changing alternator onbmw r1200cl

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BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

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Toyota Yaris 2006 up models 5 speed and Automatic Instruction Manual

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Filed Under (Toyota Manuals) by admin on 23-05-2011

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Using the ⑥ bolt (1) and #15 bracket spacer B (1), attach #5 alternator bracket as shown in illustration. Install the alternator upside down. Using the ⑧ head bolt (1) and washer (1), attach alternator to #5 Alternator Bracket.
6. Using ⑱ bolt (1) and ⑬ nut (1), attach the alternator on bottom alternator mount (lowest hole on Bracket A).
7. After installing alternator, make sure the A/C line does not interfere with belts. If it does, push the A/C line forward and make sure the alternator has enough clearance. ⑧Bolt Washer 8. Some models will have addition A/C lines near engine mount (not shown here). Please adjust A/C line to clear alternator pulley. Please find a suitable spot where the A/C line will not interfere with the pulleys and tie theline down with zip ties

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HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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CHANGING OIL IN THE KAWASAKI VULCAN VN 2000

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Filed Under (Kawasaki) by admin on 16-12-2010

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CHANGING OIL IN THE KAWASAKI VULCAN VN2000 ( based on a 2005 model) by tensm an1 Preparing the motorcycle: 1. To start, level the motorcycle – my preference is to put a spacer blocks under the kickstand on the left side of the motorcycle and under the frame on the right side of the bike just under the frame member. These blocks are made from scrap lumber. I find it is easier to set the right side block first as shown and tilt the motorcycle until the frame contacts the block, then, holding the handlebars, kick the left side block under the kickstand. 6″ NOTE: This dimension may not be correct for 2004 models as the 2005 models have a different kickstand – the 2004 model will likely be thicker. To be sure your blocks are the correct thickness the first time, lay a level across the luggage rack as shown. You may need to shim them slightly to hold the bike dead level. 2 7/8″”
Or, in the absence of a luggage rack, the seat will do: 2. Get the necessary tools ready: Oil filter wrench – I like the band type shown, but a metal strap type will work. 14 mm box wrench

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BMW Motorcycle R1100 RT R1100 RS R850/ 1100 GS R850/ 1100R Repair Manual

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Filed Under (BMW) by admin on 18-11-2010

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Engine Connection Nm Nm Oil filter Oil filter 11 11 Oil drain plug 32 32 Oil pump Mesh filter basket to engine block 9 9 Oil pump cover 9 9 Pressure relief valve 35 35 Oil pressure switch 30 30 Oil cooler Oil cooler pipe to engine block 10 10 Cooling oil line – banjo screw 25 25 Cooling oil line – banjo screw with oil vent valve 25 25 Oil lines to oil cooler 25 – Oil cooler to holder 9 9 Oil cooler return line to engine block 35 35 Oil cooler feed line to frame 20 20 Oil cooler feed line to engine block 25 25 Screw-in union for oil cooler connection at engine block 35 35 Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Oil cooler hose at oil thermostat – 40 Cylinders Tightening sequence M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18 Timing chain Chain tensioner 32 32 Connecting rod Big end cap Joint torque 20 20 Additional wrench angle 80° Crankcase Tightening sequence: M 10 screw (oiled) 45 45 M 8 screw (oiled) 20 20 M 6 screw Engine electrical system Connection Nm Nm Starter motor to engine 20 20 Starter cover to gearbox housing 7 – Positive lead to starter motor 10 10 Alternator to alternator support cover 20 20 Tensioning and retaining strap at alternator 20 20 Spacer at alternator 20 20 Positive lead to alternator 15 15 Belt pulley at alternator 50 50 Belt pulley to crankshaft 50 50 Poly-V belt preload 8 8 Spark plug 20 20 13 Fuel preparation and control Temperature sensor on engine block 25 25 16 Fuel tank and lines Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 18 Exhaust system Muffler to footrest 35 35 Manifold to cylinder head (with strap) 22 22 (with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50 Grease clamping face with Never Seez Oxygen sensor (lambda probe) to muffler 55 55 Grease with Never Seez

how to Changing Oil and Filter BMW K75S

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Filed Under (BMW) by admin on 26-10-2010

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Put the bike on the centerstand and put a towel under the bike to keep the belly-pan from getting scratched. If you are lucky this is all you have to do; remove the two belly-pan screws and slide the belly-pan forward ever so slightly until it falls into your hands. However, this slightly more detailed method may be required. Remove the two socket head cap screws from the front of the pan. Loosen the two screws that hold the rear tang which in turn holds the rear of the belly- pan in place. The two screws up front face straight up, and will need to be removed by laying on your back with the business end of the allen wrench (5mm) pointing up into the air. The two in back are 8 mm, and also point straight up. Be careful to get the right ones: the two bolts that hold centerstand are near the bracket bolts, and their mistaken removal could leave you with a lap full of motorcycle. The two rear bracket bolts only need to be loosened to let the nose of the belly-pan drop enough to give you maneuvering room to remove it. With the two cap screws out of the front, slide the belly-pan forward and off the mounts. The tongue that engages the grommet at the front-top-center of the pan may not want to cooperate at first, and the pan itself may hit the lower fairing before the tongue disengages from the grommet. Wiggle it around and spring the pan enough to get it off the lower front mounts and it will drop off the top front mount on its own

HARLEY DAVIDSON HIGH OUTPUT ALTERNATOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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this kit is designed for use on 1980 and later FLT and FLTC models, 1982 and later FXR, FXRS, and FXRT models and 1984 and later FXRD, FLHT, FLHTC, FXRDG, FXRS-SP, FXLR, FLHS and FXRC model vehicles. This kit contains the following parts: QTY DESCRIPTION 4 Screw, sockethead torx 1 Ring terminal 6 Cable strap 1 Rotor assembly 1 Spacer, thick 1 Spacer, thin 1 Stator assembly 1 Regulator Installation 1. Refer to applicable Service Manual for detailed removal and installation procedures. 1 CAUTION Disconnect battery (negative cable first) before performing any electrical system servicing. 2. Observe the following guidelines to ensure proper operation. A. Do not drop or pound on the new rotor assembly. Permanent damage can result. B. Do not install a new style rotor with an old style rectifier. Permanent rectifier damage can result. C. Do not install a new style rectifier with an old style rotor. Permanent rectifier damage can result. D. Route the black rectifier wire away from hot or moving parts. Secure it to the frame with cable straps. Trim excess wire length, crimp on ring terminal and attach to positive battery terminal. 3. See Figure 1. When installing rotor and stator use thin spacer inside and thick spacer outside of rotor

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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BMW R1100 – R850R Maintenance Guide

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Filed Under (BMW) by admin on 27-11-2010

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R1100 Checklist – Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check battery acid level • Fuel filter (replace 24K) • Throttle body sync • Oil and filter (replace 6K) • Check transmission fluid level (replace 12K) • Check rear wheel drive fluid level (replace 12K) • Check tires and pressure • Check all nuts and bolts • Check all air and oil hose clamps • Check all lights PARTS – TOOLS Tools Parts Misc. sockets spark plugs compressed air wrenches oil filter anti seize torque wrench air filter carb cleaner hex sockets brake pads rag hex wrenches oil – 4 qt. BMW #10 grease feeler gauges gear oil – 1 1/4 qt. flexible tubing oil filter tool alternator belt (tygon) flashlight fuel filter, o-ring, clamps measuring cylinder crush washers Mityvac -3 small = trans.drain, rear drive fill and drain digital volt meter -1 medium = oil drain heat gun -1 large = trans.fill tire change tools 5 R1100 Maintenance Steps – Carl Kulow Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet” except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Check Alternator Belt remove four bolts holding black plastic cover(4mm hex), remove cover, check belt for cracks etc., check belt tension, replace belt every 36K miles, leave cover off for valve adjustment (see Jon Diaz “Alternator Belt Adjustment”)

BMW K1100LT/ RS Repair Manual

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Filed Under (BMW) by admin on 03-12-2010

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00.3 00 Tightening torque Model K 1100 LT K 1100 RS Connection Nm 11 Engine Freewheel Cover plate/freewheel cage at countershaft gear 10 Oil – water pump Oil pressure switch 40 Temperature sensor/screw plug 9 Pressure relief valve 40 Impeller 33 Pump housing to crankcase 10 Cover to pump housing 10 (3-Bond 1209) Intermediate flange Thrust plate at intermediate flange 9 (Loctite 243) Intermediate flange at crankcase 9 Crankshaft Pinion/rotor flange at crankshaft 50 Main bearing cap to crankcase 50 Connecting rod Big end cap Wrench angle 80 ° 30 Input shaft Front bearing 18 Rear bearing 40 Engine block Crankshaft cover 9 Lower part, outer 10 Oil sump 10 Oil filter cover 10 Oil drain plug 30 Cylinder head Cylinder head bolts (SI 11 062 95 (697) Short thread (from 6/93 to 11/94): Wrench angle, 1st stage Wrench angle, 2nd stage Long thread (since 12/94): Wrench angle, 1st stage Wrench angle, 2nd stage 64° 42° 75° 75° 22 20 Cylinder head cover 9 Camshaft Bearing cap 9 (Apply a thin coat of 3-Bond 1209 only at corners and butt edges) Chain sprockets 54 00.4 Timing chain Chain tensioner 9 Slide rail at camshaft bearing cap 9 Timing case cover Timing case cover 10 (3-Bond 1209) Cover for Hall-effect signal transmitter 9 Screw plug 40 Clutch Clutch housing to output shaft Tighten to Release and re-tighten to Wrench angle 50° 140 50 Housing cover 19 Alternator Alternator to intermediate flange 22 Driver 33 Starter motor Starter motor to gearbox 9 Mixture preparation Intake stub pipe 9 Fuel injection rail 9 Cooling system Coolant stub pipe at cylinder head 9 Temperature sensor at coolant stub pipe 30 Air cleaner Lower part of air cleaner housing 21 12 Engine electrical system Starter to transmission 9 Positive lead to starter 5 Alternator to intermediate flange 22 Clutch housing 50 Base plate 3,5 Setting ring 2,5 Hall generator cover 9 Ignition coils to intermediate flange 5 Spark plug 20 Model K 1100 LT K 1100 RS Connection Nm 00.5 13 Fuel preparation and control Injection rail 9 Intake stub pipe 9 Lower section of air cleaner housing 21 Intake air line 9 Motronic control unit 5 17 Radiator Connecting screw, temperature sensor 9 Fastening, thermostat cover 3 Radiator to frame 9 Coolant stub pipe to cylinder head 9 (with Loctite 243) Temperature sensor to coolant stub pipe 30 18 Exhaust System Exhaust system to cylinder head 21 Front silencer (muffler) 12 Exhaust system holder to footrest plate 33 Exhaust system to holder/footrest plate 9 Retaining bracket to gearbox 41 Oxygen sensor Hand-tight 21 Clutch Clutch housing to output shaft tighten to loosen and retighten to tightening angle 50° 140 50 Housing cover

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