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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

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PRO-CYCLE AND PRO-CYCLE XLT 1,000-Lbs. Capacity Motorcycle Lift

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Filed Under (Tips and Review) by admin on 27-11-2010

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1. Always inspect the lift for freight damage and make note of any damage on the bill of lading. 2. In case of freight damage, call the truck line immediately and report the damage as a freight claim. Final Set-Up for model Pro-Cycle This lift is more than 90% factory pre-assembled. The following steps will guide you through the final set-up. IT WOULD BE EASIER FOR TWO MEN TO COMPLETE FOLLOWING STEPS. 1. Unpack the lift from the shipping skid. With the lift table up side down, connect the air hose to the air cylinder (Part # 26). 2. After tightening the hose to the cylinder, flip the lift over with the table surface up. 5 3. Lift up the table manually to the first lock position to make sure the lift is rising freely. Lubricateing the joints again before use will ensure a better performance of the lift. 4. Connect the other end of the air hose to the foot-operated valve. Then connect the foot- operated valve to 100 PSI air supply. DO NOT USE AIR SUPPLY WITH PRESSURE MORE THAN 100 PSI. 5. Release the safety bar by pushing the handle down. Operate the foot valve by stepping on the footpad forward to raise the lift. The safety bar should engage the ladder automatically while lift is rising. Step on the footpad again to set the pad in middle position to stop the lift when it reaches the desired height. ALWAYS LOWER LIFT IN THE NEAREST LOCKED POSITION BEFORE BEGINNING WORK. NEVER USE THE LIFT UNLESS YOU ARE IN A LOCKED POSITION. The lift should never be left unattended while attached to air pressure. Disconnect the air pressure when lift is not attended by qualified persons. 6. Install the vise using bolts and nuts supplied with the lift (part # 6 to 12). See fig #1. 7. Install the approach ramp by dropping it into the holes punched on the rear edge of the table. The final Set-Up for the Pro-Cycle model is complete

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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COMMANDER 1,000 LBS. CAPACITY MOTORCYCLE LIFT INSTALLATION AND OPERATION MANUAL

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Filed Under (Tips and Review) by admin on 25-11-2010

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Your lift comes packaged as a single unit. A fork-lift, floor-jack or other heavy-lifting equipment may be necessary to separate the components. Exercise caution when disassembling the packaged lift, as shifting may have occurred during shipping. 2] Carefully unpack the lift. Check for any obvious shipping damage. (Remember to report any shipping damage to the carrier and make a notation on the delivery receipt.) 3] Carefully turn the table upright into operating position before removing shipping cable restraint from scissor mechanism. 4] Connect foot-operated air valve to 100 psi maximum air supply. The lift may be damaged and/or personal injury may result if the pressure exceeds the maximum 100 psi rating. 5] Stand clear of lift table, and depress the “UP” side of the foot valve to raise the table. 6] To lower table, lift locking bar from safety latch and lower to next position, or to the floor. 7] Place drop-out cover over drop out opening. 8] Insert ramp mounting pins into holes at either end of table to mount ramp. NOTE: If cycle vise is being installed, ramp must be mounted opposite the cycle vise. OPERATION and MAINTENANCE 1] Loads must be centered on table at all times. Table is rated for a maximum load of 1,000lbs. 2] Loads must be firmly positioned and secured on table at all times. 3] All moving parts have been lubricated at the factory and should be re-lubricated every six (6) months to prevent problems. Grease points are located at each end of frame pivot shaft and at top ends of inside frame assembly. 4] Lightly oil cylinder rod when it becomes dry. 5] Squirt some oil through bleed hole in plate end of cylinder to lubricate piston and its seal every six (6) months. 6] Pivot shaft set screws should be checked frequently to be sure they are tight. These are located at the top end of the inside frame assembly.

Motorcycle wheel assemblies Repair Manual

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Filed Under (Tips and Review) by admin on 19-11-2010

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Safe working practices are observed throughout the task in accordance with legislative requirements. Range personal safety, safety of others, motorcycle safety, workshop safety, environmental safety, tools and equipment safety. 3.2 Suitable tools and equipment are selected and used that enable the wheel assembly to be repaired in accordance with service information. 3.3 The hub bearings are serviced in accordance with service information. 3.4 The wheel assembly is reassembled in accordance with service information. 3.5 Rivets and bolts are checked and repaired or replaced in accordance with service information. Please note Providers must be accredited by NZQA, or an inter-institutional body with delegated authority for quality assurance, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment. Industry Training Organisations must be accredited by NZQA before they can register credits from assessment against unit standards. Accredited providers and Industry Training Organisations assessing against unit standards must engage with the moderation system that applies to those standards. Accreditation requirements and an outline of the moderation system that applies to this standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The AMAP also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements. Comments on this unit standard

TOYOTA Engine Serial Number Location

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Filed Under (Toyota Manuals) by admin on 06-10-2011

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YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2000-2009 4Runner, Avalon, Camry, Corolla, Land Cruiser, RAV4, Sienna, Solar a, Tacoma, Tundra 2007-2009 Camry HV, FJ Cruiser, Yar is 2000-2005 Celica, Echo, MR2 Spyder 2006-2009 Highlander HV 2001-2009 Highlander, Prius, Sequoia 2003-2009 Matrix 2009 Venza The purpose of this TSB is to assist in the identification and location of engine serial numbers on 2000-2009modelyear Toyota vehicles. NOTE When writing a Field Technical and/or Product Report the serial number of the engine MUST be provided.

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Crankshaft Durability of Rover K-Series Engine: Comparison of ENGDYN Analysis with Dynamic Measurements

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Filed Under (BMW) by admin on 17-11-2010

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The Rover K-Series engine has now been in production for over 10 years, initially of 1.4 L capacity. Since then 1.1L, 1.6L, 1.8L and 1.8L VVC (Variable Valve Control) have been introduced with an accumulative build of two million engines since 1989. The 1.8L engine is also built under official licence for Lotus and Caterham, and also in the MGF motorsport series. The K-Series is an attractive buy due to its reduced cost and low weight, which is a necessity for sport cars. This report aims to validate Ricardo ENGDYN software with respect to Rover K-Series 1.8 Litre VVC crankshaft durability. The software will be used to output the behaviour of the crankshaft under as realistic conditions as possible. The oil film thickness and bearing load characteristics of the crankshaft through the running range of the engine will be compared to results obtained from in-house software. The torsional and bending vibration output from ENGDYN will then be compared with results obtained from dynamic measurements. Finally, the crank stress and durability results from ENGDYN will be compared to strain gauge measurements at comparative points on the crankshaft. ENGDYN is a computer program used for analysing the dynamics of the engine, and in particular the crankshaft and its interaction with the cylinder block. In this analysis the software will be used to predict the time-domain response of the 3-dimensional vibration of the crankshaft coupled to the block by way of a non-linear oil film. When this loading and motion has been calculated the software can perform a fast Fourier transform to break down the time-domain response into its corresponding frequencies. This allows the results to be post-processed in the frequency domain. 2 Method of Analysis 2.1 Engine Specifications Configuration: in-line 4 Fuel: Gasoline Cylinder bore: 80 mm Piston stroke: 89.3 mm Swept volume: 1.8L Crankpin Peak Power: 107 KW @ 7000 rpm Peak Torque: 174 N/m @ 4500 rpm Engine running range: 750-7200 rpm 2.2 Component Modelling 2.2.1 Crankshaft To perform the analysis within ENGDYN two crankshaft models were created. These included a complete stiffness representation of the crank (excluding the crank nose hub and the flywheel), and a detailed model of the crank from main bearing 4 to main bearing 5, with mesh density increased around the fillets. ENGDYN can however perform crank analysis of any portion of the crank as long as the model incorporates at least two main journal bearings. Features such as bolt holes and oil drilling were omitted on both models, which were meshed using solid tetrahedral elements

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Demonstrate knowledge of motorcycle braking systems and repair procedures

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Filed Under (Tips and Review) by admin on 21-11-2010

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Demonstrate knowledge of motorcycle braking system repair procedures. Performance criteria 2.1 Fault diagnosis procedures are described in accordance with service information. Range safety procedures when diagnosing, logical inspection procedure, checking fault codes, recognising wear, damage, scoring, poor adjustment, seized parts, corrosion, air in hydraulics, brake squeal, brake shudder, brake grab. 2.2 Hydraulic cylinder inspection procedures are described in accordance with service information. Range layout of components, cylinder operation, cleaning methods, measuring wear, attention to cleanliness, limits of corrosion and scoring. 2.3 Brake repair procedures are described in accordance with service information. Range repairing cylinders and callipers, safety implications, replacing cables and rods, fitting shoes and pads, adjusting brakes, replacing brake fluid, clearing fault codes, testing brake operation. Please note Providers must be accredited by NZQA, or an inter-institutional body with delegated authority for quality assurance, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment. Industry Training Organisations must be accredited by NZQA before they can register credits from assessment against unit standards. Accredited providers and Industry Training Organisations assessing against unit standards must engage with the moderation system that applies to those standards. Accreditation requirements and an outline of the moderation system that applies to this standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The AMAP also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements

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