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HONDA 2008 CRF 450 F SLIP-ON EXHAUST SYSTEM REPAIR MANUALS

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Filed Under (Honda) by admin on 25-12-2011

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The Akrapovic Slip-On system is designed for recreational Honda CRF 450 enthusiasts. It delivers an excellent combination of quality, performance, visual enhancement, easy installation and affordability. The Akrapovic Slip-On is designed for two markets; in the US it is available with an approved spark arrester, and for the EU and other non-US markets it comes with a noise damper. PERFORMANCE Measurements of the Akrapovic SLIP-ON system on the HONDA CRF 450 R (with muffler insert): Power & Torque: Up to 5600 rpm the Akrapovic Slip-On essentially follows the stock power and torque curves. It shows its true colors above that range, where it delivers significant increases to both power and torque. Max. increased power of 2.8 HP was measured at 6600 rpm. At the top of the rpm range the Akrapovic curves again follow the stock power and torque curves. CONFIGURATION The system is composed of a flared stainless steel link pipe which is welded to the muffler. It is attached to the stock header assembly with a sleeve joint secured with a metal clamp. The muffler is the offroad design with a titanium outer sleeve, and stainless steel inlet cap, outlet cap and inner perforation. The muffler is attached to the frame using an Akrapovic carbon-fiber clamp. In the US the system is available with an approved spark arrester, and for the EU and other non-US markets it comes with a standard noise damper

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BMW PISTONS AND RINGS INSTALLATION INSTRUCTIONS

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

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1. Always clean the grooves before installing rings. Carbon build-up in the groove will lead to ring “bottoming” and can result in engine seizure. 2. Check the fit of rings in the groove. A maximum of .003″ side clearance is allowable. 3. Check the cylinders for taper and out-of-roundness. Any taper of out-of-roundness will have an adverse effect on the performance of an engine. Excessive piston clearance will detract from maximum performance as well. 4. Allow ample ring gap. There is far more danger of ring butting than of an appreciable compression loss through the ring gap. Gaps, if staggered, do not cause any measurable reduction of compression. Compression rings should be fitted with a minimum of .004″ end gap per inch of cylinder deglazing. 5. Always deglaze cylinder walls before installing new rings. A 400 grit stone is recommended for deglazing. 6. All parts should be spotlessly clean before installation. Dirt in any form is the worst enemy of a hi- performance engine. You may wash all parts in hot, soapy water. Ring Gap Installation 1. Do not gap oil control rings. Start with the oil control expander. Expander Ring ends butt together. Do not overlap them. 2. Install oil control rings. Set gap 90 from where expander ring butts together. Gap top oil control ring 180 from lower oil control ring gap. 3. Install 2nd and top ring also with marks up. Stagger gaps

Aprilia RXV 450 – 550 MAINTENANCE MANUAL

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

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DIMENSIONS Max. length 2240 mm (88.19 in.) Max. width 830 mm (32.68 in.) Max. height (front fairing included) 1250 mm (49.21 in.) Seat height 950 mm (37.40 in) Wheelbase 1485 mm (58.46 in.) Minimum ground clearance 320 mm (12.60 in.) Dry weight 123 kg (271.12 lb) ENGINE Model (RXV 450) 45RX Model (RXV 550) 55RX Type twin-cylinder, 4-stroke with 4 valves per cylinder, single overhead camshaft Number of cylinders 2 Total displacement (RXV 450) 449 cu. cm (27.40 cu in). Total displacement (RXV 550) 553 cu. cm (33.75 cu in). Bore/stroke (RXV 450) 76 mm x 49.5 mm (2.99 in x 1.95 in) Bore/stroke (RXV 550) 80 mm x 55.0 mm (3.15 in x 2.16 in) Compression ratio (RXV 450) 13 ± 0.5 Compression ratio (RXV 550) 12.5 ± 0.5 Starting electric Engine idling rpm 1800 ÷ 2000 rpm Clutch Multiplate in oil bath. Lubricating system Double separate lubrication with external reservoir Air filter with dry filter cartridge Cooling system liquid-cooled TRANSMISSION Type mechanical, 5 gears with foot control on the left side of the engine CAPACITIES Fuel (including reserve) 7.5 l (1.98 gal) Fuel reserve 2.2 l (0.58 gal) Engine oil 1.3 l (0.34 gal) Fork oil 100 mm (3.94 in.) of air (per leg, measured without spring and compressed rod) Coolant 1.1 l (0.29 gal) (50% water + 50% coolant with ethylene glycol) Seat 1 GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 1st 22/56 = 1: 2.545 12/31 = 1: 2.583 15/48 = 1: 3.200 1 : 21.042 2nd 13/25 = 1: 1.923 1 : 15.664 3rd 15/23 = 1: 1.533 1 : 12.489 4th 19/24 = 1: 1.263 1 : 10.288 5th 21/22 = 1: 1.047 1 : 8.533 DRIVE CHAIN Type with master link

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Honda CRF/ XR50 Carburetor Kits, Air Filters INSTALLATION AND REMOVAL

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Filed Under (Honda) by admin on 18-12-2011

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The CRF/XR50 engineers never intended “large” people to be competitively thrashing their design. As a result, failed frames are becoming quite common at the track. Laid-out forks, tweaked, ill-functioning suspensions and bent frames are symptoms we’ve all witnessed. This CRF/XR50 frame kit addresses all these problems with not only a stronger framer but also with added knee-to-bar clearance for taller riders.. Features: • Heat-treated chromoly steel frame • TIG welded • Fully gusseted • Thicker-walled main tube that is also larger in diameter • Conservatively estimated at 4 times stronger than the stock unit • Race legal open cradle configuration, but with fully closed loop rear sub frame under the seat for added strength and safety • Stronger swing arm pivot area prevents wallowing • Frame is 1″ longer than stock, resulting in greatly enhanced handling characteristics This Chromoly 1″ longer frame with chromoly removable subframe is the off the hook! It features a detachable chromoly subframe with all hardware as well as a 1″ rise in gas tank and seat height for more more leg room and to allow bigger carburetor modifications. Extended frame also provides: • Much needed knee-to-bar clearance • Improved rider position • Better Center of Gravity • Better control Features: • Heat-treated chromoly steel frame • TIG welded • Fully gusseted • Thicker-walled main tube that is also larger in diameter • Conservatively estimated at 4 times stronger than the stock unit • Race legal open cradle configuration, but with fully closed loop rear sub frame under the seat for added strength and safety • Stronger swing arm pivot area prevents wallowing • Frame is 1″ longer than stock, resulting in greatly enhanced handling characteristics • Gas Tank is raised 1″ for added clearance

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HARLEY DAVIDSON TURN SIGNAL TRIM RINGS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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INSTALLATION 1. Remove turn signal lens 2. Place O-ring (4) in groove between lens and turn signal housing. 3. Reinstall signal lens. 4. Install the trim ring (3) onto the turn signal. Notches on turn signal lens must be aligned with notches on trim ring. 5. Secure trim ring with the provided screw (1) and nut (2). Tighten securely. 6. Repeat Steps 1-5 for the other turn signal. SERVICE PARTS See Figure 1 and Table 1. 1 B A 2 4 3 is00628 Figure 1. Service Parts: Turn Signal Trim Rings Table 1. Service Parts: Turn Signal Trim Rings Part Number Description (Quantity) Item 3824 Screw 1 8006 Nut 2 Not Sold Separately Trim Ring 3 11371 O-ring 4 Items mentioned in text but not included in kit: Original lens and screw A Turn signal housing

HARLEY-DAVIDSON V-ROD BIG BORE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The cylinder sleeves provided with the Wiseco V-Rod big bore kit have been finished honed to size and the piston to cylinder clearance has been set. Prior to installation, the sleeves must be washed in hot soapy water (not parts washer solvent) and dried. Coat the bore surface with motor oil and wipe it with a white towel. If the towel shows any remaining grit, repeat the hot soapy water washing process until the towel will only show clean motor oil. CAUTION: Test fit the cleaned sleeve (without O-Rings installed) into the engine block. Sleeve should drop into position. If sleeve will not easily drop into position, warm the engine block with a hair dryer until sleeve will drop into position. Remove sleeve, then continue installation procedures. From the bottom side of the sleeve, gently roll the 2-cylinder sleeve O-rings into the two grooves on each sleeve. Apply motor oil to the O-rings and gently install the sleeves into the block until bottomed. CAUTION: DO NOT ATTEMPT TO INSTALL SLEEVES WITHOUT LUBRICATING THE O-RINGS. FAILURE TO LUBRICATE O-RINGS COULD RESULT IN TORN OR DAMAGED O-RINGS THAT WOULD NOT BE EVIDENT UNTIL ENGINE WAS STARTED. INCORRECTLY INSTALLED O-RINGS CAN RESULT IN CATASTROPHIC ENGINE DAMAGE. NOTE: REFER TO THE OEM SERVICE MANUAL FOR ALL TORQUE SPECIFICATIONS PISTON RING PREPARATION Wiseco V-Rod pistons incorporate an advanced 2 ring system • The top ring is file-fit, and as such, requires that the end gap must be clearanced. The proper end gap clearance is .016-.018″ with the ring installed squarely in the bore. The top ring must be installed on the piston with the dot marking toward the top of the piston. • The oil ring is comprised of the expander and two rails. Install the expander first, and then the rails. Check to make sure the expander tips have not overlapped. It is not necessary to clearance the end gaps on the oil rails. The rails should be installed without modification. PISTON INSTALLATION The Wiseco V-Rod big bore kit is supplied with pistons that are front and rear cylinder specific. Install the front piston 4792M10795 in the front cylinder with the arrow facing the front of the engine. Install the rear piston 4793M10795 in the rear cylinder with the arrow facing the front of the engine. A piston ring compressor is required to install the pistons into the cylinders. Front of engine ➔ 4792M10795 ( Front piston) 4793M10795 ( Rear piston) FWD 4793M10795 FWD 4792M10795 For further information call the Wiseco Tech Line:

ATK 450 MX SPECIFICATIONS

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

Model: ATK 450 MX Year: 2008 Category: Enduro / Engine and transmission Displacement: 449.00 ccm (27.40 cubic inches) Engine type: Single cylinder, four-stroke Power: 48.00 HP (35.0 kW)) @ 10000 RPM Compression: 12.3:1 Bore x stroke: 95.0 x 63.4 mm (3.7 x 2.5 inches) Fuel system: njection. EFI Fuel Injection Fuel control: DOHC Ignition: 12v Battery w Constant Energy Inductive Coil Cooling system: Liquid Gearbox: 5-speed Clutch: Magura Hydraulic Chassis, suspension, brakes and wheels Frame type: Aluminum Twin-Spar Front suspension: 46mm Ohlins 12” Travel Front suspension travel: 305 mm (12.0 inches) Rear suspension: Ohlins POS 12.6” Travel Rear suspension travel: 320 mm (12.6 inches) Front brakes: Single disc. Dual piston, 240mm Rotor Front brakes diameter: 240 mm (9.4 inches) Rear brakes: Single disc. Dual piston, 220mm Rotor Rear brakes diameter: 220 mm (8.7 inches) Physical measures and capacities Dry weight: 109.8 kg (242.0 pounds) Power/weight ratio: 0.4373 HP/kg Seat height: 965 mm (38.0 inches) If adjustable, lowest setting. Ground clearance: 361 mm (14.2 inches) Wheelbase: 1,486 mm (58.5 inches) Other specifications Starter: Electric

2007 KTM 250 SX-F 450 SX-F INSTALLATION MANUAL

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Filed Under (KTM) by admin on 06-02-2012

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Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hot start lever If you pull the red hot start lever [2] 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. 2 1 A 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. OPERATION INSTRUMENTS »
Starter button (450 SX-F) Pushing the black starter button [3] will actuate the E-starter. ENGLISH 6 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”). Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open the filler cap: Turn the filler cap 45 ° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. OFF ON 1 A 2 3 ENGLISH 7 OPERATION INSTRUMENTS » Choke If you pull the choke button [1] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat” fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. 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 is located between first and second gear. Kickstarter (250 SX-F) The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). Plug in stand The plug-in stand can be attached to the wheel spindle on the left side of the motorcycle

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Air Shock Installation Instructions

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Filed Under (Tips and Review) by admin on 24-11-2010

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Air HoseInstallation. Choose the most convenient loca- tiononyour motorcycle for the air fill valve. Drilla 5/16″hole and install the air fill valve as shown in Figure 3orsecure air fill valve to frame tube. 2. Keep hose ends clean during installation because dirt can cause air leaks. 3. Install hose connector, tube clamp and two O-rings onto one end of the air hose (See Figures4&5) Apply rubber lubricant (soap solution, not oil) to the O-rings to ease installation on the air hose& into the shock absorber inlet. Plastic connector should just bottom on fitting. Do not overtighten! The function of the nut is to hold everything together in place, the O- rings do the sealing. Fin- gertightenonly (10 in/lb maximum). 4. After routing the air hose, trim the length to fit air fill valve. Install hose connector, tube clamp, and twoO-rings onto end of hose (See figures 4&5). Lubricate as above and assemble to air fill valve. Use the same procedure formating hose. Important —leaveasmall amount of slack in hose near shock absorber to allow for the slight move- mentofthe shock. Caution! Do not install hose near ex- haustsystem, battery or any other sharp edges or seat movement. Keep hoses clear of moving parts such as wheels or suspension components. Do not allow hoses to have excess slack and sag below the motorcycle. The hoses could catch on road surfaces or debris and could be damaged while the motorcycle is in motion. 5. If necessary the air hose can be secured along the motorcycle’swiringharness with tie-wraps. 6. Testing: Inflate system to 50 psi. Apply soapy water solution to all connections and check for air leaks. If there are any leaks, disconnect the suspected fitting and check for dirt or damage to the air line or the O-rings. Remove any dirt or foreign matter, re-lubricate the O-rings and reinstall. If unable to locate the leak, remove rubber boot from shocks and submerge pressurized components under water (in- cludingT-Valve) and check for leaks. If you cannot solve the air leak problem, please contact our technical staff for assistance

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Honda CRF/ TRX 450R Camshaft Installation

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Filed Under (Honda) by admin on 19-11-2011

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Break-in of this camshaft is important and you should adhere to all of the following instructions. It is also very important to use plenty of engine assembly lubricant, recommended is Coastal Engine Assembly Lube or Clevite 77, both are available from most automotive supply companies. We recommend you change the engine oil before the initial start-up of the engine after the assembly. Then change the oil again after the break-in of the cams to remove the excess
phosphate from the coated cams. These steps will help ensure that the camshaft breaks-in properly and that you have a long lasting product. Using full synthetic engine oil during break-in is not recommended but, is OK to use after the one-hour break-in period is over. Following a regular maintenance schedule is the best way to ensure durability and performance over the long run. Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. Remove the fuel tank and thoroughly clean the inside of the frame rails, around the carburetor, and behind the radiators. Be sure to remove the ignition coil assembly and using high-pressure air, clean the spark plug hole out before the plug is removed. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly

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