crf50 carb rebuild guide

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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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HW Prowler Carburetor Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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1. Remove both seats and the plastic seat pans under the seats. 2. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. 4. Disconnect the engine breather hose from the bottom of the air box 5. Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape. 7. Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig. #1 9. Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. #2 10. Loosen the clamp on the rear of the carb holding the carb on 11. Pull the carb out of the intake boot 12. Set OE carb to the side. 13. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. 14. Route all the breather lines connected to the carb down under the carb. 15. Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. See Fig. #3 16. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. See Fig. #3 17. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. 18. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. 19. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. 20. Remove the plastic nut from the bottom of the choke handle on the choke cable. 21. Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this

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Honda VT1100 Shadow Guide Plug Patch Repair Manual

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Filed Under (Honda) by admin on 24-04-2011

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Find the guide plug.bn The guide plug is shown in the shop manual with the engine removed from the frame and the left crankcase cover removed. (You’ll find this illustration in the “ELECTRIC STARTER/STARTER CLUTCH” chapter in the “STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL” section.) It’s a little bit harder to find it on the bike. Start by following the yardstick to see where the guide plug is on my bike. To find it on your bike, lie on the ground (or, preferably a mechanics creeper) next to the bike (without the yardstick) and peek under the shift lever and over the frame There it is, just barely visible from the side of the bike. Here’s what a new one looks like: 2. Clean the guide plug and crankcase. From the front of the bike, clean the guide plug and crankcase with brake cleaner in a VERY focused spray. Let the cleaner evaporate before moving to the next step. Page 4 Rev: Draft 5/20/2007 Page 4 of 5 3. Reposition the guide plug. a. From the side of the bike, use the yardstick (or a long screwdriver if you prefer) to gently push the guide plug back into the crankcase. (Note the JB Weld from the previous patch operation.) b. From the front of the bike, gently push upward on the bottom of the upper tab (as shown below) or the bottom of the forward tab to rotate the guide plug into the proper position while maintaining pressure with the yardstick

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42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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Mikuni HSR 42/ 45 Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at ½ to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle.

CYLINDER HEAD REPAIR MANUAL

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Filed Under (Tips and Review) by admin on 28-10-2010

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ADJUSTABLE CYLINDER HEAD STAND Head can be rotated 360 degrees. Stays in any position using a simple locking mechanism. Use on twin or four cylinder heads. Shipping weight: 14 lbs. Adjustable length-10-1/2″ to 20-1/2″ long x 14″ width x 10-3/4″ high. 35-8602 Cylinder Head Stand VALVE GUIDE DRIVERS Use for removal and installation of valve guides into cylinder head. Available in the following sizes: 35-8418 4.5mm YM-4116 35-8416 6mm YM-4064-A 35-8417 5mm YM-4097 35-8414 7mm YM-1225-A 35-8408 5.5mm YM-1122 35-8413 8mm YM-1200 VALVE GUIDE DRIVER SET (REMOVE & REPLACE) Designed for speed and accuracy, this eleven piece set provides the right tool for the job. Driver set includes two valve guide drivers (5.5mm and 6.6mm), four valve guide installers, one cutter, three cutter pilots (5.5mm, 6.6mm, and 7.7mm) and one tap handle extension bar. 35-9445 Valve Guide Driver Set YAMAHA VALVE GUIDE INSTALLERS These installers are used for installation of Yamaha shoulder less valve guides to a specific depth into the cylinder head. To use, position onto the valve guide and drive into the cylinder head until installer makes contact with cylinder head surface. Note: Must use with Valve Guide Driver. Available in the following sizes: 35-8439 4.5mm YM-4117 35-8437 5.0mm YM-4098 35-8419 5.5mm YM-4015 35-8435 6mm YM-4065-A 35-8423 7mm YM-4017 VALVE GUIDE REAMERS Reaming valve guides after installation assures a proper valve stem to valve guide fit. Available in the following sizes: 35-3829 4.5mm YM-4118 35-3851 7mm YM-1227 35-3836 5.5mm YM-1196 35-3852 8mm YM-1211 35-3847 6mm YM-4066 CLOVER VALVE LAPPING COMPOUND KIT The world famous green can with the four leaf clover. For seating valves, mating gears, and sharpening. Sold as a kit with coarse 120 grit (roughing) and 280 fine grit (finishing). 35-0309 Clover Valve Lapping Compound VALVE LAPPING TOOL The ultimate vacuum stick for insuring perfect surfaces on valves and valve seats. Interchangeable cups make unit suitable for use with virtually any size valve. Set includes vacuum stick, 3/4″ and 1/4″ diameter rubber cups. 35-8998 Valve Lapping Too

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2000 – 2005 Celica REAR DISC BRAKE PAD INSTALLATION

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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A. Install the two brake pads with the anti-squeal shims to the brake caliper. B. Install the two (2) guide pins to fix the brake pads. 2. Install spring No. 1. A. Hook the spring upper portion to guide pin No. 1. Spring No. 1 B. Hook the spring lower portion to the center hole of the brake pad. 3. Install spring No. 2. A. Hook the spring upper portion to guide pin No. 1 Secure the guide pins with the retaining clip. A. Insert the retaining clip end into the hole of guide pin No. 1. B. Insert the other clip end into the hole of guide pin No. 2. NOTE: The retaining clip should be fully inserted into guide pin No. 1 and No. 2. If NOT, the guide pins will come off and the brake caliper will be damaged

1999 – 2005 Aprilia Falco SL 1000 Scottoiler Installation Guide

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

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Locate the vacuum – There is a rubber bung over a spigot on the inlet tract. Remove this bung and then press the Damper Elbow, part number 4, onto the spigot. For further information see our easy step installation guide – Vacuum Connectors, General . See third picture The RMV can be mounted under the seat. The more vertical the RMV the better and remember to avoid exhaust and engine components. For further information, see our easy step installation guide – RMV Positions, General. See picture bottom left The Dispenser Assembly can be routed along the Swingarm using Dispenser Mounting Sleeves & Glue and secured to the paddock stand bobbin mount using a cut down Dispenser Plate & Clip, parts 19 & 20. For further information see our easy step installation guide – Dispenser Assemblies, General . The nib should feed the rear sprocket between the 6 & 7 o’clock positions, with the cut face facing outwards. Note: Picture shows a similar Swingarm Once fitted, fill and prime the system and set the adjuster knob to ‘prime’. Start the engine and turn the adjuster knob until a flow of between 1 and 2 drops per minute is achieved. Check the condition of your chain after a ride, and then adjust as required

Toyota 1/ 2JZE Fitting Guide

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Filed Under (Toyota Manuals) by admin on 20-06-2011

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When installed correctly your VEMS ECU will provide you with long trouble-free
service. Please take time to read this guide, and pay special attention to the section
on Ground Wires. If you have any problems understanding any of the information
here, please contact your VEMS Reseller.
The information contained here should be sufficient to install and run your pre-
configured VEMS and wiring loom. It is designed to compliment the VEMS User
Guide which you should take time to read and refer to as you progress through the
installation and calibration of your VEMS

Ducati 900ss Scottoiler Installation Guide

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

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Locate the vacuum – There is a vacuum point on the inlet tract, as shown below left. Remove the screw and replace with the M5 Brass Spigot from the Scottoiler kit, using some RTV Silicon Sealant on the threads to ensure an airtight seal. Then press the Damper Elbow, part number 4, onto the spigot. The Dispenser Assembly, shown bottom left, is routed along the underside of the Swingarm using Dispenser Mounting Sleeves, Cable Ties & Glue. Note: an epoxy resin (eg. Araldite) is req’d to bond the sleeves to the Swingarm. For further information see our easy step installation guide – ‘Dispenser Assemblies, General’ . The nib should feed the sprocket between the 6 & 7 o’clock positions, with the cut face facing outwards. The Dual Injector (sold separately) is shown below. The RMV can be mounted on the frame, where indicated by the arrows in the third picture. The more vertical the RMV the better and remember to avoid exhaust and engine components. For further information, see our easy step installation guide – ‘RMV Positions, General’

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