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Suzuki SV1000 COOLING AND LUBRICATION SYSTEM REPAIR MANUAL

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Filed Under (Suzuki) by admin on 25-02-2011

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At the time of manufacture, the cooling system is filled with a 50 :50 mixture of distilled water and ethylene glycol anti-freeze . This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above -31 °C (-24 °F) . If the motorcycle is to be exposed to temperatures below -31 °C (-24 °F), this mixing ratio should be increased up to 55 % or 60 % according to the figure. CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water . Do not mix an alcohol base anti-freeze and different brands of anti-freeze. • Do not rut in more than 60%anti-freeze or less than 50 %. (Refer to the right figure.) • * Do not use a radiator anti-leak additive. A WARNING COOLING AND LUBRICATION SYSTEM 5-3 20 40 60 80100 0 10 20 30 40 50 60 Density (%) Fig .2 Engine coolant density-boiling point curve • * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot . After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off . • * The engine must be cool before servicing the cooling system . • * Coolant is farmful; • * If the comes in contact with skin or eyes, flush with water. • * If swallowed accidentally, induce vomiting and call physician immediately . • * Keep it away from children . Anti-freeze density Freezing point 50% -31 °C (-24 °F) 55% -40 °C (-40 °F) 60% -55 °C (-67 °F) 50 % engine coolant including reservoir tank capacity Anti-freeze 1 100 ml (2.3/1 .9 US/Imp-pt) Water 1 100 ml (2.3/1.9 US/Imp.pt) Density (%) Fig.1 Engine coolant density-freezing point curve (°F) (°C) 302 150 (kgf/cm2) 284 140 1.5 c Q 266 130 0.9 0) a) :0 248 120 0.5 0) m Z3 230 110 0 (7 212 100 (F) (C) 32 0 14 -10 -4 -20 C 0 Q -22 -30 O) C N -40 -40 a) a) U- -58 -50 -76 -60 -94 -70 5-4 COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT THERMOSTAT RESERVOIR TANK RADIATOR NO. 1 CYLINDER HEAD NO . 1 CYLINDER NO. 2 CYLINDER NO. 2 CYLINDER HEAD WATER PUMP INSPECTION Before removing the radiator and draining engine coolant, inspect the cooling circuit for tightness. • * Remove the body cowling. (=6-6) • * Remove the radiator cap ® . • * Connect the tester 02 to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 110 kPa (1.1 kgf/cm 2, 15 .6 psi) and see if the system holds this pressure for 10 seconds. • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged

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HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

Aprilia RSV4 Exhaust Systems Installation instructions

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

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REMOVAL OF STOCK EXHAUST SYSTEM 1. 2. 5 Figure 3 Figure 4 Remove the metal collar and rubber damper from the stock muffler hanging bracket (Figure 3, 4). 3. 6 Unscrew the marked bolts and remove the plastic fasteners from the left and right side of the cowling (Figure 5, 6). 4. Figure 5 Figure 6 7 Unscrew the marked bolts and remove the lower part of the cowling (Figure 7). 5. Figure 7
8 Figure 8 Figure 9 Coat the bolt and interior of the metal clamp with spring hook whit Akrapovič anti-seize lead-free copper paste (black tube) and correctly install it onto the stock collector. Hand tighten the bolt (Figure 9, 10). WARNING: use anti-seize copper paste on bolt threads and interior of the metal clamp! 2. 1. Coat the bolt and interior of the metal clamp with Akrapovič antiseize lead-free copper paste (black tube) and correctly install it onto the link pipe (Figure 8). WARNING: use anti-seize copper paste on bolt threads and interior of the metal clamp

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1990 – 2006 Toyota And Scion Models With Port Electronic Fuel Injection FUEL INJECTOR CLEANING

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Filed Under (Toyota Manuals) by admin on 24-10-2011

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Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): Idle air control device Throttle plate (both sides if possible) Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 – 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system.

BLACK POWDER COATED ANTI-VIBRATION PEGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-12-2010

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These pegs, mounts and hardware have a nickel/chrome base coat under the satin black powder coat finish. This is done to prevent any rust or corrosion at the wear points. Its is normal for some of the black powder coating to wear off (exposing the nickel/chrome base) where the pegs pivot on the mounting blocks and on the bolt heads. Again this is normal and they will not rust at these points. If desired the satin black finish can be touched up using a satin black model or spray paint.

HARLEY-DAVIDSON SPORTSTER MODEL'S 215 and S 215 INSTALLATION and CLEANING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 16-03-2012

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1. Refer to Figures 1 & 2. 2. Remove taillight and remove seat. SAFETY: DISCONNECT BATTERY PRIOR TO ALL WIRING MODIFICATIONS 3. Disconnect Right turn signal connector inside taillight. Pull wire from the underside of fender. Cut the wire approximately 2 inches from the connector, 02/16/09 save for reinstallation. Ensure the wires are loose from all retaining clips under fender. 4. Remove nut located behind fender holding the turn signal. 5. On the right side only, Remove the two torx bolts from fender strut, carefully pull and rotate fender strut cover to remove. Pull turn signal wire completely out. Remove bolt holding turn signal to the fender strut cover. SADDLEBAG INSTALLATION 6. Reinstall the fender strut cover using the 1 7/8″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the front hole and the 1 1/2″ Hex Spool Bolt Assembly and 1/8″ x 5/16″ Aluminum Spacer in the rear hole. Refer to view “B”. Insert the chrome caps into the existing turn signal holes. Bend tabs over to ensure a snug fit. 7. Repeat disassembly and installation on opposite side. TURN SIGNAL RELOCATION 8. Install turn signal bracket between license plate and license plate bracket with ears of bracket facing the front of the motorcycle, using 1/4 – 20 x 3/4 Hex cap screws, 1/4 flat washers, and 1/4 – 20 locknuts. 9. Mount turn signals directly to bracket using 5/16 – 18 x 3/4 hex cap screws with a Black Plastic Spacer, and 5/16 star washer. For a clean installation slide rubber grommet over the wire and secure into hole in turn signal, remove top center mounting bolt on license plate bracket and run wires through this hole. Splice the connector back on the wire, and reconnect to wire harness. Ensure all wires are secure under fender. Reinstall taillight. 10. Connect battery and test turn signals for function. Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points. 11. Mount saddlebags over spools on fender strut and secure with clips retained inside bags. 12. Inspect each clip to verify each clip is properly seated in retaining groove. See View “A”

HARLEY-DAVIDSON SPORTSTER TURN SIGNAL RELOCATION KIT INSTALLATION AND CLEANING INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 23-10-2010

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Remove turn signals. Observe and mark “left” and “right” for reinstallation. h Turn signal bracket may be oriented forward or backward as required. 4. Install turn signal bracket between license plate and license plate bracket using 1/4”- 20 x 3/4” Hex cap screw, 1/4” SAE flat washers, and 1/4” – 20 locknuts. Note: For Bullet style turn signal light models refer to fig. 3, disassemble and discard turn signal extension and insert 8 x 22 x 5mm black plastic spacer in place of the extension. 5. Mount turn signals directly to bracket using 5/16” – 24 x 3/4” hex cap screws with 5/16” lock washers and 5/16” flat-washers. If original wire was inside stalk, remove plug and reroute wires to outside. For a clean installation remove top center mounting bolt on license plate bracket and run wires through this hole. h Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. h WARNING: Some states may have minimum width requirements on motorcycle turn signals, so check your local laws. 6. Turn signal wires must be extended. We recommend splicing inside turn signal housing. Splice wires, one at a time, while observing color code. 7. Connect battery and test turn signals for function. SADDLEBAG INSTALLATION h Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points.
Leatherlyke Refer to Figure 2. 9. Remove rear fender mounting bolt on each side and replace original bolt with the two 5/16” x 2 1/4” socket head bolts and 5/16” mounting spools with chamfer on spool under socket head bolt. Install 5/16” – 18 locknuts on inside of fender. Verify that adequate clearance exists between the ends of the bolts and tire. 10. Remove upper shock bolt and replace with (2) – 1/2″ x 1″ FLAT WASHERS and 1/2″ x 2 1/8″ hex spool & bolt assy.

SUZUKI 1400/ 800 INTRUDER TURN SIGNAL RELOCATION INSTALLATION AND CLEANING INSTRUCTIONS

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Filed Under (Suzuki) by admin on 09-11-2010

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1. Refer to Figure 1. 2. Remove seat. Safety: disconnect battery prior to all wiring modifications LeatherLyke 510 5/1/2009 3. Disconnect wires to turn signals. 4. Remove turn signals and retain hardware for reinstallation. Observe and mark “left” and “right” for reinstallation. Information: Do not remove license plate bracket . 5. Remove license plate. Turn signal bracket must be oriented with flange (side with only 2 holes) on top. 6. Install turn signal bracket behind license plate bracket and license plate using 6 x 35mm pan phil machine screws for the 800 or 6 x 20mm pan phil machine screws for the 1400, 1/4″ flat washers, and 6mm locknuts. Insert black spacer spool between license plate bracket and turn signal bracket. 7. Mount turn signals directly to turn signal bracket using 6 x 10mm hex cap screws and star lock washer. Information: Observe all color-coding of wires and splice one wire at a time. 8. Cut each turn signal wires three inches from end and splice 10 inches of supplied wire. Secure wires to inner fender clips. 9. Follow route of tail light wires and connect wires into harness. 10. Secure wires together behind license plate bracket with tie wrap. 11. Connect battery and test turn signals for function. 12. Install seat. Information: Not all license plate mounts are grounded. In some cases, it may be necessary to run a ground wire to turn signal bracket. WARNING: States may have minimum width requirements on motorcycle turn- signals, so check your local laws. LeatherLyke 510 5/1/2009 SADDLEBAG INSTALLATION 13. Refer to Figure 2. Information: Cover plates are pressed into strut. 14. Remove round cover plate at end of fender mount strut on right side. 15. Remove nut on right rear and replace with 1.2″ hex adapter. If hex adapter is less than flush with the outside of both fender struts, add a 5/16″ flat washer. 16. Assemble 5 x 30mm flathead screw and 5mm mounting spool with chamfer on spool under head of screw. Insert assembly thru 1 1/4″ fender washer for the 1400 or 1″ for the 800. 17. Install spool assembly into previously installed 1.2” hex adapter. Information: Do not remove washer on shock absorber. Hex adapter will protrude 1/4″ beyond fender strut. 18. Remove round cover plate over right rear shock, remove shock absorber nut and install .75″ hex adapter. 19. Assemble 5 x 30mm flathead screw, mounting spool and cup washer with chamfer on spool under head of screw. 20. Install spool assembly into previously installed hex adapter. 21. Insert 5/8” finishing plug into old turn signal hole on right side. 22. Repeat procedures on opposite side

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KAWASAKI 1500 CLASSIC SADDLEBAG INSTALLATION AND CLEANING INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Refer to Figure 1. Information: Longer bolts may be required if Sissy Bar is installed. 2. Remove rear fender mounting bolts on right side and replace original bolts with two 8 x 65mm bolts and 8mm mounting spools with chamfer on spool under head of Allen bolt. Do not tighten bolts at this time. “Play” is needed to align bags with spools. 3. Repeat procedure on opposite side. Information: Bags will be easier to mount and remove if a small amount of silicone lubrication is applied to rubber mounting points. 4. Mount saddlebags over spools and secure with clips retained inside bags. 5. Tighten all bolts with bags installed. Verify that adequate clearance exists between end of bolts and tire. 6. Inspect each clip to verify each clip is properly seated in retaining groove. See View “A”.

1998 BMW R1100RT LCD Temperature Gauge Scale Calibration LCD Fuel Gauge Calibration Fuel Sender Testing and Cleaning

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

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Oil Temperature and Gauge 2.1. Introduction My 1998 BMW R1100RT came with an LCD temperature gauge that shows horizontal black bars in a vertical motif, to indicate temperature. This is difficult to interpret at speed (how many bars are exposed?) and does not actually tell me what the oil temperature is. 2.2. Normal Operation The bike seems to run at 5 or six bars under normal conditions. It appears that the oil thermostat for the cooler is set to ’5 bars’. 2.3. Over Heating The LCD panel indicates that 8 bars is the maximum normal operating temperature. It would be useful to know what the actual temperature is. Modern oils have a normal operating temperature of approximately 110 degrees Celsius and will not show any serious degradationii at this temperature. The maximum sustained operating temperature (at the bearing surface) is approximately 130 degrees Celsius for any oil formulated in the past 5 years and some high performance synthetics will not appreciably degrade even at this temperature. However, the degradation curve is a polynomial and degradation will increase rapidly with increasing temperature. According to the oil’s formulation (pure synthetics will show the least increase with temperature), by approximately 160 degrees Celsius (or about 300 degrees Fahrenheit), oil degradation can be up to 10 times faster then at 110 Deg. C. 2.4. Scale To fix the ‘number of bars’ problem, I determined that an overlay with numbers would be the best idea. 2.4.1. Addendum The number scale became too much to maintain. Rather than this, I cut a mm or so wide stripe out of the self sticking stripping meant for the side of a car. Using a red material, I put it through the middle of the fifth bar of both the temperature and fuel display. The stripe is slightly smaller than the thickness of the bar. This allows me to tell when I am at normal operating temperature and when approximately half a tank is used

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