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Brakes, Wheel Assemblies, and Tires tips

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Filed Under (Tips and Review) by admin on 09-02-2012

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BRAKING SYSTEMS The braking systems used on motorcycles and ATVs, like virtually any type of braking system, reduce the machine’skineticenergyby transforming it into heat energy known as friction heat . Therefore, a brake is an energy-conversion device that converts the energy of motion (kinetic energy) into heat energy. Motorcycle braking is accomplished by the friction (resistance to movement) produced when a brake lining is forced against a rotating drum or disc. Friction between the linings and drum or disc serve to slow and eventually stop wheel rotation. The brakes used on motorcycles fall into two categories: Mechanical drum, sometimes called expanding shoe Hydraulic disc Motorcycle brakes commonly use either hydraulic (fluid pressure) or mechanical (cable or linkage) mechanisms to apply the brakes. Brakes, Wheel Assemblies, and Tires 1 Mechanical Drum Brakes First, let’slookatthedrum brake, sometimes called the mechanical, expanding double-shoe brake ( Figure 1 ). Generally used for rear wheels, this brake is also used on some front wheels. With this kind of brake, a backing plate that’sconnectedtothe forks holds the two brake shoes. The wheel and brake drum rotate around the brake shoes. When the rider applies the brake, a cam pushes the two semicircular shoes outward. The circle formed by the two shoes expands. When the shoes expand, they press against the rotating drum, thereby limiting its free rotation

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Harley Davidson BoonDocker Nitrous System Installation MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2012

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BoonDocker Liquid Nitrous – 1589 Hollipark Dr. Idaho Falls, ID 83401 – (208) 542-4411 web site: www. boon dockers. com – email: info@boon dockers. com Revised 02-27-04 Page 2 of 10 This manifold is also designed to vary the float bowl pressure in relation to nitrous pressure, thus keeping the nitrous and fuel delivery in sync. Fluctuations in bottle temperature greatly affect nitrous pressure, which affects nitrous delivery. By automatically adjusting the fuel delivery as nitrous pressure varies, this manifold makes nitrous safe, reliable, and easy to use. Be sure to understand and follow the tuning instructions at the end of these instructions. Proper tuning is an important part of any performance-enhancing product. Part I – Bottle Installation A. Bottle Valve Fittings Insert the 4AN x 1/8″ NPT fitting and the 1/8″ NPT Plug into the bottle valve (these are attached to the lid of the box for the bottle) . Use Teflon tape to seal the threads – be sure not to get tape inside the threads! B. Bottle Mounting Position With nitrous in the bottle, both nitrous liquid and nitrous gas are present under high pressure (760 psi at 70 deg F) . Due to gravity and acceleration forces, the liquid portion of the nitrous will be at the bottom and rearward parts of the bottle. For this nitrous system to work properly, it is important that nitrous liquid be drawn from the bottle. Nitrous vapor will cause a significant decrease in performance. For best results, the bottle should be mounted so the valve is pointed down and towards the back of the vehicle as shown below. ************** *************** ******** ********* *************** (can be installed on top or bottom of air boot) ********** ********* push-button switch (mounts on handlebar) +12 V *********** ************ **** ****** *! “**#$******%* *! “**#$*#*%* 20 deg to 90 Front of motorcycle Rear of motorcycle BoonDocker Liquid Nitrous – 1589 Hollipark Dr. Idaho Falls, ID 83401 – (208) 542-4411 web site: www. boon dockers. com – email: info@boon dockers. com Revised 02-27-04 Page 3 of 10 Bottle mounted inside airbox: For some applications, a small bottle can be mounted inside the airbox as shown. Note: because of the restricted space, it was necessary to mount this bottle at a non-optimal angle (the valve is pointed towards the front instead of the rear)

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1989 – Current All Mode SENSOR INSPECTION FOR AIR CONDITIONING SYSTEM REPAIR

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Filed Under (Toyota Manuals) by admin on 30-10-2011

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specifications. The inspection procedure for each type of sensor differs from the others. Select the appropriate inspection procedure from the table below according to vehicle specifications and perform the inspection. EQUIPPED WITH AUTOMATIC LIGHT CONTROL SYSTEM A/C SYSTEM WITH RIGHT/LEFT INDEPENDENT TEMPERATURE CONTROL INSPECTION PROCEDURE No No A No Yes B Yes Yes C Yes No D Procedure A: a. Disconnect the solar sensor connector. b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions: Cover the sensor with a cloth to avoid direct light. Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light. NOTE: Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, connect the positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor. HINT: If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light

Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

Kawasaki VN1600 Highway Bar INSTALLATION AND OWNER'S MANUAL

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

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PREPARATION 1. Insure that the motorcycle is on flat level ground. 2. It is recommended that the motorcycle sit for at least one hour prior to installation to allow the engine to cool. During installation tight all fasteners to hold. Wait until you check all clearances and operation of the brake and shift lever to firmly tighten and torque all fasteners. INSTALLATION Right Side Highway Bar 1. Remove the front floor board bolt (M10). (14mm Socket) Figure 1. Right and Left side of Motorcycle is determined while sitting on the bike.
MAINTENANCE / CAUTION The high quality chrome finish of your National Cycle Chrome Highway Bar can be maintained with any quality chrome cleaner and / or polish applied with a soft cloth. Check hardware for tightness regularly. Never ride with loose mounting hardware. Check to be sure your Highway Bar does not contact any part of the motorcycle at a full turn left and right. Correct any problem before using the motorcycle. ©2005 National Cycle, Inc. PO Box 158, Maywood, IL60153-0158 USA 708-343-0400 / Fax: 708-343-0625 / www.nationalcycle.com / e mail: info@nationalcycle.com Page 2 of 2 10-114857-000 09/05 Install Upper “U” Bolt 2. Place “U” Bolt between the radiator and the down tube at the location shown in Figure 2. Threaded ends of “U” will face out- ward. 3. Select the right side Highway Bar. 4. Loosely install the Highway Bar at the lower mount point using the stock screw. (14mm Socket) Figure 3. While installing the Whizlock Nuts in the following Step #5 , be certain to tighten the nuts evenly, alternating left and right as you tighten. When complete you want the same amount of threads exposed on the ends of the “U” to insure the bolt does not rotate. 5. Install the upper Highway Bar with Whizlock Nuts. (1/2″ Socket) Figure 4. Orient assembly so Whizlock Nuts face outside. Firmly tighten after all clearances are checked. LEFT SIDE INSTALLATION 6. Repeat Steps 1 and 2. On the Left Side due to tight clearances between the radiator and the down tube you must locate the point where the radiator is “notched out” slightly. Figure 5. 7. Select the left side Highway Bar. 8. Repeat Steps 4 and 5.

FC Shock Spring Installation Guide

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Filed Under (Tips and Review) by admin on 14-12-2010

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Installation: 1. Remove the fork springs according to the OEM Owner’s Manual. 2. Check/adjust fork oil level and weight according to OEM Specifications. Caution: Most inverted forks will not require the use of any shim washers or spacers. In cases where use is necessary with the twin chamber style fork, the shims must be placed at the bottom of the spring. Most conventional forks (non-inverted) will use shim washers or spacers at the top of the fork spring. 3. Install Factory Connection fork springs and refer to OEM Owner’s Manual for proper assembly procedures. 4. Be sure to double check all fasteners. Note: Most modern day forks require special tools for disassembly and assembly of the components. Examples : Showa 47/49mm Twin Chamber, KYB 48mm Twin Chamber, WP 07 SX Models/SXS Components. Installing fork springs is an intricate process that should be performed with extreme care by a qualified suspension technician. Failure to install the springs correctly could cause damage to one or more components of the fork. This damage, although not readily apparent, could lead to unexpected failure or rider injury. Factory Connection manufactures models specific fork springs. Installation of a Factory Connection spring not designed for your motorcycle may result in unexpected failure and rider injury. Please consult your Factory Connection spring dealer or call Factory Connection directly if you are unsure about a spring/or springs. 1. Factory Connection’s Limited Lifetime Warranty Factory Connection warrants, to the original retail purchaser (“consumer”) who retains ownership of the vehicle on which the suspension spring(s) (“products(s)”) was originally installed, all suspension springs for life against factory defects in material and workmanship (other than defects in finish) when used under normal use and operating conditions. 2. Your Remedy Upon verification of warranty coverage, Factory Connection at its option will replace defective or prematurely worn-out product (s), without charge, or refund the purchase price of the products(s). This is the Consumer’s sole and exclusive remedy for any loss or damage, however arising, due to a nonconformity or defect in the product(s). 3. Warranty Claim Procedure To make claim under this warranty, the consumer should contact the Factory Connection dealer or Factory Connection where the product(s) was purchased. Factory Connection reserves the right to test the returned product(s) to evaluate the nonconformity or possible defect. The Consumer is responsible for all costs of returning the defective or prematurely worn-out product(s) to the Factory Connection dealer as well as all costs for removing the product(s) from and installing the products(s) on the vehicle.

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Hot-Start Kit For Yamaha YZ/ WR 400F

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

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Blaster Rear Brake Kits 121-01298 • YFS200 Blaster ’88-’98 • This cable will eliminate the stock cable from the handlebar. Cable will go from the rear brake pedal to the caliper. 121-01299 • Same as 121-01298 +4″ • Cable is 4″ longer for extended swingarms. 121-01027 Replacement Ratchet Spark Plug Wrench 121-08147 • Designed specifically to fit where there is limited space • Ratchet mechanism works one way • Fits standard 13/16″ plugs
INDEX PAINT HANDLEBARS STREET LEVERS FORK SEALS CABLES SUSPENSION ELECTRICAL FILTERS BRAKE LINES BRAKES CABLE MAKING SUPPLIES CONTROLS DUAL SPORT MANUALS FSO PRODUCTS EMGO DRIVE DISPLAY JETS BEARINGS EYEWEAR VINTAGE MIRRORS EUROPEAN KICKERS SHIFTERS MISC HARD PARTS SHOP TOOLS CHEMICALS TOOLS R . 03-15-06 21 (626) 792-7384 www.FlandersCompany.com Fax: (626) 792-5341 www.FlandersCo.com Specialty Tools Swingarm Bearing Tool 121-080213 • Designed for installation of the swing arm bearings on late model Japanese motorcycles • Using the correct size insert (various sizes included in kit) and the puller, the mechanic can draw the bearing into the swingarm without beating on it with a hammer Main Jet Wrenches • High-quality die cast construction • 6mm round and hex jets and 8mm round • Cap holds a few spare main jets • Sold each 121-08023 6mm Hex (Fits 6mm hex main jets) 121-08024 8mm Round (Fits 8mm round main jets) 121-08025 6mm Round (Fits 6mm round main and pilot) Allen Extension 121-080184 • 5mm allen on a 6.25″ long, 3⁄8-drive extension for hard-to-reach case bolts • Designed for use with air tools • Great for splitting engine cases

HONDA 420 RANCHER 2×4/4×4 2007-2009 CLUTCH KIT INSTRUCTIONS

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Filed Under (Honda) by admin on 22-12-2011

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Remove key from the ignition switch. Remove the side panels from both sides. Remove both foot wells. 2. Drain coolant. Remove the oil drain plug from the motor; if you carefully drain it into a clean container you should be able to reuse it. 3. Disconnect shift motor (on electric shift models only). Remove coolant hoses. 4. Remove the bolts that mount the front differential to the frame, no other parts need to be removed. Carefully slide the front differential towards the front of the machine; you might need to lift up slightly to get the differential to move. Remove the drive shaft. Remove o-ring on output shaft (on motor). 5. Remove the fuel pump. 6. Loosen the front crankcase cover bolts, keep track of each bolt length and location. Slowly remove the crankcase cover. Carefully watch for o-ring shims and dowel pins that may fall out. 7. Unstake the nut holding the clutch on and remove nut. Using Honda tool #07933-HB3000A thread the large part of the tool into the center of the clutch. Tighten the center bolt on the tool while holding the large part of the tool with a wrench. This will pull the clutch off the machine. Place the clutch on a clean work surface. EPI performance.com
8. Using the c-clamps push down slightly on the outside cover and remove the four e-clips. Keeping track of which way they come off, remove the round metal plates one at a time. This will allow you to see the complete spring. Remove one end of each spring using a spring tool or needle nose pliers and then remove springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the hole. Install the metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up. Slide the clutch into the machine. The Sprague clutch is marked “outside” when installing make sure this is facing out. Torque clutch nut to 87 ft/lbs. 9. Clean the gasket surface on the motor and on the cover. Put a thin layer of Honda Bond or Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase cover. Carefully install crankcase cover, do not force cover on. Torque bolts to 9 ft/lbs. 10. Install the fuel pump. 11. Install the o-ring on the output shaft (on motor) and install the drive shaft. Carefully slide the front differential back into place and mount to the frame. Install the coolant hoses. Refill your engine coolant to the proper level according to your owner’s manual. 12. Install the oil drain plug. Refill your engine to the proper level according to your owner’s manual. You can reuse your oil if it is clean and was drained into a clean container. Only use manufactures recommended oil. 13. Be sure to double check coolant and oil levels and to look for any leaks after the machine has run for a few minutes. 14. Go out and ride your machine. If your performance doesn’t seem right double check to make sure everything has been done properly. 15. EPI is constantly testing our products. Sometimes there is a need to contact the user with new technical information. To ensure that you are receiving this information visit our web site EPIperformance.com to register your clutch kit.

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