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Sanyang JET 50/100 and JET Euro 50/100 Specifications And Service Manual

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Filed Under (Sym) by admin on 24-11-2010

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Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Used engine oil Caution Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off. Battery Caution y Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. y Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist. y If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor. y Keep electrolyte beyond reach of children. Brake shoe Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying. Caution Inhaling dust may cause disorders and cancer of the breathing system. Brake fluid Caution Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children

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Yamaha V-Star 650 REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 10-01-2012

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Instruction sheet 54-600 1 Front head pipe 54-600-01F 1 Rear head pipe 54-600-01R 1 Front heat shield 54-600-02F 1 Rear heat shield 54-600-02R 1 Outlaw muffler 50-103-127 1 Muffler bracket 54-600-40 1 Head flange 54-110-41 7 2″ standard hose clamps 70-100-35 2 1 3/4″ HD Hose clamp 70-100-37 2 5/16″-18 carriage bolts 70-100-10 2 5/16″-18 flange nuts 70-100-15 1 8mm x 1.25 x 25mm flange bolt for front head flange 70-100-09 2 8mm x 1.25 x 20mm bolts /muffler bracket 70-100-05 2 10mm x 1.25 x 35mm bolts 70-100-85 2 Spacer .250 x .438 x .875 50-100-74 2 8mm x 1.25 Flange nut 70-100-22
Disassembly 1. Remove both Allen bolts that hold the muffler together (Fig. 1) . Also Loosen clamp from the front muffler to front head pipe (Fig. 2) , and remove allen bolts from rear head pipe and remove in one peace carefully (Fig. 3) . Figure 1 Figure 2 Figure 3 2. Once the two mufflers are removed with the rear head pipe, remove bracket by removing two 8mm bolts as shown and remove bracket. (Fig 4) Figure 4
3. Remove spring from brake light switch to the brake rod located on the right side footrest. (Fig 5) Figure 5 4. Remove two bolts holding the footrest, and brake pedal (Fig. 6) . Carefully rest right side footrest on the floor or you can use a two by four to rest the footrest onto. Figure 6

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HERO HONDA CD-100 / SS100 / SLEEK / SPLENDOR / PASSION

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Filed Under (Honda) by admin on 14-11-2011

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1500 91255-169-003 30-42-11 FRONT FORK SEAL (S/S) (SLEEK) Improved Quality 200 20 PCS
1500A ————— SET OF 2 PCS FRONT FORK DUST SEAL (S/S) 100 10 PCS 1501 90756-198-000 7-37-7.5 FRONT FORK TRIPLE (COLLER) (CD-100) 200 20 PCS 1502 91202-302-01013.8-24-5 KICK SHAFT 200m20 PCS 1502A 91202-302-010m13.8-24-5+1514 KICK SEAL(SPL.GRADE O.E TYPE) MATERIAL WITH PUCH ROD RUBBER 100 10 PCS 1503 91205-350-000 6-25-6 CLUTCH 200 20 PCS 1504 91202-GK4-722 18.9-30-5 MAGNET
200

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APRILIA QUASAR 50-100-125-180 maintenance Manual

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Filed Under (Aprilia) by admin on 26-11-2010

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CHANGING ENGINE OIL CAUTION In case of oil leakage or malfunctions, contact an Aprilia Authorised Dealer . Do not dispose of oil in the environ- ment. Dispose of engine oil – stored in a sealed container – through the nearest waste oil reclamation firm or through the supplier. Carefully read page 34 (MAINTE- NANCE) To change engien oil: ◆ Ride for a few kilometres until engine reaches the operating temperature, then stop the engine. ◆ Position a graduated container (1), under the drain plug (2). ◆ Loosen oil filler plug (4) and drain plug (2). ◆ Let oil flow out of the sump. ◆ Loosen oil filter (3) and carefully clean it. ◆ Refit the filter and tighten fully. ◆ Tighten drain plug (2) and pour recommended oil into filler plug (4), see page 58 (LUBRICANT CHART). ◆ Tighten the filler plug. CAUTION Carefully tighten filler and drain plugs and ensure oil does not leak out. Periodically check for leaks at the casing cover gasket. Do not use the vehicle with insufficient lubrication or with contaminated or unsuitable lubricants, since this would cause early wear of the moving parts and may also cause irreparable failures Fluid reservoir (1) is under rear right wheelhouse. CAUTION Position the vehicle on firm and flat ground. ◆ Make sure that the fluid contained in the reservoir exceeds the ” MIN ” mark stamped on the reservoir. MIN = minimum level. WARNING Do not use the vehicle if the braking system is leaking fluid. CAUTION Do not use the vehicle if the fluid is below the “MIN” mark. 1
27 use and maintenance Quasar 50 – 100 – 125 – 180 CAUTION Brake fluid level decreases as the brake pads wear down. Should the level be too low: ◆ Check the brake discs and pads for wear, see page 27 (CHECKING THE BRAKE PADS FOR WEAR) If the pads and/or the disc do not need re- placing: ◆ Contact an Aprilia Authorised Dealer that will top up the fluid. WARNING Check the brake for proper operation. When the brake lever has exceeding travel or if you notice a loss of braking, contact an Aprilia Authorised Dealer . The braking system may need bleed- ing. CHECKING THE BRAKE PADS FOR WEAR Carefully read page 26 (BRAKE FLUID – recommendations) , page 26 (DISC BRAKES) and page 34 (MAINTE- NANCE). Periodically check brake pad wear. The rate at which brake pads will wear depends on vehicle usage, riding style and road surface condition. Outlined below is a quick brake pad inspection procedure: ◆ Visually check between brake disc and pads, check both pads (1) looking from the bottom at the rear end. ◆ Should friction material (of even one pad only) be worn down to 1.5 mm of thickness, have both pads replaced

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Bajaj Removing And refitting Automatic Cam Chain Tensioner

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Filed Under (Bajaj) by admin on 31-10-2010

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1. Remove the 2 Flanged Bolts securing the Tensioner Assembly. 2. Remove Tensioner Assembly from the engine block. 3. Unscrew and remove Lock Bolt. 4. Remove Pushrod, Ball & Retainer, Spring and “O” ring. Clean parts thoroughly and apply grease to the Balls & Retainer. Re-assembly procedure : 1. Place Spring on Pushrod and compress the spring beyond the hole in the Pushrod. 2. Insert a pin or wire into the hole in the Pushrod to hold the Spring in its’ compressed position. 3. Place Balls & Retainer onto Pushrod. 4. Insert Pushrod into the Tensioner body with the small flat on the Pushrod facing, and aligned with, the Locking Bolt hole. 5. Insert the Locking Bolt and tighten it against the small flat on the Pushrod to lock the Pushrod in the compressed position. Remove the pin that’s holding the Spring compressed. 6. Install the Tensioner assembly onto the cylinder block and install and tighten both Flanged Bolts. Be sure that the “O” ring has been installed at the base of the flange. 7.Looosen the Lock Bolt to release the Pushrod, then re-tighten the lock bolt

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TRIUMPH BONNEVILLE, T-100 BONNEVILLE AND THRUXTON 900 CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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REAR WHEEL REMOVAL- PAGE 14-14 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 2 allen-screws from rear seat section. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-13 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 Torx head screws– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-10 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove both rear tank-mounting bolts. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface

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Audiovox CCS-100 Cruise Control Installation Manual

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Filed Under (Tips and Review) by admin on 10-11-2010

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You can see where I drilled the holes to mount the bracket. (2566, 2567) You’ll have to bend the bracket to fit and reposition it on the servo (the extra holes are already there on the servo to move the bracket). Just bend it until it lays flat on the back of the plastic box. You’ll have to unbolt the two bolts that hold the plastic box in place to work on it. I made the hole in the front of the box (where the servo cable goes through) way too large, but I wasn’t sure what angle it would be at when I installed it, so I kept cutting it bigger so the cable wouldn’t be bent too sharp. (2565) I ran the servo cable along the top frame under the tank, around the front cylinder and into a bracket (that came with the unit) that I cut off to fit. I attached the bracket to the screw on the air cleaner, but you really have to do a lot of grinding on the bracket to get it to fit the area so that it will lay flat and tighten up with the screw. You’ll see what I mean when you put a piece of metal or bracket up to that hole. It’s not flat, so I used a moto-tool to cut slots in the bracket and a grinder to grind it down smaller so that it would fit in that area. I used the long “cable” and no bead chain to connect to the throttle. (2560) First take off your throttle grip and release the “pull” cable (the front one) so you can remove it from the carb lever. Then put the cable end over the throttle cable end and re-insert it, then re-assemble your throttle. Hook the ball on the end of the long cable (there are two or three cables in the kit, use the long one) to one of the bead chain connectors (you have to spread it first) and then close it back up. (2563) Spread the other end and hook it to the servo cable and then using your pliers, close it again. Ok, now you have the servo all hooked up. You’ll need a vacuum canister, which you can buy at JC Whitney, or make one from PCV pipe (2″) with caps. (2554, 2555) Drill two 5/16″ holes in the pipe, tap(1/8″) them and insert brass 3/16″ nipples for your vacuum hose. (2568) Hook the black of the Napa one-way vacuum check valve end up to your engine vacuum and the blue end to your canister. I disconnected the emissions canister from the cylinder number one intake. I then uncapped the vacuum tap on the number two cylinder intake and connected the two together with a “T” (from the kit) and the connected the remaining end of the “T” to the black end of the check valve. (2556) The other nipple on your canister gets connected to the servo (drill a whole in the bottom of the black box to run it in). Wiring: Drill a hole in the top of the black box to run the wiring harness out. I’d suggest you take a roll of electrical tape and tape it up first. Leave the black ground wire out of the tape and also leave the purple and red wires out of the taped area about 8″ or 10″ up from the servo. You’ll want them near the servo so you can cross them over the bike to the right side and hook the black wire directly to the negative side of the battery. The purple wire connects to the yellow brake light wire and the red wire connects to the blue wire, which is hot when the key is on. The rest of the harness you can run along the left side of the frame, using wire tires to tie it off. Leave the blue wire out of the harness as you get to the front cylinder (so you can hook it to the front coil), or you could use the back cylinder coil. You can make a little “Y” harness out of spade connectors (female on one end, and male on the other two ends) to join the blue wire to the coil. Use the gray wire on the front coil or the orange wire on the rear coil

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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HONDA XR 100 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 09-11-2011

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installation of a Baja Designs Dual Sport kit by itself does not make an off-road motorcycle street legal. Each state has different equipment requirements for street legal motorcycles, including but not limited to such items as DOT approved tires, left and right side mirrors, speedometers, quiet exhaust, chain guards, and side reflectors. Contact your state’s department of motor vehicles or highway patrol for a comprehensive list of equipment that is required for street motorcycles before riding your bike on the street

CCS- 100 ELECTRONIC CRUISE CONTROL INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 10-11-2010

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UNDER HOOD INSTALLATION Connecting the Cruise Control Cable to the Throttle NOTE: Prior to attaching servo cable to throttle, locate an accessible area to mount the cruise control servo, but do not mount it. Leave the servo in this area (unmounted) and route cable to throttle attachment area. CAUTION: Attach the cruise control cable so that it parallels the existing throttle cable as nearly as possible. Choose a mounting method from the figures below: Attachment area for securing cable Bead Chain Coupling Sleeve (#23) Bead Chain Coupling (#24) 3 BEAD CONNECTOR FIG. 6 FIG. 7 FORD LINKAGE ADAPTOR Rubber Ring WIRE LOOP FOR PULLEY Carburetor Existing Snap-On Throttle Arm On Vehicle FIG. 2 SNAP-ON THROTTLE ARM MOUNT FIG. 3 CLAMP-ON THROTTLE ARM MOUNT Determine a suitable point on the throttle linkage to mount the cable connector. The mounting point chosen should have between 1-1/2″ to 2″ total linkage travel. It must operate smoothly by hand. There should be at least 5 beads between the throttle connector and servo cable end. The cable must pull in a straight line from throttle linkage. Some vehicles that do not have enough total linkage travel have to be connected at the accelerator pedal. The bead chain and servo cable end must be inserted into the bead chain connector. Then the bead chain coupling sleeve must slide over bead chain connector to insure that the end will not hang in the connector. FIG. 1 Cable Bead Chain Eyelet Connector (#25) Pull off Throttle Arm and Insert Bead Chain Connector between it and Carburetor Arm. Be sure additional thickness of adaptor does not bind linkage. 20° Bead Chain Eyelet Connector (#25) Cable Must Be within 20° of same angle as Throttle Rod Throttle Cable Throttle Wire Loop (#29) Barrel Wire Adaptor (#30) WIRE BARREL FOR PULLEY FIG. 5 FIG. 4

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