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HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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2010 CSR Naked 125 Engine and transmission Chassis, suspension, brakes and wheels

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Filed Under (CSR) by admin on 27-10-2010

Model: CSR Naked 125 Year: 2010 Category: Naked bike Rating: Price as new (MSRP): Euro 2199. Prices depend on country, taxes, accessories, etc. Engine and transmission Displacement: 124.80 ccm (7.62 cubic inches) Engine type: Single cylinder, four-stroke Fuel system: Carburettor Cooling system: Liquid Transmission type, final drive: Chain Chassis, suspension, brakes and wheels Frame type: Steel Front tyre dimensions: 90/90-13 Rear tyre dimensions: 130/90-15 Front brakes: Single disc Rear akes: Single disc Physical measures and capacities Dry weight: 161.0 kg (354.9 pounds) Weight incl. oil, gas, etc: 179.0 kg (394.6 pounds) Overall height: 1,085 mm (42.7 inches) Overall length: 2,110 mm (83.1 inches) Overall width: 650 mm (25.6 inches) Fuel capacity: 18.00 litres (4.76 gallons) Other specifications nStarter: Electric Color options: Black, silver Comments: Also called NKT 125. Spanish brand. Further information Parts and accessories Check out parts and accessories from our partners.nAsk questions Join the 10 CSR Naked 125 discussion group. Insurance, loans, tests Check out insurance here. Search the web for dealers, loan costs, tests, customizing, etc. Related bikes List related bikes for comparison of specs

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2008 KTM 125 SX, 144 SX, 250 SX OWNER'S MANUAL

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Filed Under (KTM) by admin on 25-11-2010

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Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: Press the release button [2] and turn the tank cap in a counterclockwise direction. To close it: Put the tank cap back on and turn in a clockwise direction until the release button snaps into place. Install tank breather hose [3] without kinks. 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. Choke knob When pulling the choke knob [4] fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This results in a rich fuel-air mixture, that is needed for a cold start. When pressing the choke knob downward in the carburetor, the bore is closed again. ON OFF 4 1 2 3 ENGLISH 7 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, or the idle speed, is located between first and second gear. OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). 1 N 2,3,4,5, (6) 2 3 1 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Turn the screw [1] clockwise to increase damping, turn it counterclockwise to reduce damping during compression. STANDARD ADJUSTMENT: -turn adjusting screw clockwise as far as it will go -turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 14187D01 . . . . .14 clicks Typ WP Suspension 14187D03 . . . . .14 clicks

HARLEY DAVIDSON PUSHBUTTON FUEL CONSOLE DOOR RELEASE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION 1. Open the fuel door. Remove and discard stock lock and nut. 2. See Figure 1. Install pushbutton lock (2) and nut (1) on fuel door. 3. Remove screws (A) and replace the stock hinge mounting clip with the hinge mounting clip (3) from the kit. Install stock screws. Do not over-tighten. 4. Close the fuel door. A small amount pressure will be needed to close the fuel door because it is now spring- loaded. NOTE To keep the pushbutton lock assembly operating smoothly, lightly spray lubricant on the mechanism as needed. SERVICE PARTS 1 2 3 B C A is05361 Figure 1. Service Parts: Console Pushbutton Fuel Door Release Table 1. Service Parts Part Number Description (Quantity) Item 84850-92 Nut, hex 1 Not Sold Separately Fuel release, pushbutton 2 10334 Clip, hinge mounting 3 Items mentioned in text, but not included in kit. Screw (2) A Hinge pin B Fuel door

Aprilia Sportcity One 125 Technical Specifications

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Filed Under (Aprilia) by admin on 06-11-2010

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Engine Single cylinder 4-stroke. Forced air cooling. 2 valve head with overhead camshaft. Fuel Unleaded petrol. Bore and stroke 57 x 48.6 mm. Displacement 124 cc. Compression ratio 12:11 (125 cc). Maximum power 7.0 kW (9.52 HP) at 8,000 rpm. Max torque 10.04 Nm at 7,000 rpm. Fuel system Carburettor, Ø 26 mm. Ignition Electronic inductive discharge ignition with variable advance. Starting Electric. Alternator 300 W. Lubrication Wet sump. Forced circulation with mechanical pump. Gearbox Automatic variator. Clutch Automatic centrifugal dry clutch. Primary drive V belt. Final drive Gearbox. Frame Single cradle frame in high strength steel tube. Front suspension Hydraulic telescopic fork with 32 mm stanchions. Wheel travel 85 mm. Rear suspension Engine unit acting as swingarm. Single hydraulic shock absorber with adjustable spring preload. Wheel travel 84 mm. Brakes Front: 220 mm stainless steel disc with twin piston floating caliper. Rear: 140 mm drum. Wheels Light alloy. Front: 3.00 x 14″. Rear: 3.50 x 14″. Tyres Tubeless. Front: 120 / 70 x 14″. Rear: 120 / 70 x 14″. Dimensions Overall length: 1950 mm. Overall width: 740 mm. Wheelbase: 1358 mm. Seat height: 775 mm. Fuel tank Capacity 7.5 litres (including 1.5 litre reserve)

2011 APRILIA RS4 125 Engine and transmission Specifications

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

Engine type: 1 cylinders, 4-stroke, Single
Displacement: 125 cc (7.64 cubic inches)
Bore × stroke: 58 mm × 47 mm (oversquare – shortstroke)
Cooling system: Water cooled
Power: 16.04 HP (11.8 kW)
Throttle: Cable operated
Valves
Valve train: DOHC, variable
Valves per cylinder: 4
Fuel and ignition
Sparks per cylinder: 1
Fuel supply system: Fuel injection
Ignition type: Digital CDI
Compression: 12.5:1
Engine mounting: Transverse
Lubrication system: Wet sump
Gear box: Manual 6-speed
Clutch: Wet, multiple discs, cable operated
Final drive: Chain
Starter: Electric
Dimensions
Physical measures
Length: 1953 mm
Width: 740 mm
Height: 1138 mm
Wheel base: 1350 mm
Seat height: 820 mm
Weight
Curb weight: 120 kg

APRILIA QUASAR 50-100-125-180 maintenance Manual

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

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CHANGING ENGINE OIL CAUTION In case of oil leakage or malfunctions, contact an Aprilia Authorised Dealer . Do not dispose of oil in the environ- ment. Dispose of engine oil – stored in a sealed container – through the nearest waste oil reclamation firm or through the supplier. Carefully read page 34 (MAINTE- NANCE) To change engien oil: ◆ Ride for a few kilometres until engine reaches the operating temperature, then stop the engine. ◆ Position a graduated container (1), under the drain plug (2). ◆ Loosen oil filler plug (4) and drain plug (2). ◆ Let oil flow out of the sump. ◆ Loosen oil filter (3) and carefully clean it. ◆ Refit the filter and tighten fully. ◆ Tighten drain plug (2) and pour recommended oil into filler plug (4), see page 58 (LUBRICANT CHART). ◆ Tighten the filler plug. CAUTION Carefully tighten filler and drain plugs and ensure oil does not leak out. Periodically check for leaks at the casing cover gasket. Do not use the vehicle with insufficient lubrication or with contaminated or unsuitable lubricants, since this would cause early wear of the moving parts and may also cause irreparable failures Fluid reservoir (1) is under rear right wheelhouse. CAUTION Position the vehicle on firm and flat ground. ◆ Make sure that the fluid contained in the reservoir exceeds the ” MIN ” mark stamped on the reservoir. MIN = minimum level. WARNING Do not use the vehicle if the braking system is leaking fluid. CAUTION Do not use the vehicle if the fluid is below the “MIN” mark. 1
27 use and maintenance Quasar 50 – 100 – 125 – 180 CAUTION Brake fluid level decreases as the brake pads wear down. Should the level be too low: ◆ Check the brake discs and pads for wear, see page 27 (CHECKING THE BRAKE PADS FOR WEAR) If the pads and/or the disc do not need re- placing: ◆ Contact an Aprilia Authorised Dealer that will top up the fluid. WARNING Check the brake for proper operation. When the brake lever has exceeding travel or if you notice a loss of braking, contact an Aprilia Authorised Dealer . The braking system may need bleed- ing. CHECKING THE BRAKE PADS FOR WEAR Carefully read page 26 (BRAKE FLUID – recommendations) , page 26 (DISC BRAKES) and page 34 (MAINTE- NANCE). Periodically check brake pad wear. The rate at which brake pads will wear depends on vehicle usage, riding style and road surface condition. Outlined below is a quick brake pad inspection procedure: ◆ Visually check between brake disc and pads, check both pads (1) looking from the bottom at the rear end. ◆ Should friction material (of even one pad only) be worn down to 1.5 mm of thickness, have both pads replaced

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APRILIA ATLANTIC 125 – 200 REPAIR/ SERVICE MANUAL

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Filed Under (Aprilia) by admin on 19-11-2010

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DISASSEMBLING THE COMPONENTS – Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use a suitable spanner. – Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention. – Mark each part clearly to avoid confusion when refitting. – Thoroughly clean and wash any components you have removed using a detergent with low flash point. – Mated parts should always be refitted together. These parts will have seated themselves against one another in service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting. – Certain components are matched-pair parts and should always be replaced as a set. – Keep the motorcycle and its components well away from heat sources. ELECTRICAL CONNECTORS To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to irreparable damages to the connector and the wiring as well. If present, press the special safety hooks. ENGINE OIL DANGER Prolonged or repeated contact with engine oil may cause severe skin damage. Wash your hands thoroughly after handling engine oil. Do not release into the environment. Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves during servicing. Change engine after the first 1000 km (621 mi) and then every 6000 km (3728 mi), 2.11.2. (Recommended) oil fork , see 1.8.1. FRONT FORK OIL DANGER Modifying the suspension settings or the viscosity of the front fork oil will affect its response. Standard oil viscosity: SAE 20 W. Choose the oil viscosity to determine the type of response required (SAE 5W for a softer suspension, 20W for a stiffer suspension). The two grades can also be mixed in varying solutions to obtain the desired response. F.A. or Fork have special properties, which enable them to retain virtually the same viscosity regardless of temperature to give constant damping response

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HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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Wildfire Scooter WF 250CB Owner's Manual

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

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• Check before Riding • Make sure the brakes work properly and adjust if necessary. • Check all nuts and bolts for tightness. • Make sure that the gas tank is full. • Check tire pressure. • Check all gauges. • Check and make sure that all of the lights are working properly, headlight, taillight, turn signal etc. • Check the engine oil. STARTING, RIDING, STOPPING AND PARKING Before starting, put the kickstand up. • Practice in an empty area away from people and vehicles. • Always remember to obey your local and state laws and regulations. • Be sure your bike has fuel and oil. • Be sure the bike is in neutral. • Apply the rear brake. • Turn the key on. • Press the electric start button. • After engine warms up, push the choke 1/4 in then 1/2 in and in 1 minute completely off. • If the engine is warm it should start without choking. • For a cold engine, let the engine idle for 1-3 minutes before driving, then begin to turn the choke off. • Never exceed 4 seconds when engaging the starter. • Release the button immediately after the engine starts. • Do not apply the key while the engine is running, it can cause damage to the starter. • Sit on the bike keeping one foot on the ground for stability, release the clutch by pulling in the lever, shift bike into first gear by using the foot shifter. • Apply the throttle gradually as you release the clutch lever slowly until the clutch engages. • To shift into the next gear release the throttle pull the clutch lever in and shift into the next gear, after you shift, gradually apply the throttle and slowly release the clutch. • Use this sequence when shifting to all gears. • Only put your feet on the ground when coming to a stop. • When coming to a stop decrease your speed by releasing the throttle and applying the brakes and the clutch, if the tire skids release the brake and reapply. • Parking: Put your kick stand down. Park away from pedestrians. NOTE: The muffler and exhaust pipe are h

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