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2006 KTM 250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING, REPAIR MANUAL

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Filed Under (KTM) by admin on 05-05-2012

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Hot start lever (250 SX-F) If you pull the red hot start lever [1] 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.
ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXCUSA) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button (EXC) Pushing the black starter button [2] will actuate the E-starter. Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 2 3 4 5 6 Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on

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2007 KTM 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING INSTALLATION MANUAL

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Filed Under (KTM) by admin on 05-02-2012

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Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button Pushing the black starter button [2] will actuate the E-starter. Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on. ENGLISH 7 2 Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 3 4 5 6 1 OPERATION INSTRUMENTS » ENGLISH 8 TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21″ with production tires). Afterwards the display will return to the previous display mode

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Harley Davidson Big Twin EVO Engines Edelbrock Performer-Plus Camshaft , Performer RPM Camshaft , & Performer RPM Camshaft INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-03-2012

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Disconnect the battery. Secure the motorcycle on a suitable stand with the rear wheel off the ground. Remove components necessary for easy access to rocker covers, pushrod covers, and gear case cover, i.e., exhaust system, gas tank, air cleaner, foot rest, etc. Remove spark plugs. 2. Remove top and middle sections of rocker boxes, then rotate engine so both valves are closed on the cylinder head being worked on (put transmission in high gear and move rear wheel to slowly rotate engine). Remove the two 5/16″ bolts nearest the rocker arm shafts (keep all shafts, rocker arms, and pushrods in order so they can be installed in their original position). Remove the pushrod covers and pushrods. NOTE: The use of adjustable time-saver pushrods will simplify installation. Follow the manufacturer’s recommendations for installation of those parts. 3. It is not necessary to remove the tappet guides if you use a cam installation tool such as Crane #9-0020 to hold the tappets in place during cam installation. If you remove the tappet guides, you must use a tappet block alignment tool such as Crane #9- 0021 to re-install the tappet guides. Tappets can be held up in place during removal of guides by using U-shaped piece of safety wire or paper clip hooked to the tappets. 4. Remove ignition covers on gearcase cover by drilling out rivets to gain access to sensor plate. Remove the inner cover, sensor plate and rotor. NOTE: For re-installation, use new rivets H-D #8699 or drill and tap for 10-32 screws. 5. Remove the gearcase cover screws and remove cover while holding end of cam inward. Now remove the camshaft, spacing washer and thrust plate

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KTM 250 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING OWNER`S MANUAL

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Filed Under (KTM) by admin on 28-11-2010

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Digital speedometer, indicator lamps The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move. The engine must be started in order for the speedometer to be supplied with electricity from the generator. An impulse must be received from the wheel sensor to activate the display; the front wheel must turn at least one time. TEST All of the display elements will light up for 1 second for the function test. WS (wheel size) The display will change and briefly show the diameter of the front wheel in millimeters. If the front wheel does not turn, the display will automatically change to the SPEED/H mode. If the front wheel turns, the display will automatically change to the SPEED /ODO mode. SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. SPEED/ODO display mode The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode. The information will disappear in the display when the front wheel stops turning for 1 minute. NOTE: A Tripmaster switch (part no 583.14.069.244) is available as an accessory and enhances the electronic speedometer by providing the following functions: 2x Tripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles

Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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2008 KAWASAKI KX 250 F RACING AND EVOLUTION EXHAUST SYSTEM

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

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the Akrapovic Racing and Evolution complete exhaust systems are the flagships of our product lines. They are designed for competition-oriented MX riders who demand maximum performance from their exhaust systems. With their production quality, engine performance improvements and modern Hexagonal muffler design they satisfy the requirements of all riders. The systems are designed for two markets; in the US they are available with an approved spark arrester, and for the EU and other non-US markets they come with a noise damper. New for 2008 is additional chamber that helps to reduce noise emission and provides better power and torque at low rpm range. PERFORMANCE Measurements of the Akrapovic EVOLUTION system on the KAWASAKI KX 250 F (with muffler insert): Power & Torque: The Akrapovic Evolution and Racing systems deliver a performance increase throughout nearly the entire rpm range. It is most pronounced in the bottom and the top of the range. The systems deliver increased torque similar to the power increase. Max. increased power of 0.7 HP was measured at 12260 rpm, while max. power of 34.6 HP was measured at 11400 rpm. CONFIGURATION Akrapovic Racing and Evolution systems are of a recognised Hexagonal off-road form. They differ only in terms of the material of the pipe: we use stainless steel for Racing and titanium for Evolution. The header tube is conical, made from stainless steel (Racing) or titanium (Evolution) with additional chamber. It is jointed with a conical SS/titanium link pipe by a sleeve joint, which is secured with a silicon-shielded spring. The link pipe is welded to the muffler. The inlet cap, due to the method of connection with the link pipe, is made from stainless steel (Racing) or titanium (Evolution), same for the internal perforation. The outlet cap is made of carbon-fiber for evolution and composite polymer for Racing system. The outer sleeve of the muffler is available either made from titanium or carbon fiber. The system is attached to the motorcycle with the Akrapovic carbon fiber clamp. The Akrapovic carbon fiber heat shield is also intended for this system. The system comes with a built-in noise damper for the European and other markets, and an approved spark arrester for the American market, which is marked with a laser engraving

Kawasaki KVF650/ 700, KSV 700 Camshaft Installation Instructions

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Filed Under (Kawasaki) by admin on 29-04-2012

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Liberally apply assembly lube to every surface of the camshaft. Install the camshaft into the cylinder head (the lobes should be pointed down) and align the decompressor shaft dowels with the weight arms. Install one of the camshaft sprocket holder bolts and tighten to less than finger tight, you should be able to move the camshaft very slightly back and forth, roll the crank over until the other bolt hole is exposed and insert the sprocket bolt and tighten to less than finger tight. Install the cam chain tensioner assembly, do not install the spring, spring dowel, washer, and bolt. Using the spring from the cam chain tensioner very slowly push the tensioner shaft in until the cam chain slack has just been taken out, this is witnessed by the very slight lifting of the opposite end of the cam out of the cylinder head cam journal, do not over tighten the cam chain at this point, if you do, remove the tensioner assembly and retract the plunger again and start over. (If it stays too tight it will stretch the cam chain prematurely and cause cam sprocket damage when the engine is assembled) Roll the camshaft toward the back of the machine (clockwise) loading the sprocket bolts against the back of the sprocket bolt holes, while holding the camshaft in that direction, tighten the sprocket mounting bolt to 14 ft/lb of torque. Rotate the engine in the opposite direction that you rotated it earlier and align the TDC mark, tighten the other sprocket-mounting bolt to 14 ft/lb of torque. Verify the cam timing and crankshaft TDC marks are in alignment

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Fairing bodywork in glass-reinforced plastic Cruciata Racing

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Filed Under (Tips and Review) by admin on 27-10-2010

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The fairing bodywork that they have I use in contest is made in sturdy and flexible glass-reinforced plastic. The fairing bodywork in glass-reinforced plastic they succeed to replace the fairing bodywork originates them nearly perfectly, thanks to the predisposition holes. The greater part of the fairing bodywork in glass- reinforced plastic in production has the points of attachment with the moto reinforces to you in carbon on every attack with the chassis of the moto. Between the types of fairing bodywork and as point of reference between the fairing bodywork is as an example fairing bodywork it Cruciata Racing, worked always handicraft with passion for it gets passionate to it to you, which has enjoyed in particular way of the progresses and the evolution of the materials and the members. fairing bodywork the Cruciata Racing is constructed entire in woven of glass with reinforces in carbon in correspondence of the attacks to the motor and between the parts in glass-reinforced plastic. In the line racing standards are included plexiglass of height (to pierce), neoprene sponge cm 1,5 (supplied already sagomata). It fairing bodywork Cruciata Racing is which between the types of fairing bodywork is distinguished for its use, that is, this fairing bodywork is born and it is developed in order to answer carefully and to satisfy the requirements of the pilots. Fairing bodywork the Cruciata Racing in glass-reinforced plastic obviously is demanded for that it regards the sport within and the contests in track, because they are the only ones like characteristic to resist to the sollicitations impegnative thanks to theirs reinforces inner. Moreover to being resistant, these fairing bodywork offer to an optimal elasticity and lightness. Fairing bodywork the Cruciata Racing of sure the fairing bodywork better is produced with the best materials on the market. The fairing bodywork in glass-reinforced plastic they can be acquired crude, or can be painted and prepared in in professional way, applying all the processes of preparation that guarantee a final result of elevated quality, is from the aesthetic point of view, the point of view of the duration and from the point of view of I use it of the fairing bodywork.

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2009 Daytona 675 Motorcycle Race Kit Manual

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Filed Under (Triumph) by admin on 29-10-2010

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1. Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Position a piece of solder (with a diameter approximately 1.3 mm) on the four squish surfaces of each piston. Position the solder in line with the corresponding squish surfaces on the cylinder head and hold in place with a small amount of grease. 3. Refit the cylinder head with the head gasket. 4. Slowly turn the engine over, by hand, to compress the solder to the same height as the squish clearance. 5. Remove the cylinder head and head gasket. 6. Measure the compressed thickness of the solder. The squish clearance must be a minimum of 0.65 mm. If the thickness of the solder is less than 0.65 mm repeat steps 2 to 6 with a thicker head gasket until the squish clearance is at an acceptable level. NOTE •In some cases, it may be necessary to use a standard cylinder head gasket to achieve the correct squish clearance. 7. Fit the chosen cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Warning Running the engine at less than the minimum recommended squish height can lead to the pistons contacting the cylinder head, causing major engine damage. This could cause loss of motorcycle control and an accident. Triumph Designs Ltd 2009. Camshaft, Valve Spring & Camshaft Sprocket Kits Parts Supplied Camshaft, Inlet – A9618055 Camshaft, Exhaust – A9618056 Valve Spring Kit – A9618086 Camshaft Sprocket Kit – A9618095 Warning The Race Kit camshaft, valve Spring and camshaft sprockets must be fitted as a complete set. If they are not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.

2007 – 2009 KAWASAKI Z 1000 RACING AND EVOLUTION EXHAUST SYSTEM

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

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The Akrapovic RACING OPEN & EVOLUTION OPEN line is the highest level of Akrapovic exhaust systems and with hexagonal shaped muffler fits perfectly with the aggressive character of the ‘Z’. The conical tubing with interference crossover tubes between the header tubes work exceptionally well. With the Akrapovic exhaust system you will get massive power boost, more torque, a sportier sound and an even more aggressive top- level look on this muscular roadster. You can choose between classy titanium or carbon- fiber mufflers that stand out through their excellent quality. The systems are available in open version only. Besides great power and torque, you will also save in overall weight, as the Akrapovic system weighs 10.21 kg (RACING) or 11.5 kg (EVOLUTION) less than the stock assembly. PERFORMANCE Measurements of the Akrapovic RACING OPEN & EVOLUTION OPEN system on the Ka- wasaki Z 1000: The power curve shows a huge increase over the stock performance figures. It is much more linear, which means the engine is pulling strong and consistently right from the lowest rpm to the highest part of the overrev range. We measured a maximum increased power of 10.0 HP at 10270 rpm. The same goes for torque, which is also increased through entire rpm range. The drop-outs in the stock curve are filled and like the power curve, there is a major increase from 4000 rpm on. CONFIGURATION The configuration of the Akrapovic RACING OPEN & EVOLUTION OPEN system for the Z 1000 is 4-2-1, made of conical stainless steel or titanium tubes. The system includes interference crossover tubes between the header tubes, giving the Kawasaki increased performance characteristics. The muffler is available with either a titanium or carbon-fiber outer sleeve, attached to the motorcycle with an Akrapovic carbon-fiber muffler clamp. The individual elements of the system – header tubes, collector, link pipe and muffler – are connected with sleeve joints, secured with silicon-shielded springs.

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