bajaj re compact alternator

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BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

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Toyota Yaris 2006 up models 5 speed and Automatic Instruction Manual

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Filed Under (Toyota Manuals) by admin on 23-05-2011

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Using the ⑥ bolt (1) and #15 bracket spacer B (1), attach #5 alternator bracket as shown in illustration. Install the alternator upside down. Using the ⑧ head bolt (1) and washer (1), attach alternator to #5 Alternator Bracket.
6. Using ⑱ bolt (1) and ⑬ nut (1), attach the alternator on bottom alternator mount (lowest hole on Bracket A).
7. After installing alternator, make sure the A/C line does not interfere with belts. If it does, push the A/C line forward and make sure the alternator has enough clearance. ⑧Bolt Washer 8. Some models will have addition A/C lines near engine mount (not shown here). Please adjust A/C line to clear alternator pulley. Please find a suitable spot where the A/C line will not interfere with the pulleys and tie theline down with zip ties

HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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BMW Motorcycle R1100 RT R1100 RS R850/ 1100 GS R850/ 1100R Repair Manual

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Filed Under (BMW) by admin on 18-11-2010

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Engine Connection Nm Nm Oil filter Oil filter 11 11 Oil drain plug 32 32 Oil pump Mesh filter basket to engine block 9 9 Oil pump cover 9 9 Pressure relief valve 35 35 Oil pressure switch 30 30 Oil cooler Oil cooler pipe to engine block 10 10 Cooling oil line – banjo screw 25 25 Cooling oil line – banjo screw with oil vent valve 25 25 Oil lines to oil cooler 25 – Oil cooler to holder 9 9 Oil cooler return line to engine block 35 35 Oil cooler feed line to frame 20 20 Oil cooler feed line to engine block 25 25 Screw-in union for oil cooler connection at engine block 35 35 Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Oil cooler hose at oil thermostat – 40 Cylinders Tightening sequence M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18 Timing chain Chain tensioner 32 32 Connecting rod Big end cap Joint torque 20 20 Additional wrench angle 80° Crankcase Tightening sequence: M 10 screw (oiled) 45 45 M 8 screw (oiled) 20 20 M 6 screw Engine electrical system Connection Nm Nm Starter motor to engine 20 20 Starter cover to gearbox housing 7 – Positive lead to starter motor 10 10 Alternator to alternator support cover 20 20 Tensioning and retaining strap at alternator 20 20 Spacer at alternator 20 20 Positive lead to alternator 15 15 Belt pulley at alternator 50 50 Belt pulley to crankshaft 50 50 Poly-V belt preload 8 8 Spark plug 20 20 13 Fuel preparation and control Temperature sensor on engine block 25 25 16 Fuel tank and lines Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 18 Exhaust system Muffler to footrest 35 35 Manifold to cylinder head (with strap) 22 22 (with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50 Grease clamping face with Never Seez Oxygen sensor (lambda probe) to muffler 55 55 Grease with Never Seez

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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HARLEY DAVIDSON HIGH OUTPUT ALTERNATOR INSTALLATION MANUAL

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

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this kit is designed for use on 1980 and later FLT and FLTC models, 1982 and later FXR, FXRS, and FXRT models and 1984 and later FXRD, FLHT, FLHTC, FXRDG, FXRS-SP, FXLR, FLHS and FXRC model vehicles. This kit contains the following parts: QTY DESCRIPTION 4 Screw, sockethead torx 1 Ring terminal 6 Cable strap 1 Rotor assembly 1 Spacer, thick 1 Spacer, thin 1 Stator assembly 1 Regulator Installation 1. Refer to applicable Service Manual for detailed removal and installation procedures. 1 CAUTION Disconnect battery (negative cable first) before performing any electrical system servicing. 2. Observe the following guidelines to ensure proper operation. A. Do not drop or pound on the new rotor assembly. Permanent damage can result. B. Do not install a new style rotor with an old style rectifier. Permanent rectifier damage can result. C. Do not install a new style rectifier with an old style rotor. Permanent rectifier damage can result. D. Route the black rectifier wire away from hot or moving parts. Secure it to the frame with cable straps. Trim excess wire length, crimp on ring terminal and attach to positive battery terminal. 3. See Figure 1. When installing rotor and stator use thin spacer inside and thick spacer outside of rotor

BMW R1100 – R850R Maintenance Guide

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Filed Under (BMW) by admin on 27-11-2010

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R1100 Checklist – Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check battery acid level • Fuel filter (replace 24K) • Throttle body sync • Oil and filter (replace 6K) • Check transmission fluid level (replace 12K) • Check rear wheel drive fluid level (replace 12K) • Check tires and pressure • Check all nuts and bolts • Check all air and oil hose clamps • Check all lights PARTS – TOOLS Tools Parts Misc. sockets spark plugs compressed air wrenches oil filter anti seize torque wrench air filter carb cleaner hex sockets brake pads rag hex wrenches oil – 4 qt. BMW #10 grease feeler gauges gear oil – 1 1/4 qt. flexible tubing oil filter tool alternator belt (tygon) flashlight fuel filter, o-ring, clamps measuring cylinder crush washers Mityvac -3 small = trans.drain, rear drive fill and drain digital volt meter -1 medium = oil drain heat gun -1 large = trans.fill tire change tools 5 R1100 Maintenance Steps – Carl Kulow Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet” except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Check Alternator Belt remove four bolts holding black plastic cover(4mm hex), remove cover, check belt for cracks etc., check belt tension, replace belt every 36K miles, leave cover off for valve adjustment (see Jon Diaz “Alternator Belt Adjustment”)

KAWASAKI ZX1400 A6F/ B6F SPECIFICATIONS

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

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

Motorcycle Engine Guard Adjustable Light Housing

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

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ADJUSTABLE HOUSING This highly polished, adjustable aluminum housing provides a very attractive means of adding the safety of Cuda TriOptic LED lighting to the engine guards on your Police Motorcycle. This newly developed 2.5 X 5.5 inch housing comes mounted on a ball swivel and can be adjusted and tightened to point LED lighting in any desired direction. This compact housing fits conveniently into position on the engine guard and is available with an engine guard clamp in a 1.00 inch or 1.25 inch diameter, which fits the engine guards of most popular motorcycles. The entire assembly is constructed of a highly polished aluminum alloy which blends very nicely with the chrome trim and accessories that are common on most motorcycles. COMPACT , LOW PROFILE CUDA LIGHT Our Engine Guard housing contains a newly developed model of the popular Cuda TriOptic light series with six LEDs positioned in a low profile format. This light housing provides a more compact but equally penetrating light source as the larger Cuda models. BUILT IN FLASHER As is Standard with all Cuda TriOptic products, this model can be programmed, prior to installation, to flash any one of eight selectable flash patterns; making the need for an external flasher unnecessary. EFFECTIVE LIGHT OUTPUT Cuda TriOptic lighting incorporates third generation, high intensity LEDs for dramatically bright light output. This high output light power is further enhanced by specially shaped lenses to ensure superior on and off-axis light distribution for maximum visibility. LOW AMP DRAW In addition to being extremely bright, the LEDs significantly reduce power consumption – a critical concern for fully equipped motorcycles. The 351011 (2-up) model, that is contained in this light housing, draws 0.7 amps per unit. RELIABILITY Cuda TriOptic LEDs are rated for over 100,000 hours of useful life – compared to 2500-5000 hours for a typical halogen bulb. Plus, Federal Signal LED products come with a 5- year warranty, and meet SAE and CAC standards for radio frequency interference. See the back of this page for technical specifications and ordering information so you can start specifying Cuda TriOptic LEDs for your motorcycles today!

BMW Motorcycles F 650 GS/Dakar Driveability Issues

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

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Concern: Customer complains about hesitation, surging and stalling when the engine is operated at low to medium RPM. Service Measure: In the event of a customer complaint on the above concerns, please check the following points, adjusting to specification as necessary: Fuel pressure: Measure fuel pressure under all operating RPM. If fuel pressure is outside of specification, replace fuel filter with pressure regulator. Recheck fuel pressure, with new components installed, to confirm fuel pressure is to specification. Fuel pressure specification = 3.5+/- 0.2 bar Clutch adjustment: Clutch may not disengage completely with engine cold. Oil in the viscosity range 20W50 may be in use. Insure that the clutch is adjusted correctly and change oil to viscosity range 10W50. Control unit update: Using the BMWMoDiTeC CD 8/x, Update 3, update the programming of the BMS COMPACT control unit. The update of a BMS COMPACT control unit program is not to take place unless a customer has a complaint about hesitation, surging and stalling, these complaints have been verified by the retailer and the service measures covering fuel pressure, clutch adjustment and oil viscosity have been completed. Important Note: Always comply with the instructions, as included with the update CD, for the correct installation of CD 8/x, Update 3. Identification Label: Print a new identification label ( YELLOW for update ) and affix it to the BMS- COMPACT control unit. Please note that it is not permissible to deliver an updated motorcycle to a customer without the correct identification label affixed to the control unit.

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