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KTM Starter Gear Maintenance Instructions

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Filed Under (KTM) by admin on 26-11-2010

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Checking the electric starter motor for wear -Check Bendix 1 for smooth operation and signs of wear. -Check the sprocket of the electric starter for wear and radial clearance. -Replace O-ring 2 of the electric starter. -Replace gasket 3 . -Check starter idler gear 4 for smooth operation and wear, check that the bearing bushings are seated firmly. Electric starter motor – checking for and adjusting play -Mount the electric starter and the starter idler gear. -Mount the tighten cover 5 . -Move starter idler gear 4 back and forth in the direction of rotation, the maximum play may not exceed half the width of a tooth. -If play is larger, cover 5 must be removed and as many shims 6 with a thickness of 0.10 mm as necessary must be added to eliminate all play. Then remove one shim again. -Check the play again; the maximum play may not exceed more than half of the width of a tooth. 1 2 3 4 5 4 5 6

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1999 Toyota Camry LE V6 Body and Interior Maintenance Record

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Filed Under (Toyota Manuals) by admin on 03-10-2011

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Action Date Mileage Day Cost (with tax) By Interval Notes Oil and Oil Filter Change 8/30/1999 2494 Monday$77.97 Dealer 2494Non-synthetic 5w-30 (Toyota dealer stock) Oil and Oil Filter Change 10/31/1999 5484 Sunday $30 Owner 2988.5Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 12/30/1999 8460 Thursday$30 Owner 2975.9Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 2/21/2000 11414 Monday $30 Owner 2953.3Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 4/22/2000 14479 Saturday$30 Owner 3065.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 7/4/2000 17339 Tuesday$30 Owner 2860.1Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Air Filter – Replace 7/4/2000 17339 Tuesday$15 Owner 17339Purolator A24690 Air Filter Oil and Oil Filter Change 9/16/2000 20161 Saturday$30 Owner 2821.9Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Transmission Drain and Fill 10/27/2000 21913 Saturday$15 Owner 21913Drain and Fill 2.5 Quarts Mobil 1 Dexron III Synthetic ATF Transmission Drain and Fill 10/28/2000 21920 Sunday $15 Owner 7Drain and Fill 2.5 Quarts Mobil 1 Dexron III Synthetic ATF Oil and Oil Filter Change 11/19/2000 23066 Sunday $30 Owner 2904.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 2/11/2001 26062 Sunday $30 Owner 2996.1Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Transmission Flush 4/30/2001 28351 Monday$135 Dealer 2835113 Quarts Mobil 1 Dexron III Synthetic ATF – TransTech Flush Tires – Rotate 5/12/2001 28766 Saturday$0 Dealer 28766Tires – Rotate Coolant Flush 5/12/2001 28766 Saturday$112 Dealer 28766Toyota Red Coolant + MOC Flush (Extended warranty with service) Oil and Oil Filter Change 5/13/2001 28793 Sunday $30 Owner 2730.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Air Filter – Replace 5/13/2001 28793 Sunday $15 Owner 11454Purolator A24690 Air Filter PCV Valve – Replace 5/26/2001 31083 Saturday$10 Owner 31083Toyota OEM PCV Valve Windshield Wipers – Replace 5/26/2001 31083 Saturday$10 Owner 31083Windshield Wipers – Replace Oil and Oil Filter Change 5/27/2001 31296 Monday $30 Owner 2502.8Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 9/15/2001 34374 Saturday$30 Owner 3078.5Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Tires – Replace 9/28/2001 34784 Friday$431.23 Dealer 34784 (4) Bridgestone RE950 Tires (2 of original tires had tread separation – ~30% tread remaining) Oil and Oil Filter Change 11/12/2001 37365 Monday $30 Owner

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2008 KTM 250 SX-F 250 XC-F, XCF-W 250 EXC-F, EXC-F SIX DAYS INSTALLATION MANUAL

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Filed Under (KTM) by admin on 22-10-2010

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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”). 1 A Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 2 Headlamp switch (XCF-W) In this model the headlamp is switched on with the pull switch [5] . 5 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
OPERATION INSTRUMENTS » ENGLISH 7 1 2 3 4 5 Starter button Pushing the red starter button [1] will actuate the E-starter. Emergency OFF switch (EXC-F Australia) The red emergency-OFF switch [2] 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 [3] will actuate the E-starter. Indicator lamps The green control lamp [4] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [5] lights up when the high beam is on. TEST All of the display segments briefly light up for the display function test. Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The button is used to change between display modes. The + and – buttons are used to control various functions

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REMOTE ENGINE STARTER OWNER’S GUIDE

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Filed Under (Toyota Manuals) by admin on 16-06-2011

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The REMOTE ENGINE STARTER allows you to start your engine from outside the vehicle. It uti-
lizes your vehicle’s keyless entry remote, so there is no need to carry around an extra remote.
The REMOTE ENGINE STARTER is operated the same way for vehicles equipped with or without
the Smart Entry / Push Start system; simply push the remote’s LOCK button in a quick, two-
step sequence. In addition, the REMOTE ENGINE STARTER can activate the heater or air condi-
tioner according to your preset temperature controls, providing you with a comfortable cabin
upon entry. As an added convenience, the REMOTE ENGINE STARTER can also activate the
defroster (when preset) to clear up the windshield during cold weather

How to Replace your starter : 99 Corolla VE

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Filed Under (Toyota Manuals) by admin on 17-06-2011

Use a 10mm ratchet attachment to remove the battery from the vehicle. Negative terminal first, then positive. Be careful not to cause an arc between the two terminals as intense pain will result.
Remove the plastic plate that the battery sits in. 2. Using the 10mm attachment again, remove the 6 bolts that hold the passenger side front splash guard from underneath the front bumper. 3. From underneath the vehicle, locate the oil filter. Look above oil filter and you will see the starter. Locate the bottom 14 mm bolt that attaches the lower portion of the starter to the engine. The bolt drives from left to right. The starter is mounted toward the front of the vehicle and underneath the intake manifold. Still cant find it?
Follow the cable that leads from the positive battery terminal. It ends at the starter. Not sure you have the right bolt? Stick your 14mm attachment on it with your fingers and see if it fits on properly

MACHINE SPECIFICATION FOR 115cc (UNDERBONE) (4-stroke horizontal layout engine)

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Filed Under (Tips and Review) by admin on 12-12-2010

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(This is for clarification only. Other parts not listed in Art. 2.5 & 2.6 can be altered or replaced. Change of specification means modification, changes or removal of the parts.) 2.6.1 Change of compression ratio is allowed. 2.6.2 Setting of carburetor, attachment or size change of air funnel. 2.6.3 Inlet opening of fuel tank for fuel charge may be modified but cannot be relocated. 2.6.4 Change of fuel pipe and fuel cork. 2.6.5 Change of exhaust pipe and muffler, but must have silencer. 2.6.6 Material of clutch discs and specifications of spring. Hand clutch is allowed. 2.6.7 Gear ratios are free. 2.6.8 Starting device and parts relative to this device may be removed. 2.6.9 Modification or removal of air cleaner box, wire harness and control wires. 2.6.10 Removal of speedometer (including meter gearbox and cable.) 2.6.11 Removal of drive chain case and cover. Change of drive chain is allowed. 2.6.12 Change of final gear ratio is allowed. 2.6.13 Attachment of bead stopper and balance weight to tyre. 2.6.14 Modification and change of rear brake part is allowed. 2.6.15 Frame body may be strengthened. 2.6.16 Modification and change to brackets and pedals including footrest. 2.6.17 Front suspension unit must remain as originally produced by the manufacturer. However, the following internal parts of the fork can be modified: Shims, hydraulic piston, oil passages, springs and spacers. 2.6.18 Attachment of stabilizer to strengthen or reinforcing rear swing arm is allowed. 2.6.19 Removal of dust seals. 2.6.20 Rear suspension unit must remain as originally produced by the manufacturer. However rear suspension unit is free. The rear linkage must remain as originally produced by the manufacturer. 2.6.21 Handle bars, clutch and front brake lever may be changed by an after market copy. Clutch springs may be changed. 2.6.22 Steering dampers may be fitted. They must not act in any way as a steering lock limiting device. 2.6.23 Materials of streamlining and material of seat cowling. (However, expensive materials such as carbon fibre and kevlar are not allowed). 2.6.24 Removal of rear mudguard and side cover. Front mudguard may be cut but not less than 6 inches from the front fork on original part. 2.6.25 All lubricants are free 2.6.26 Adjusting and polishing any parts are allowed. Adjusting is defined as : “To select each part or assembly complete with-in the limit of single or total tolerance” (i.e. that of valve clearance, ignition timing etc.) 2.6.27 Cutting unnecessary stays is

HARLEY DAVIDSON XL STARTER MOTOR COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation 1. Remove exhaust system according to Service Manual instructions. 2. See Figure 1. Remove the outer primary screw shown and retain it for reinstallation. 3. See Service Parts Illustration. Insert the thread cleaning screw (9), through the primary cover and the crankcase until the full screw diameter protrudes through the crankcase. Remove any debris from from the tip of the thread cleaning screw. Remove thread forming screw and discard. NOTE If thread cleaning screw binds in crankcase hole, remove thread cleaning screw and chase threads with 1/4 – 20 tap. 4. Install set screw (8) from outer primary side using the wrench provided. Set screw should extend past the crankcase approximately .375″. 5. With wrench in set screw to prevent rotation, install the backplate over the set screw and fasten with the 1/4-20 nylock nut (5). 6. Reinstall the primary cover screw saved in Step 1. Torque to 80-110 in-lbs (9-12 Nm). 7. Remove the the oil hose clamp from the starter stud. Do not remove the clamp from the hoses. 8. Replace the original equipment starter stud with stud (7) provided. Torque to 39-65 in-lbs (4-7 Nm). 9. Install bracket (2) over stud (7) and fasten with #10-24 nylock nut (6). Rotate bracket until the tab on the bracket rests on starter motor. 10. Install oil hose clamp onto bracket (2) using one of the #10-24 screws (4). Tuck the hoses down as far as possible without contacting the drive belt or kinking the hose. Contacting the drive belt or kinking the hose may cause damage to the hoses or powertrain. 11. Install the cover (1) to the backplate (3) and bracket (2) using four of the #10-24 screws (4) with the wrench provided. The cover should fit inboard of the gear cover and partially on top of the sprocket cover. Start the bracket screw first, then follow with the (3) backplate screws. 12. Reinstall exhaust system according to Service Manual Instructions

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

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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2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

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