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Harley-Davidson Valves, Guides And Seats Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1: Clean carbon from old guide O.D. before removal. 2: Guide to head press fit .0015″ / .002″ (head smaller than guide). 3: Heat head to approximately 200° – 250° F. 4: Install the guide at room temperature (Head hot & Guide at room temperature). 5: Let head cool to room temperature before final sizing of the bore. 6: Determine desired clearance valve to guide. Recommended clearance Shovel Head with cast iron guides Intake .001″ – .0015″ Exhaust .0015″ – .002″ (Ampco-45 add .001″) 7: Select the correct plug gage by adding the valve stem diameter and clearance desired for the finish diameter. 8: Select a plug gage .0005″ under finish size for the other end of the handle. 9: Finish hone the bore to size, check the size as you hone with the -.0005″ under size pin gage, finish hone to size with the finish plug gage pin. 10: Cut or Grind the seats, lap the valves to seats and check valve seat concentricity before assembling valve springs. 11: Use a good assembly lube, S’NS works great. 12: Use valve stem seals. Factory OE seals will stay tight with guide top size +.005″ to -.015″ from published size. 13: After the head is assembled and still on the bench check for any leakage valve to seat

KTM OM-2 Split Body Floating Ball Valves Installation and Maintenance Instructions

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Filed Under (KTM) by admin on 26-01-2012

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Remove the valve from the shipping package (box or pallet) with care taken to avoid any damage to the valve and actuator (plus accessories where applicable). •Before installation, remove the seal discs from the flange. Clean the inside of the valve using an air line that includes an appropriate air-filter. Ensure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on the valve seat. •Confirm that the materials of construction listed on the valve nameplates are appropriate for the service intended for and are as specified. When in doubt contact KTM, or your local Tyco facility. •Define the preferred mounting orientation with respect to the system pressure. The arrow on the body helps to identify the upstream side (high pressure) and downstream side (low pressure). •Ensure that all stud bolts and nuts of the body joint are firmly fastened. Caution •Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional. •See the Actuator User Manual for the actuator preparation. 2.2. Installation Instructions •Ball valves are normally installed in horizontal pipes with the stem facing up. However, there are no limitations regarding the pipe or stem orientation. •Unless otherwise recommended by KTM, the valve should be installed with the ball in the open position, to ensure that the seat rings are not damaged during installation. •Particular care should be taken for valves equipped with “fail-close” actuators. •For operating temperatures above 200°C (392°F), thermal insulation of the valve body is recommended to protect the actuator/accessories from heat beyond the recommended temperature range. •Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in points 1.2. and 1.3

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Basic Motorcycle Maintenance/ Repair Manual

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Filed Under (Tips and Review) by admin on 24-11-2010

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1. Types of Motorcycles and Components a. Identify off-road, street bikes, three and four wheel cycles. b. Identify motorcycle components. 2. Demonstrate Safe Working Habits in the Shop. a. Demonstrate, list, and discuss personal safety habits. b. Demonstrate, list, and discuss shop safety. 3. Correct use of Tools (common and measuring) and Equipment a. Perform work on cycles using proper hand tools. b. Perform work on cycles using shop equipment correctly. 4. Specifications in a Shop Manual a. Locate engine tune-up specification. b. Locate engine lubrication and cooling capacities. 5. Identify and Describe Different Types of Fasteners a. Threaded and non-threaded. b. Nuts, bolts, and washers. c. Metric and English. d. Strength and Grade. e. Thread inserts. 6. Identification and Description of Engine Fundamentals a. Basic two cycle engine. b. Basic four cycle engine. c. Displacement and compression ratios. d. Horsepower and torque. 7. Disassembly, Service, and Reassembly of the Components of the Clutch and Final Drive Assembly a. Remove, measure and replace clutch components. b. Clean, lubricate, and measure chain. c. Clean and measure sprockets. d. Adjust and align rear wheel. e. Discuss shaft drive. 8. Service of Brakes, Tires, and Wheel Assemblies a. Service and adjust drum brake. b. Service disc brake caliper. c. True a wheel by adjusting spokes. d. Replace or repair a tire. 9. Attitudes and Work Habits a. Identify and develop positive attitudes toward tasks and fellow employees appropriate for the workplace, including giving and accepting criticism and praise. b. Identify and develop productive work habits, including attending to detail, completing tasks, maintaining the work setting and recording data. c. Identify and develop collaborative/teamwork skills, including solving problems in groups, building consensus, and responding to supervision

1993 – 2008 Applicable Models ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION

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Filed Under (Toyota Manuals) by admin on 25-10-2011

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This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. Bank 1 (B1) refers to the bank that includes cylinder No. 1. Bank 2 (B2) refers to the bank opposite bank 1. Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. Sensor 2 (S2) refers to the sensor that is located after the catalytic converters

A750 Transmission Solenoid Identification Automatic Transmission/ Transaxle

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Filed Under (Toyota Manuals) by admin on 19-09-2011

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Provided below isachartlisting the Repair Manual name of each solenoid used in the A750 transmission, as well as the part name description provided in the electronic parts catalog. REPAIR MANUAL SOLENOID NAME PARTS CATALOGP ART DESCRIPTION S1 3WayTransmission Solenoid S2 Transmission Solenoid#3 SL1 Clutch Control Solenoid#1 SL2 Clutch Control Solenoid#2 SLT Line Pressure Control Solenoid SLU Lock UpControl Solenoid SR

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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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Basic Rotor Installation Instructions

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Filed Under (Tips and Review) by admin on 10-01-2011

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1. Take wheel off the bike. 2. Install rotors offset on the wheel. (refer to pictures below) 3. Replace the wheel on the bike keeping the axle, pinch bolts, and caliper bolts loose. 4. Begin to pump the brakes, applying the pads, making contact with the rotors. 5. While maintaining pressure, tighten the axle and all of the bolts. 6. This aligns the wheel, rotor, caliper, and pads to ensure optimum contact between rotor and pad. 7. Check that brake fluid level is not too high after install. 8. Make sure the wheel spins freely. 9. Bed in easily for first 100 miles.

HARLEY DAVIDSON TOURING MODEL BASIC SLIP ON'S INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 22-12-2010

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1. Remove both saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. 3. Working with one muffl er at a time, support the muffl er (assistance may be required) while removing the 5/16″ bolts from the saddlebag support and slide muffl er off of the head pipe. 4. Repeat the process for the opposite muffl er. NOTE: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe 1. Install the band clamps (supplied) over the front of each muffl er so that the bolt is to the inside and the nut is facing down (Figure 1). NOTE: New band clamps are supplied, do not use the old clamps. 2. Install muffl er by sliding it on to the head pipe and bolting it to the saddlebag support using the stock 5/16″ bolts. 3. Repeat installation procedure for opposite muffl er. 4. Align muffl ers and tighten hardware, beginning with the 5/16″ bolts on the mounting brackets followed by the Torca band clamp. Torque spec. is 40-45 Ft./Lbs. 5. Replace the saddlebags. 6. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up. 7. Be sure to tighten all hardware before starting your motorcycle

KAWASAKI TERYX EFI Installation And Removal Instructions

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Filed Under (Kawasaki) by admin on 06-05-2012

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1. The Stage IV controller can be mounted in numerous places. Placement depends on personal preferences. Only mount in locations where no damage may occur from sharp or hot objects. 4. Start the UTV and in approximately four seconds the lights on the Stage IV controller will be visible. With a proper install, you should see lights going from side to side on the controller. This will last approximately eight seconds and then will stop. After lights have stopped going side to side, you will notice a great light on the left side of the controller. When you rev the motor, lights will increase across the controller and even change colors. 5. Double check all fasteners and connections. 7. The Stage IV controller has been programmed for ultimate performance when using Trinity Racing’s Stage IV exhaust system and Powerflow intake system on an otherwise stock engine. Different products, modifications, or other conditions may require additional adjustments. Please refer to Basic Tuning Adjustments and all final fuel adjustments are the customer’s responsibility. 8. You are now ready to ride! Enjoy your new Stage IV fuel management controller! 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

CARBURETOR: BASIC PRINCIPLES

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

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On the right, the main components of a Dell’Orto motorcycle carburetor are shown: 1. starting lever; 2. air intake; 3. venturi; 4. starter jet; 5. float chamber; 6. atomizer; 7. fuel valve; 8. needle; 9. throttle valve; 10. float chamber air intake; II. fuel connection; 12. Idle mixture adjusting screw; 13. throttle valve adjusting screw; 14. float; 15. idle emulsion tube, 16.idle jet; 17. main jet. This is a diagram of the gasoline delivery in the inducted airflow: the fuel inside the float chamber rises in the atomizer (31), going through the jet (32) which adjusts the delivery together with the needle (28); the liquid is emulsified first with the air arriving from the channel (13) inside the nozzle (30) then going into the venturi (29) it mixes with the air coming from the intake