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Suzuki motorcycles VL800 procedures for its inspection/ service and overhaul of its main components

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

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GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION VL800K2 (’02-MODEL) FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (For USA and CANADA) 1.Use only unleaded gasoline of at least 87 pump octane ( ) method or 91 octane or higher rated by the Research Method. 2.Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible. 3.Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4.Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5.If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6.Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above

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1999-2002 SUZUKI SV 650 OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL, ENGINE OIL AND COOLANT RECOMMENDATION FUEL Your motorcycle requires regular unleaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method) . In some areas,the only fuels that are available are oxygenated fuels. Oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your motorcycle without jeopardizing the New Vehicle Limited Warranty or the Emission Control System War- ranty. NOTE: Oxygenated fuels are fuels which contain oxygen-carrying additives such as MTBE or alcohol. Gasoline Containing MTBE Unleaded gasoline containing MTBE (Methyl Tertiary Butyl Ether) may be used in your motorcycle if the MTBE content is not greater than 15%. This oxygenated fuel does not contain alcohol. Gasoline/Ethanol Blends Blends of unleaded gasoline and ethanol (grain alcohol), also known as GASOHOL, may be used in your vehicle if the ethanol content is not greater than 10%. Gasoline/Methanol Blends Fuels containing 5% or less methanol (wood alcohol) may be suitable for use in your motorcycle if they contain co-solvents and corrosion inhibitors. DO NOT USE fuels containing more than 5% methanol under any circumstances. Fuel system damage or motorcycle performance problems resulting from the use of such fuels are not the responsibility of Suzuki and may not be covered under the New Vehicle Limited Warranty or the Emission Control System Warranty . Fuel Pump Labeling In some states, pumps that dispense oxygenated fuels are required to be labeled for the type and percentage of oxygenate, and whether important additives are present . Such labels may provide enough information for you to determine if a particular blend of fuel meets the requirements listed above. In other states, pumps may not be clearly labeled as to the content or type of oxygenate and ad- ditives . If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel suppliers

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1999-2002 SUZUKI SV650 OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 12-12-2010

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Gasoline/Ethanol Blends Blends of unleaded gasoline and ethanol (grain alcohol), also known as GASOHOL, may be used in your vehicle if the ethanol content is not greater than 10%. Gasoline/Methanol Blends Fuels containing 5% or less methanol (wood alcohol) may be suitable for use in your motorcycle if they contain co-solvents and corrosion inhibitors. DO NOT USE fuels containing more than 5% methanol under any circumstances. Fuel system damage or motorcycle performance problems resulting from the use of such fuels are not the responsibility of Suzuki and may not be covered under the New Vehicle Limited Warranty or the Emission Control System Warranty . Fuel Pump Labeling In some states, pumps that dispense oxygenated fuels are required to be labeled for the type and percentage of oxygenate, and whether important additives are present . Such labels may provide enough information for you to determine if a particular blend of fuel meets the requirements listed above. In other states, pumps may not be clearly labeled as to the content or type of oxygenate and ad- ditives . If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel suppliers. d of. ; NOTE: • * To help clean the air, Suzuki recommends that you use the oxygenated fuels . • * Be sure that any oxygenated fuel you use has octane ratings of at least 87 pump octane ((R+M)/2 method) . • * If you are not satisfied with the driveablity or fuel economy of your motorcycle when you are using an oxygenated fuel, you should switch back to regular unleaded gasoline . • * If engine pinging is experienced, substitute another brand as there are differences between brands . A CAUTION Spilled gasoline containing alcohol can harm your motorcycle. Alcohol can damage painted surfaces. Be careful not to spill any fluid when filling the fue

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SUZUKI VX800 ENGINE MANUAL

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

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1. Use only unleaded gasoline of at least 87 pump octane by the F method or 91 octane or higher rated by the Research method. alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above COOLANT Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distrilled water only. WATER FOR MIXING Use distrilled water only. Water other than distrilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/COOLANT The coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the coolant should be used at all times even though the atomospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200NA anti-freeze/coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator

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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HARLEY DAVIDSON FLHX MIRROR COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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INSTALLATION 1. Remove the outer fairing using service manual instructions. 2. See Figure 1. Remove the mirrors (1) and retain the flange nuts (2) and plastic backing plates (3) securing the mirrors to the inner fairing. Do not heat or bake plastic parts after painting. Applying heat can damage plastic parts. (00615b) NOTE The adhesive will not bond correctly if it is applied at temperatures less than 50° F (10° C). 3. For primed/painted mirror kits: See Figure 2. Install mounting tape to the mirror covers as follows: a. Clean the tape mounting surface of the mirror cover (1) with alcohol pads provided. Allow to dry com- pletely. b. Get the primer tube and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the tape mounting surface of the mirror cover. c. Rub the adhesive backing of the mounting tape (2 or 3) to activate the adhesive then remove the backing. d. Install mounting tape to the mirror cover in the locations shown. Press tape and hold in place for 60 seconds. e. Repeat steps c and d and attach each piece of mounting tape to the mirror cover as shown, then repeat step 3 for the opposite mirror cover. 4. Clean the backside of the mirrors with the alcohol pads provided. Allow to dry completely. 5. Get the primer tube and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back face of the mirror. 6. Rub the adhesive backing on the backside of the mirror cover to activate the adhesive then remove the backing. 7. Place the mirror cover over the backside of the mirror and press into place for a minimum of 60 seconds. 8. Repeat steps 4 through 6 for the opposite mirror. 9. With the mirror post on the outboard side, place the plastic backing plate against the inner fairing engaging two holes in the washer with the threaded stud and index pin. The letters “L” or “R” are stamped on the backing plate posts to differentiate between the left and right side. Repeat for opposite mirror. 10. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 11. Install the outer fairing using the service manual instruc- tions

HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

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HARLEY DAVIDSON REAR BRAKE CALIPER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION Prepare the Motorcycle for Service To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Follow the Service Manual instructions to disconnect the negative (-) battery cable. Remove Rear Brake Caliper Remove the Brake Pads 1. For models equipped with saddlebags: Remove the right-side saddlebag. Refer to the SADDLEBAGS section of the Service Manual. 2. Remove the rear master cylinder reservoir cover. 3. Pry both the inside and outside pads away from the brake disc and toward the caliper assembly to push the caliper pistons back into their bores. Use steady pressure to prevent scoring the brake disc. Pry between the pads and the brake disc. 4. When the pistons are fully retracted into their bores, pull the pad pins out to allow the pads to drop from the caliper assembly. Note the pads’ original orientation for installa- tion. 5. Install the cover on the rear master cylinder reservoir. NOTE Place a container under the brake caliper to catch brake fluid released when removing the brake line from the caliper. 6. Remove the banjo bolt fastening the rear brake line to the stock rear brake caliper. Save the banjo bolt for brake caliper installation and discard the two steel/rubber gas- kets. Remove the Stock Rear Brake Caliper 1. Apply isopropyl alcohol to the rubber bumper on the brake caliper to ease removal. 2. Lift the stock rear brake caliper toward the front of the motorcycle. The notch in the caliper must clear the weldment on the swing arm. 3. Remove the caliper from anchor weldment on rear swingarm. Inspect Pad and Pins 1. Inspect the brake pads. If friction material above the backing plate on either pad is 0.040 in. (1.02 mm) thick or less, replace the set. Follow the instructions in the Service Manual. 2. Inspect pad pins for wear and grooving. If wear is more than 0.015 in. (0.38 mm), replace both pins. 3. Inspect the brake disc and, if necessary, follow the instructions in the Service Manual to replace the brake disc. Install the Rear Brake Caliper NOTE Pay close attention to all warnings, cautions, and torque specifications in this instruction sheet and in the service manual when installing this rear brake caliper. NOTE Apply isopropyl alcohol to the rubber bumper for ease of installation. 1. See Figure 1. Position the caliper (1) between the brake disc and the rear fork. The weldment on the fork should fit between the notch and rubber bumper on the caliper. Verify that the full length of the rubber bumper contacts the underside of the weldment

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HARLEY DAVIDSON FLHT RADIO AND GAUGE FACEPLATE TRIM INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 02-02-2011

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This kit fits 1996 and later FLHT models. Additional Parts Required The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE The instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents Table 1. Kit Contents Part Number Description 74612-06 Radio and gauge faceplate trim There are no Service Parts available with this kit. INSTALLATION NOTE Mounting surface of faceplate trim must be above 60°F (16°C), or the trim may not stay attached. 1. Using a 50:50 isopropyl alcohol/water solution, thoroughly clean the surface where the faceplate trim will be installed. Do not clean with denatured alcohol, mineral spirits, or other solvent products, or damage to the radio may occur. (00411b) 2. Allow the surface to dry completely before continuing to install kit. 3. Test the fit of the faceplate trim prior to removing adhesive backing. 4. Remove the adhesive backing from the back of the faceplate trim. 5. See Figure 1. Install the faceplate trim, locating it upward as far as possible. This position will align the opening in the faceplate trim with the indicator lights. NOTE If you do not position the faceplate trim properly, this may prevent proper clearances between the CD door and trim for 2006 and later models. 6. Let the adhesive cure for at least 24 hours at no less than 60°F (16°C). is01435 Figure 1. Indicator lights properly aligned through faceplate NOTE For models earlier than 2006, the installation is complete after the faceplate trim is installed.

HARLEY DAVIDSON CHROME FRONT BRAKE MASTER CYLINDER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. See Figure 2. Drain the brake fluid. a. Open bleeder nipple cap on front brake caliper. b. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. c. Open bleeder valve about 1/2-turn. d. Pump brake hand lever to drain brake fluid. e. Remove cover. f. Close bleeder valve. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 2. Remove bolt and 2 steel/rubber washers to disconnect fitting of hydraulic brake line from master cylinder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 3. 5/32 in. (4 mm) Cardboard Insert 3. See Figure 3. Place the cardboard insert between the brake lever and lever bracket. 4. Using T27 TORX® drive head, remove the 2 screws with flat washers securing the handlebar clamp to the master cylinder housing. Remove the brake lever/master cylinder assembly and clamp from the handlebar. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 5. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. 6. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE New master cylinder comes with all internal components preassembled. It is not necessary to remove the components from the bore of the old master cylinder. See Figure 9. Use denatured alcohol to clean clutch system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause clutch failure, which could result in death or serious injury. (00296a) 7. With denatured alcohol, clean and inspect all parts that will be reused. Replace as necessary and wipe dry with a clean lint free cloth

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