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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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VICTORY BLACK LIGHT LEAK DETECTOR KIT

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

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AMMCO HONE KIT Rigid hone to correct tapered and out of round cylinders. Range: 47.6 mm – 69.8 mm (1 7/8″ – 2 3/4″). Contains 60 and 220 grit stones, driveshank with depth stop and metal storage box. Oversize stone kits increase range to 92 mm ( 35/8″). Replacement Stone Kits are shown below. All stones shown below are included in the kit including the new PU-49876. 2870304 – REPLACEMENT STONE KIT – 60 Grit (47.6 0 69.8mm) 2870305 – REPLACEMENT STONE KIT – 220 Grit (47.6 – 69.8mm) 2870306 – REPLACEMENT STONE KIT – 60 Grit (69.8-92.8mm) 2870307 – REPLACEMENT STONE KIT – 220 Grit (69.8 0 92.8mm) 2871536 – REPLACEMENT STONE KIT – 69.8 for Ni-Ca-Sil deglazing PU-49876 – 320 GRIT REPLACEMENT STONE SET 2870386 PISTON PIN PULLER Removes 18 mm piston pins from all Polaris pistons. Required for many Polaris puller attachments. Note: Some engines require adapters. Available Adapters: 2871342 2871445 2870390 PISTON SUPPORT BLOCK Safely supports piston while disassembling or assembling engine top end. 2870569 CRANKSHAFT TRUING STAND For holding crankshaft while checking runout for all Polaris engines. 2870588 HONING OIL 12 oz can with dispensing tip. Promotes better finishes, faster cutting and longer stone life. Engine VICTORY 83 PU-46219 OIL EXTRACTOR Used to draw the engine oil from the crankcase. PV-35457 BLACK LIGHT LEAK DETECTOR KIT The Black Light Oil Leak Detector provides an effective time saving method for pinpointing engine oil leaks. Simply add 1 oz. of fluorescent oil additive to the engine crankcase (6 – 1 oz. bottles included). Run the engine for ten minutes to circulate the fluorescent oil additive throughout the engine. Oil leak will fluoresce a bright yellow when illuminated with PV-35457 Black Light. Includes: Fluorescent Black Light PV-28431-6 Oil Additive (6) 1 oz. Bottles (available separately) PV-28431-6 – LEAK DETECTION DYE PV-35667-A CYLINDER LEAKDOWN TESTER PV-35667-A will test for worn piston rings, cylinder walls, valves, gaskets and any other related leakage problems. Uses shop air. M12 x 1.25 Adapter and instructions included. PV-39951-A ENGINE TACHOMETER This digital tachometer accurately measures engine RPM and maximum RPM of 2 or 4-stroke engines. The dual display allows for readings of current RPM alone or current and maximum RPM. Also features two maximum RPM memories for comparison

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MZ 125 SXJSM Repair Manual

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

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Front suspension · Design Telescopic fork · Spring travel 220 mm Rear suspension · Design long swinging fork · Spring travel/adjustment 220 mm/adjustable spring base Steering bearing Deep groove ball bearing Clutch lever and throttle twist grip · Play in the clutch lever 3-5 mmattheendofthe clutch · Play in throttle Bowdencable 2-3 mmatthetwist grip flange Wheels – spoked wheels Variant MZ125 8X Variant MZ125 8M Front tire 90/90 -21 110170-17 Tire pressure 190 kPa/1,9 bar/28 psi 180 kPal1,8 bar/26 psi Rim size 1.85×21 3.00 x17 Rim wobble limit vertical 0,5mm 0,5mm side 0,5mm 0,5mm Rear tire 120/80 – 18 130170-17 TIre pressure (value at perm. axle load) 200 (250) kPa/2 (2,5) bar/29 (36) psi 230 (260) kPal2,3 (2,6) bar/33 (66) psi Rim size 2.50 x18 3.50 x17 Rim wobble limit vertical 0,5mm 0,5mm side 0,5mm 0,5mm Front wheel brake · Design hydraulic single-disc brake with a two-piston floating caliper I and manually operated cylinder · Outside diameterxplate thickness 280x4mm · Thickness of the brake pad 5,Omm · Wear limit <2,Omm · Main brake cylinder inside diameter 11 mm · Brake caliper cylinder inside diameter 2×25,4 mm · Brake fluid DOT4 Rear wheel brake · Design hydraulic single-disc brake with a two-piston floating caliper and manually operated cylinder · Outside diameterxplate thickness 220x4mm · Thickness of the brake pad (wear limit) 5,Omm · Wear limit <2,Omm · Main brake cylinder inside diameter 13mm · Brake caliper cylinder inside diameter 2x 25,4mm · Brake fluid DOT4 Brake level and brake pedal · Play in brake lever 2-5 mmattheendofthe brake lever · Position of brake pedal 25 mmunderthe footrest rubber surface

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APRILIA SPORTCITY 125-200 Technical specifications

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Filed Under (Aprilia) by admin on 07-11-2010

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The engine and transmission assembly also acts as swing arm. Suspension is provided by two rear shock absorbers. Spring preload is adjustable for maximum efficiency under all load and road conditions. Rear wheel travel is 80 mm , more than enough to smooth out even the roughest surfaces. The SPORTCITY 250 i.e. is equipped with 15 inch wheels and large, high profile tubeless tyres (120/70 at the front and 130/80 at the rear). Rolling diameter is therefore equivalent to that of a 16 inch tyre but the ability to absorb shocks from rough road surfaces is far better, ensuring a superbly smooth ride. In conjunction with the excellent frame, this intelligent choice of tyres gives the SPORTCITY 250 i.e. excellent stability and the sort of intuitive feel that makes it a piece of cake to ride even for novices . The brakes are another of the strong points of the SPORTCITY 250 i.e. . The new system features triple discs for far shorter stopping distances and far greater active safety. Even inexperienced riders will have no trouble in pulling up well ahead of trouble. At 90 km/h the SPORTCITY 250 i.e. takes just 2.7 seconds to come to a full stop . The front brakes feature two 260 mm discs and floating calipers with two parallel pistons . The rear disc is a 220 mm unit with single piston caliper. Engine technology is another major plus point for the SPORTCITY 250 i.e. Its new electronic fuel injected engine is state of the art on the scooter scene . Powerful, flexible, and extremely low on emissions and consumption, this 250 cc single cylinder unit is perfect for the job in hand. Developing 22.5 HP at 8,000 rpm with 21 Nm of torque at 6,250 rpm, the engine delivers standard-setting performance . It also enables the Sportcity to function as a fun to ride sports scooter not only in town centres but on fast urban ring roads too. And the SPORTCITY 250 i.e. respects the environment wherever it goes, being one of the few scooters to conform to Euro 3 emission control standards. Finally, miserly fuel consumption and a generous 9 litre tank give the SPORTCITY 250 i.e. great autonomy . Engine Horizontal, single cylinder, 4 stroke. Forced liquid cooling with centrifugal pump. 4 valve head with overhead camshaft Fuel Unleaded petrol Bore and stroke 72 x 60 mm Displacement 244,29 cc Compression ratio 11:1 Maximum power 16.5 HP (22.5 kW) at 8,000 rpm Maximum torque 21 Nm at 6,250 rpm Fuel system Electronic fuel injection Ignition Electronic inductive discharge ignition with variable advance Starting Electric Alternator 300 W Lubrication Wet sump. Forced circulation with mechanical pump Gearbox Automatic torque converter Clutch Automatic centrifugal dry clutch Primary drive V belt Final drive Gearbox Frame Open cradle in high tensile strength steel Front suspension Hydraulic telescopic fork with 35 mm stanchions. Wheel travel 100 mm Rear suspension Engine unit acting as swinging arm. Double hydraulic shock absorber with adjustable preload. Wheel travel 80 mm Brakes Front: Twin ∅ 260 mm stainless steel discs. Twin piston floating callipers Rear: ∅ 220 mm stainless steel disc Wheels Light alloy Front: 2.75 x 15″ Rear: 3.00 x 15″ Tyres Tubeless. Front: 120 / 70 x 15″ Rear: 130 / 80 x 15″ Dimensions Maximum length: 1,985 mm Maximum width: 880 mm (at mirrors) Wheelbase: 1,360 mm Seat height; 815 mm Dry weight 148 kg Tank capacity 9 litres (reserve 1.5 litres) Colours Excalibur Grey, Shot Grey, Couture Blue, Moka Black Accessories 28 litre top box, 32 litre top box, 35 litre top box, large windshield, sports windshield, leg cover

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WAAREE A -1 4 T20W40 OIL 4 stoke Motorcycle Engine Oil

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Filed Under (Tips and Review) by admin on 16-11-2010

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APPLICATION •Designed for all high power 4 Stroke Motorcycle & Scooters •Recommended for use in 4 Stroke Motorcycles & Scooters of Hero Honda, Bajaj, TVS, Yamaha, Suzuki, LML & all other makes where OEM is recommending 20w40 Oil. BENEFITS •Excellent heat resistance capability to ensure more power for greater pick up •Excellent Enginecleanliness, outstandingthermal & oxidation stability to help fight deposit formation leading to longer drain intervals and excellent fuel efficiency. •Excellent Valve Train Wear Performance & High Temperature characteristics ensuring longer engine life •Excellent formulation to handle the different requirements of three critical zones of 4 stroke Motorcycle engines , Gear and Clutch. PERFORMANCE STANDARD •API SM*(*VTW ONLY) •JASO-MA2 TYPICAL PRODUCT DATA CHARACTERISTICS WAAREE A1 4T 20W40 KV, cSt @ 1000C 14.80 VI , min 115 Flash Point (COC) c0Min 236 TBN mg KOH/g Min 7.40 Pour Point 0 C Max -21 (These are typical figures and do not constitute a specification

Zen and the Art of Motorcycle Maintenance

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Filed Under (Tips and Review) by admin on 22-11-2010

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Pliers. It’s useful to have severaltypes of pliers. Basic pliers work in a variety of situations, but you’ll also need to get a pair of needle-nose pliers—the kind that look like they’re made from a hummingbird’s beak. These are useful when working in tight places and with small objects. I also like to have a pair of Channellock or adjustable pliers. I use these for everything from holding odd- size large bolts to removing oil filters when my filter wrench won’t fit. ◆ Oil-filter wrench. These wrenchescome in several varieties. Get one that best fits around your particular oil filter—that is, if your motorcycle has a spin- on filter. ◆ Soft-face mallet. You will sometimesneed it to convince an obstinate part to move. ◆ Lubricants. You’ll need to have some kind of penetrating spray lubricant on hand to loosentight bolts. If you have a chain-driven motorcycle, you’ll also need special cleaners and lubricants for your chain. ◆ Funnels. You’re going to need at least a few different-size funnels on hand. Get one small funnel for filling electrolyte in your battery, a larger one with a longer spout for filling oil, and a fairly large one with a screen in the spout forfilling gasoline. 220 Before you change your oil, make certain that you know where you can dispose of the used oil. It’s illegal and unsafe to dump the oil or spread it on a road. Some areas provide certified oil-recycling stations. Usually, service stations or drive-in oil-change places have large waste-oil storage capabilities. If you ask nicely down at the local Kwiki Lube, they may let you dump your waste oil in with theirs. Just remember not to make a mess and to clean up afterward, or you won’t be welcome back.

ATK 605 Enduro SPECIFICATIONS

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

Model : ATK 605 Enduro
Year : 2001
Category: Enduro / offroad
Rating : 75.3 out of 100
Engine and transmission
Displacement: 597.00 ccm (36.43 cubic inches)
Engine type: Single cylinder, four-stroke
Power: 48.00 HP (35.0 kW)) @ 7200 RPM
Bore x stroke: 97.0 x 81.0 mm (3.8 x 3.2 inches)
Valves per cylinder: 4
Fuel system: Carburettor
Gearbox: 5-speed
Transmission type,
final drive: Chain
Chassis, suspension, brakes and wheels
Front suspension travel: 300 mm (11.8 inches)
Rear suspension travel: 330 mm (13.0 inches)
Front tyre dimensions: 80/100-21
Rear tyre dimensions: 110/100-18
Front brakes: Single disc
Front brakes diameter: 260 mm (10.2 inches)
Rear brakes: Single disc
Rear brakes diameter: 220 mm (8.7 inches)
Physical measures and capacities
Dry weight: 127.0 kg (280.0 pounds)
Power/weight ratio: 0.3780 HP/kg
Seat height: 925 mm (36.4 inches) If adjustable, lowest setting.
Wheelbase: 1,498 mm (59.0 inches)
Fuel capacity: 16.00 litres (4.23 gallons)

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YAMAHA XT660R(W) XT660X(W) SUPPLEMENTARY SERVICE MANUAL

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

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CHASSIS SPECIFICATIONS Item Standard Limit Rear wheel Wheel type Spoke wheel —- Rim Size 17M/C × MT2.75 (XT660R) 17M/C × MT4.25 (XT660X) —- —- Material Aluminum —- Wheel travel 200.0 mm (7.87 in) (XT660R) 191.0 mm (7.52 in) (XT660X) —- —- Wheel runout Maximum radial wheel runout —- 2.0 mm (0.08 in) Maximum lateral wheel runout —- 2.0 mm (0.08 in) Wheel axle bending limit —- 0.25 mm (0.01 in) Front tire Tire type With tube —- Size 90/90-21M/C 54S, 90/90-21M/C 54T (XT660R) 120/70R 17M/C 58 H, 120/70ZR 17M/C 58W, 120/70ZR 17M/C 58W (XT660X) —- —- Model/manufacturer TOURANCE FRONT/METZELER, SIRAC/MICHELIN (XT660R) DRAGON/PIRELLI, SPORTEC M1/ METZELER, RADIAL PILOT SPORT/ MICHELIN (XT660X) —- —- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 210 kPa (2.10 kgf/cm, 30 psi) (XT660X) —- —- 90 (198 lb) ~ Maximum load* 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 220 kPa (2.20 kgf/cm, 31 psi) (XT660X) —- —- * Load is the total weight of the cargo, rider, passenger and accessories. Off-road riding 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) —- Minimum tire tread depth —- 1.6 mm (0.063 in)
- 7 – SPEC CHASSIS SPECIFICATIONS Rear tire Tire type With tube —- Size 130/80-17M/C 65S, 130/80-17M/C 65T (XT660R) 160/60R 17M/C 69H, 160/60ZR 17M/C 69W, 160/60ZR 17M/C 69W (XT660X) —- —- Model/manufacturer TOURANCE/METZELER, SIRACA/ MICHELIN (XT660R) DRAGON/PIRELLI, SPORTEC M1/ METZELER, RADIAL PILOT SPORT/ MICHELIN (XT660X) —- —- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 210 kPa (2.10 kgf/cm, 30 psi) (XT660X) —- —- 90 (198 lb) ~ Maximum load* 225 kPa (2.25 kgf/cm, 33 psi) (XT660R) 230 kPa (2.30 kgf/cm, 33 psi) (XT660X) —- —- * Load is the total weight of the cargo, rider, passenger and accessories. Off-road riding 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) —- Minimum tire tread depth —-

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ATK 450 MX SPECIFICATIONS

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

Model: ATK 450 MX Year: 2008 Category: Enduro / Engine and transmission Displacement: 449.00 ccm (27.40 cubic inches) Engine type: Single cylinder, four-stroke Power: 48.00 HP (35.0 kW)) @ 10000 RPM Compression: 12.3:1 Bore x stroke: 95.0 x 63.4 mm (3.7 x 2.5 inches) Fuel system: njection. EFI Fuel Injection Fuel control: DOHC Ignition: 12v Battery w Constant Energy Inductive Coil Cooling system: Liquid Gearbox: 5-speed Clutch: Magura Hydraulic Chassis, suspension, brakes and wheels Frame type: Aluminum Twin-Spar Front suspension: 46mm Ohlins 12” Travel Front suspension travel: 305 mm (12.0 inches) Rear suspension: Ohlins POS 12.6” Travel Rear suspension travel: 320 mm (12.6 inches) Front brakes: Single disc. Dual piston, 240mm Rotor Front brakes diameter: 240 mm (9.4 inches) Rear brakes: Single disc. Dual piston, 220mm Rotor Rear brakes diameter: 220 mm (8.7 inches) Physical measures and capacities Dry weight: 109.8 kg (242.0 pounds) Power/weight ratio: 0.4373 HP/kg Seat height: 965 mm (38.0 inches) If adjustable, lowest setting. Ground clearance: 361 mm (14.2 inches) Wheelbase: 1,486 mm (58.5 inches) Other specifications Starter: Electric

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DST-1200 WHEEL BALANCER INSTALLATION AND OPERATION MANUAL

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Filed Under (Tips and Review) by admin on 27-11-2010

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1. Remove the carton from the pallet. 2. Remove the shipping bolts making sure to keep hands clear of all pinch points. 3. Remove straps and plastic wrap holding the hood and tower in shipping position. z Do not use the control tower, face-plate, hood or threaded shaft to lift the balancer. z Use help to remove the balancer from the pallet. The unit is heavy and the weight is not evenly distributed. z Dropping the unit from the pallet may cause personal injury or equipment damage. Electrical Requirements YOUR MACHINE HAS A DUAL VOLTAGE MOTOR and can be run on either 110 or 220 volts. STANDARD WIRING IS 110 VOLTS. Your balancer features a dual voltage, (110/220volt) dual phase (50 or 60 HZ.) power system. Simply position the switch located at the back of the machine to the desired voltage setting then install a required plug if necessary

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