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SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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Moto Guzzi Breva V1100 Repair Manual

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Filed Under (Moto Guzzi) by admin on 18-11-2010

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1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated area. Never run the engine in an enclosed place. Use an exhaust emission extraction system when working indoors. DANGER Exhaust gases contain carbon monoxide, a poisonous gas which, if inhaled, may cause loss of consciousness or even death. FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine off. Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare flames, sources of sparks and any other source which may ignite fuel or lead to explosion. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped. Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down before proceeding. USED GEARBOX AND FORK FLUIDS DANGER Wear latex gloves when servicing. Prolonged or repeated contact with gear fluid may cause severe skin damage. Wash your hands thoroughly after handling. Dispose of it through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves when servicing. DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. BRAKE FLUID WARNING Brake fluid can damage plastic, rubber or painted parts. When servicing the brake system, protect all such parts with a clean cloth. Always wear safety glasses when servicing the brake system. Brake fluid is highly irritant. Avoid contact with the eyes. In case of contact with the eyes, rinse abundantly with cool, clean water and immediately seek medical attention. KEEP AWAY FROM CHILDREN

Moto Guzzi Sport 1100i Owners Manual

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Filed Under (Moto Guzzi) by admin on 29-11-2010

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General features Identification data Instruments and controls Riding your motorcycle Break-in Maintenance and adjustments Wheel removal Service schedule Cleaning – Storing Cleaning the windscreen Lubrication Valve gear WEBER injectionignition system (I.A.W.) Electrical equipment Wiring diagram Illustrations Lubrication Pressure fed by gear pump. Oil filters: wire mesh inside sump and replaceable cartridge filter outside sump. Normal lubrication pressure 3.8Ö 4.2 [5] kg/cm2, pressure valve, thermostat and cooler. Low oil pressure sensor (electrical) on crankcase. Generator/Alternator On front of crankshaft (1 4V – 25A). Ignition “WEBER MARELLI” electronic digital induced discharge, with high efficiency coil. Spark plugs: Spark plug gap: 0,7 mm. SPORT 1100 DAYTONA R NGK BPR 6 ESI NGK DR9 E IMS Starting Electric starter (12V-1,2 kW) with solenoid engagement. Ring gear bolted on flywheel. Starter button (START) on right of handlebars. Driveline data Clutch Twin driven plates, dry type, on flywheel. Hand controlled by lever on left of handlebars. Primary drive By gears. Ratio: 1 to 1.3529 (tooth ratio 17/23). Gearbox 5-speed, with constantly meshed gears with front dog clutch. Incorporated cush drive. Pedal operated on the left side of the motorcycle. Gear ratios: Low gear = 1 to 1,812 (tooth ratio 16/29) 2nd gear = 1 to 1,250 (tooth ratio 20/25) 3rd gear = 1 to 1 (tooth ratio 23/23) 4th gear = 1 to 0,833 (tooth ratio 24/20) 5th gear = 1 to 0,730 (tooth ratio 26/19) Ratio: 1:4,125 (tooth ratio 8/33) Overall gear ratios (Engine-wheel): Low gear = 1 to 10,1150 2nd gear = 1 to 6,9761 3rd gear = I to 5,5809 4th gear = 1 to 4,6507 5th gear = 1 to 4,0783 Frame Rectangular section single-beam in NiCrMo steel. Semisupporting engine base. Suspensions Front: White Power upside-down hydraulic telescopic fork with individually adjustable rebound and compression; Rear: steel swing arm with oval cross section. Single shock absorber White Power with separate adjustment of spring preload and of hydraulic rebound and compression damping. Wheels Light alloy castings with 3 hollow spokes (rear wheel with cush drive unit). Rim sizes: – front: 3,50x 17 MT H2 – rear: 4,50×17 MT H2 Tires -front: 120/70 ZR 17 – rear: 160/70 ZR 17 [160/60 ZR 17] Type: Tubeless Front: two Brembo drilled semi-floating disc brakes in stainless steel for SPORT I 100; [two Brembo drilled floating discs, Racing type for DAYTONA RS] with fixed 4 differential piston calipers. Adjustable manual control lever on the right side of the handle-bar; – disc 320 mm;

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MOTO GUZZI Quota 1100 ES Specifications And Owner's Manual

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Filed Under (Moto Guzzi) by admin on 25-11-2010

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Engine 4-stroke, twin cylinder Cylinder configuration: 90° V-twin Bore: 9 2 mm Stroke: 80 mm Capacity: 1064 cc Compression ratio: 9.5:1 Max. torque: Nm 85 (kgm 8.7) at 3,800 rpm Max. power: Kw 51 (CV 70) a 6,400 rev/min Timing system With rods and rockers and 2 valves per cylinder. One camshaft in the crankcase driven by duplex chain with automatic chain tensioner. Feed system Indirect electronic injection, timed sequential MAGNETI MARELLI IAW 15M “Alfa-N” system, single throttlebody, Weber IW031 injectors, electric pump with pressure regulator, digital control of optimized injection times. Lubrication Pressure fed by gear pump. Wire mesh and cartridge filters on oil sump. Normal lubrication pressure 3.8÷4.2 kg/cm2 (pressure valve on oil sump). Low oil pressure sensor (electrical) on crankcase. Generator / Alternator On front of crankshaft. Output power: 350W at 5000 rev./min. (14V – 25A). Ignition “MAGNETI MARELLI” Inductive discharge digital electronics. Spark plugs: NGK BPR 6 ES. Spark plug gap: 0.7 mm 2 ignition coils Starter Electric starter motor 12V-1.2 Kw with electromagnetic ratchet control. Ring gear on the flywheel. START « » push-button on right handlebar. Transmission Clutch Dry, twin driven plates. Located on engine flywheel. Clutch lever on left handlebar. Primary drive With helical gears, 1:1.3529 (Z=17/23). Gearbox 5-speed, front engaging, constant mesh. Incorporated Cush drive Control pedal on left side of machine. Gear ratios: 1st 1:2 (Z=14/28) 2nd 1:1.3158 (Z=19/25) 3rd 1:1 (Z=23/23) 4th 1:0.8462 (Z=26/22) 5th 1:0.7308 (Z=26/19) Final drive Cardan shaft with gears Ratio: 1:4.125 (Z=8/33) Overall gear ratios (engine-wheel) 1st gear = 1: 11.1618 2nd gear = 1: 7.3433 3rd gear = 1: 5.5809 4th gear = 1: 4.7223 5th gear = 1: 4.0783 Frame Double steel rectangular bar with double cradle

HONDA CB650/ 750F/ 900F/ 1100F/ GL1100 Spark Unit Set Installation Manual

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Filed Under (Honda) by admin on 05-04-2011

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INSTALLATION INSTRUCTIONS: 1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back to back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows: GREEN Ö GROUND (0 VOLTS) BLACK/WHITE Ö IGNITION SUPPLY (+12 VOLTS) VIA ENGINE STOP SWITCH YELLOW Ö IGNITION COIL OUTPUT (TO COIL —) WHITE Ö PULSE GENERATOR (WHITE RING) BLUE Ö PULSE GENERATOR (UNMARKED) There are two pulse generators, one for cylinders 1&4 and one for cylinders 2&3. The left hand one is normally for cylinders 1&4 (see fig.1). There are two wires of the same colour coming from each pulse generator, one of these wires is normally marked with a white band. The pulse generator wire with the white band connects to the white wire from the corresponding spark unit, the other pulse generator wire connects to the blue wire on the corresponding spark unit. If the white band is missing, this is normally the upper wire coming from the pulse generator. 9. Refit the seat and tank (if removed earlier). 10. Fitting is now complete, although for best results you may wish to verify the ignition timing, see the following guide

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Moto Guzzi Griso V1100 workshop manual

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Filed Under (Moto Guzzi) by admin on 27-11-2010

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DIMENSIONS Max. length 2260 mm (88.98 in.) Max. width 880 mm (34.64 in.) Max. height 1070 mm (42.12 in.) (excluding the rear/view mirrors) Seat height 800 mm (31.49 in.) Wheelbase 1554 mm (61.18 in.) Minimum ground clearance 185 mm (7.28 in.) Weight in running order 240 kg (529.1 lb) ENGINE Type twin-cylinder, 90° V transversal, 4-stroke engine Number of cylinders two Cylinder arrangement V, 90° Total displacement 1064 cu cm (65 cu in) Bore/stroke 92 x 80 mm (3.6 x 3.1 in). Compression ratio 9.6 : 1 Starting electric Engine idling speed 1100 ± 100 rpm Clutch dry, twin disc Lubricating system System under pressure, adjustment by valves and vane pump Air filter cartridge, dry Cooling system air cooled TIMING SYSTEM Timing diagram: 2 valves, with rods and rocker arms Values with inspection clearance between rocker arms and valve intake 0.10 mm (0.0039 in.) exhaust 0.15 mm (0.0059 in.) CAPACITIES Fuel (reserve included) 17.2 litres Fuel reserve 3.3 litres Engine oil Engine oil and oil filter change 3600 cu. cm (219 cu in) Gearbox fluid 500 cu cm (30.5 cu in) Transmission fluid 380 cu cm (23.2 cu in) Fork oil 520±2.5 cu cm (31.7 ± 1.5 cu in) (per leg) Seats 2 Max. vehicle load 210 kg (462.97 lb) (rider + passenger + luggage) TRANSMISSION SYSTEM primary drive gear, ratio: 24/35 = 1:1.4583 gearbox Mechanic, with 6 speeds, controlled by a pedal on engine left side overall gear ratios: 1st gear 17/38 = 1:2.2353 2nd gear 20/34 = 1:1.7 3rd gear 23/31 = 1:1.3478 4th gear 26/29 = 1:1.1154 5th gear 31/30 = 1:0.9677 6th gear 29/25 = 1:0.8621 final drive with cardan joint ratio 12/44 = 1:3.6667 FUEL SYSTEM Type Electronic injection (Weber – Marelli) with stepper motor Choke Ø 36 mm (1.417 in.) Fuel Premium grade unleaded petrol, minimum octane rating 95 (RON) and 85 (MON). FRAME Type Tube, with double cradle in high-strength steel Steering head angle 26°30′ Trail 108 mm (4.25 in.)

HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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HONDA CBR 600 RR AKRAPOVIC CARBON-FIBER PARTS installation instructions

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Filed Under (Honda) by admin on 03-11-2011

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INSTALLATION OF THE AKRAPOVIC CARBON-FIBER FRONT FENDER:
1. Make sure that the engine and the heated parts of the bike are cold before carrying out the following instructions.
2. Position the motorcycle on a side stand (we recommend a racing stand). Make sure, that surface is solid and flat.
3. Unscrew and remove bolts A on both sides of the motorcycle (Figure 1) ; unscrew the brake lines on both sides of
the motorcycle (Figure 2) and remove stock fender (Figure 3).
4. Reposition collars C and rubber mounts B (Figure 4, 5) from stock fender to Akrapovic carbon fiber fender
. Position the Akrapovic carbon-fiber fender in its location on the motorcycle, using stock bolts A (Figure 7, 8), re-
attach the brake lines on both sides of the motorcycle (Figure 9). Make sure that carbon-fiber fender is centered with
respect to the motorcycle and tighten bolts A securely

SANYANG HD 125/ 200 Specifications And SERVICE MANUAL

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

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heck and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom carburetor sufficient No fuel is supplied to carburetor Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. Perform cylinder compression pressure test. Check if sparks Weak sparks, no spark at all Low compression pressure or no pressure Re-start by following the starting procedures No ignition There are some signs of ignition, nut engine can not be started Remove the spark plug again and check it. Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1. No fuel in fuel tank 2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged. 3. Float valve clogged 4. Lines in fuel tank evaporation system clogged 5. Malfunction of fuel pump 6. Loosen or damaged fuel pump vacuum hose 7. Fuel filter clogged 1. Malfunction of spark plug 2. Spark plug foul 3. Malfunction of CDI set 4. Malfunction of AC generator 5. Ignition coil is in open or short circuit 6. Ignition coil leads open or short circuit 7. Malfunction of main switch 1. Piston ring seized 2. Malfunction of cylinder valves 3. Worn cylinder and piston ring 4. Cylinder gasket leak 5. Sand hole in compression parts 1. Malfunction of throttle valve operation 2. Air sucked into intake manifold 3. Incorrect ignition timing 1. Fuel level in carburetor too high 2. Malfunction of throttle valve operation 3. Throttle valve opening too wid

2006-2008 Honda TRX 450R SR4 4 Stroke Carbon racing system INSTALLATION

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Filed Under (Honda) by admin on 25-12-2011

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Removal of the stock exhaust, 1. Loosen stock tail pipe clamp (Fig 1) 2. Unbolt and remove stock muffler (Fig 2) 3. Remove stock header pipe (Fig 3) Installation Motoworks exhaust 1. Install Motoworks header pipe using stock nuts, finger tight at this point ( Fig 4) 2. Install Motoworks tailpipe with muffler using bolt and spacer supplied in kit on upper rear mount, use stock nut and bolt on lower mount finger tight at this point. (Fig 5 and 6) 3. Torque header pipe nuts to 1.0 kg-m ( 7.3 lb-ft ) 4. Torque tailpipe mounting bolts to 2.5 kg-m ( 18 lb-ft ) 5. Re-check all your work 6. We recommend that you clean the entire exhaust system with a mild detergent, i.e. glass cleaner prior to starting as any oily residue may cause permanent staining. 1 Instruction sheet 1 Stainless header pipe 50-1002A 1 Tailpipe with SR4 Carbon muffler 51-1002 1 8mmx1.25x65mm flange bolt 70-100-100 1 Aluminum spacer 8mmx7mmx32 SA4 1 Header pipe port flange PF8 1 Spark arrestor 75-100-01 2 Motoworks stickers 07-1002 1340 North Melrose Drive, Vista, CA 92083 Phone 951-587-9222 Fax 760-758-5991 Email: info@motoworks.com
7. Before operating check for proper clearance between Motoworks exhaust and ATV i.e. frame, plastic, brake line, fuel line etc if problems exist re-check work . Note: It is normal for the new exhaust to emit white smoke the first time you start the ATV. This is from the oil used during manufacturing.

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