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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

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.

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

KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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2007 KTM 250 SX-F 450 SX-F INSTALLATION MANUAL

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Filed Under (KTM) by admin on 06-02-2012

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Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hot start lever If you pull the red hot start lever [2] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a “lean” fuel-air mixture of the type needed for hot starts. 2 1 A Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. OPERATION INSTRUMENTS »
Starter button (450 SX-F) Pushing the black starter button [3] will actuate the E-starter. ENGLISH 6 Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see “Maintenance”). Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open the filler cap: Turn the filler cap 45 ° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. OFF ON 1 A 2 3 ENGLISH 7 OPERATION INSTRUMENTS » Choke If you pull the choke button [1] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat” fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral is located between first and second gear. Kickstarter (250 SX-F) The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). Plug in stand The plug-in stand can be attached to the wheel spindle on the left side of the motorcycle

KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB:

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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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