending the float support (#37 in Figure 1). Reinstall Installation and idle adjustment 1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns. * Starting using the K68′s (cold weather) 1. Verify fuel flow. Apply choke (pull 52 in Fig1). 2. Using the ticklers (13) allow fuel to enter the bowl until fuel drains from (14) 3. With the ignition off, kick 1 or 2 times 4. Turn ignition on, and as soon as engine is warmed up (maybe sooner) push choke mechanisms to open choke Idle Adjustment (engine running and warm) 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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SUZUKI 1400/ 800 INTRUDER TURN SIGNAL RELOCATION INSTALLATION AND CLEANING INSTRUCTIONS

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

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1. Refer to Figure 1. 2. Remove seat. Safety: disconnect battery prior to all wiring modifications LeatherLyke 510 5/1/2009 3. Disconnect wires to turn signals. 4. Remove turn signals and retain hardware for reinstallation. Observe and mark “left” and “right” for reinstallation. Information: Do not remove license plate bracket . 5. Remove license plate. Turn signal bracket must be oriented with flange (side with only 2 holes) on top. 6. Install turn signal bracket behind license plate bracket and license plate using 6 x 35mm pan phil machine screws for the 800 or 6 x 20mm pan phil machine screws for the 1400, 1/4″ flat washers, and 6mm locknuts. Insert black spacer spool between license plate bracket and turn signal bracket. 7. Mount turn signals directly to turn signal bracket using 6 x 10mm hex cap screws and star lock washer. Information: Observe all color-coding of wires and splice one wire at a time. 8. Cut each turn signal wires three inches from end and splice 10 inches of supplied wire. Secure wires to inner fender clips. 9. Follow route of tail light wires and connect wires into harness. 10. Secure wires together behind license plate bracket with tie wrap. 11. Connect battery and test turn signals for function. 12. Install seat. Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. WARNING: States may have minimum width requirements on motorcycle turn- signals, so check your local laws. LeatherLyke 510 5/1/2009 SADDLEBAG INSTALLATION 13. Refer to Figure 2. Information: Cover plates are pressed into strut. 14. Remove round cover plate at end of fender mount strut on right side. 15. Remove nut on right rear and replace with 1.2″ hex adapter. If hex adapter is less than flush with the outside of both fender struts, add a 5/16″ flat washer. 16. Assemble 5 x 30mm flathead screw and 5mm mounting spool with chamfer on spool under head of screw. Insert assembly thru 1 1/4″ fender washer for the 1400 or 1″ for the 800. 17. Install spool assembly into previously installed 1.2” hex adapter. Information: Do not remove washer on shock absorber. Hex adapter will protrude 1/4″ beyond fender strut. 18. Remove round cover plate over right rear shock, remove shock absorber nut and install .75″ hex adapter. 19. Assemble 5 x 30mm flathead screw, mounting spool and cup washer with chamfer on spool under head of screw. 20. Install spool assembly into previously installed hex adapter. 21. Insert 5/8” finishing plug into old turn signal hole on right side. 22. Repeat procedures on opposite side

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KAWASAKI TERYX EFI Installation Instructions.

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Filed Under (Kawasaki) by admin on 08-02-2011

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Basic Tuning Adjustments 1. The following instructions are for basic fuel tuning. Modes 1,2, & 3 are allowing adjustments to increase and decrease the amount of fuel the engine needs. Modes 4 & 5 are for advanced tuning only. DO NOT change modes 4 & 5 when doing basic tuning! 2. To help understand how these modes work, you can think of them as if you were working with a carburetor. 3. Remember each time you push the MODE button you will be advancing to the next mode. Push the MODE button once and you are now in mode 1, push the MODE button again and you are now in mode 2 and so on. You only need to be concerned with modes 1, 2 & 3 for basic tuning. Modes 4 & 5 are for advanced tuning ONLY. 4. If you need to go back to the settings that were pre programmed when you purchased the controller, just look at the picture in each mode, the colored square represents where the settings were when you purchased the controller. 5. Looking at the controller you will see eight lights with numbers under them, this is what you need to look at when changing settings. The #1 light on the controller represents the leanest setting. TRINITY RACING DOES NOT TAKE REPONSIBLITY FOR DAMAGES THAT MAY OCCUR DURING OPERATION OF YOUR VEHICLE UNDER IMPROPER JET SETTINGS. IT IS THE FINAL RESPONSIBLITY OF THE OWNER/RIDER TO ADJUST JETTING TO SPECIFIC RIDING CONDITIONS AND ELEVATION BEFORE RIDING. WARNING! 1.877.FAS TOYS 2.Remove both seats 6. Re-install engine cover and seats. 6. Mode 1 green light represents idle & cruise adjustment (i.e. pilot jet). To adjust this setting push the MODE button once and then push the plus or minus buttons to adjust fuel as needed. 7. Mode 2 yellow light represents an additional amount of fuel added during acceleration (i.e. needle position). To adjust this setting, push MODE twice and then push the plus or minus buttons to adjust fuel as needed. 12 34 56 7 8 12 34 56 7 8 8. Mode 3 red light represents more fuel being added during full throttle (i.e. main jet). To adjust this setting push the MODE button three times and then push the plus or minus buttons to adjust fuel as needed. 9. If you are confident about your tuning skills and feel you need to adjust other parameters, see Advanced Tuning. 12 34 56 7 8 Advanced Tuning Adjustments 1. Advance tuning has two modes in which to adjust. They are called mode 4 and mode 5. In basic tuning, you are changing the amount of fuel that the engine receives, but with advance tuning, you will be changing when the fuel will be available. In each mode you can adjust how soon the fuel delivery occurs. 2. Mode 4 yellow light and blue light represent when the fuel delivery is available during partial throttle acceleration. To adjust this setting, push the MODE button four times and then push the plus or minus buttons to adjust fuel as needed. Only the yellow light will be changing.

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SUZUKI VOLUSIA 800, C50, M50 Left/ Right Saddlebag Installation Manual

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Filed Under (Suzuki) by admin on 14-11-2010

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Your saddlebag supports will install in just a few minutes using common tools. Read all instructions carefully and completely before installing your new saddlebag supports. 1. Remove your stock fender rail bolts. 2. Install your Cobra saddlebag supports using the supplied 8mm x 65mm button head bolts (where the stock bolts were removed), the saddlebags should hang towards the rear and away from the motorcycle. 3. Torque bolts to factory specifications Cobra recommends you always wear a helmet while riding. Please never operate your motorcycle while under the influence of alcohol and/or drugs. Enjoy the new look of your motorcycle and please ride safely

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1994-2003 Suzuki GSXR750 and 1997-2004 Suzuki GSXR600 Superbike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 10-01-2011

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Step 1: Identify the key components that complete our Superbike kit: You should have 2 lines (front kit), 1 double banjo bolt and 2 lower adapters. There are also a total of 7 washers. 5 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. Inspect your brake system after every race. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. (See picture S4) Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt (see picture S5) is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, straight banjo (from right line), washer, 12-degree banjo (from left line), washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. ( See picture S6) Make sure that the 90-degree fittings on each caliper are pointing away from the bike just a little bit (see pictures S7 through S9 of calipers) . Thread each banjo end into the adapter, and torque to 6 ½ Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, we recommend using a zip-tie to bring the lines together about an inch above the lower triple clamp area. (Picture S10) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with DOT 4-brake fluid is recommended.

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Ural carburetors Installation and idle adjustment

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Filed Under (Ural) by admin on 02-11-2010

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1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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BMW Motorcycle F 650 GS/ F 800 GS Accessories

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Filed Under (BMW) by admin on 20-11-2010

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Stowage-equipment line Vario case, black, left 71 60 7 696 299 £184 / G Vario case, black, right 71 60 7 696 300 £185 / G (+) Case carrier for Vario case, including fasteners 71 60 7 696 301 £144 / G (+) Lock barrel, complete, for 2 cases 51 25 7 688 566 £20.80 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 2x) 51 25 7 681 199 £33.59 (o) Lock-barrel set 51 25 7 698 202 £15.20 / I Liner for Vario case, left 71 60 7 687 610 £67 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Vario topcase, black 71 60 7 696 302 £225 / I (+) Luggage rack, large, for Vario topcase (including adapter plate) 71 60 7 696 303 £64 / I (+) Lock barrel for topcase 51 25 7 688 568 £12.50 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 1x) 51 25 7 681 199 £33.60 / I (o) Lock barrels for 2 cases and topcase 51 25 7 688 567 £29.10 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Backrest pad for topcase 71 60 7 688 877 £45 / I Luggage carrier, small 71 60 7 701 810 £42.90 / G Tank rucksack, waterproof 71 60 7 711 240 £130 / I Enduro rear softbag 71 60 7 711 245 £35.90 / I Sport softbag, small, 19 l 71 60 7 694 117 £102 / I Sport softbag, large, 51 l 71 60 7 693 567 £139 / I Stuffbag, waterproof, 53 l 72 60 7 653 818 £90 / I Luggage strap with pull-tight buckle 72 60 2 304 808 £6.30 / E Bungee-cord spider 72 60 9 057 579 £3.95 / E Design line Spray-guard extension, rear 71 60 7 695 031 £24.20 / I Sound components Akrapović sports silencer 71 60 7 713 339 *1 £475 / G Ergonomics and comfort line Windscreen, large, tinted 71 60 7 713 834 *1 £138 / I Windscreen, large, clear (standard for F 800 GS) 71 60 7 713 833 £127 / I Windscreen, small, clear (standard for F 650 GS) 71 60 7 713 296 £87 / I Centre stand (F 650 GS) 46 52 7 700 864 *2 £83 / I Centre stand (F 800 GS) 46 52 7 700 049 *2 £91.50 / I (+) Fasteners for centre stand (F 650 GS + F 800 GS) 71 60 7 706 738 £24.90 / I Seat, low, black, 790 mm (F 650 GS), 850 mm ( F 800 GS) 52 53 7 695 013 £174 / I Heated handlebar grips and switches (see electronic parts catalogue) Navigation and communication components BMW Motorrad Navigator III plus 2008 72 60 7 716 116 *1 £650 / I (+) Holder for BMW Motorrad Navigator 71 60 7 697 785 £45.80 / E (+) Securing screw (order 4 of) 32 71 7 652 161 £4.55 / I Connecting cable for BMW Motorrad Navigator 71 60 7 686 670 £55 / E TMC module for BMW Motorrad Navigator 72 60 7 702 687 *1/3 £111 / E Car kit for BMW Motorrad Navigator 72 60 7 703 996 *3 £60.50 / E Navigator carry-bag function 71 60 7 683 161 £49 / I Safety line Hand-protector bar 71 60 7 716 043 £57 / I (+) Countersunk-head screw (order 2 of) 32 71 7 712 836 £3.34 / E Hand protector, small 71 60 7 705 963 £19.50 / I Hand protector, large 71 60 7 715 135 £23.10 / I Protector-mounted spoiler for hand protector, large 71 60 7 705 964 £15.20 / I Crash bar, left 71 60 7 699 437 £104 / I Crash bar, right 71 60 7 699 438 £104 / I (+) Fasteners for crash bar 71 60 7 702 395

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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SUZUKI PUTS THE 'STYLE' IN LIFESTYLE WITH CUSTOM ACCESSORIES INSTALLATION

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Filed Under (Suzuki) by admin on 14-02-2012

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Suzuki Genuine Accessories are available for the all-new Equator midsize pickup truck, four-door SX4 Sport, five-door SX4 Crossover, XL7 midsize crossover and rugged Grand Vitara. The accessories can be purchased through local Suzuki dealers. Suzuki Equator  All-weather floor mats – Rubberized all-weather mats, ideal for keeping dirt, moisture and harsh debris from coming in contact with the vehicle’s carpet interior.  Bluetooth® module – The Suzuki-integrated hands-free Bluetooth phone system features a clean installation, fresh look and works with most Bluetooth-enabled mobile phones. Quality sound plays through the vehicle’s factory stereo and speakers, and the phone system automatically mutes the radio during phone calls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)  Body side moldings – Durable polyurethane molding set helps protect exterior paint from door dings and road rash.  Hood mask – Durable vinyl, custom-fit mask helps protect the front end of the vehicle from damage caused by minor road debris.  iPod® interface kit – Provides a seamless connection from an iPod to the vehicle’s radio and/or steering-wheel audio controls. (Also available for SX4 Sport, SX4 Crossover, Grand Vitara and XL7.)

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