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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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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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2010 HONDA VFR1200F Dual Clutch Transmission Specifications

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Filed Under (Honda) by admin on 18-02-2011

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Specifications VFR1200F Dual Clutch Transmission (ED-type/ F-type) ENGINE Type Liquid-cooled 4-stroke UNICAM 76° V-4 Displacement 1237cc Bore  Stroke 81  60mm Compression Ratio 12:1 Max. Power Output ED: 127kW/10,000min-1 (95/1/EC) F: 83kW/9,500min-1 (95/1/EC) Max. Torque ED: 129Nm/8,750min-1 (95/1/EC) F: 115Nm/4,000min-1 (95/1/EC) Idling Speed 1,150 min-1 Oil Capacity 4.9 litres FUEL SYSTEM Carburation PGM-FI electronic fuel injection Aircleaner Oil-permeated, viscous-type paper filter Fuel Tank Capacity 18.5 litres Fuel Consumption ED/E : 15.9 km/l F : 15.9 km/l (tested in D-Mode) (WMTC mode*) VFR1200F 03/05/10 9 9 ELECTRICAL SYSTEM Ignition System Computer-controlled digital transistorised with electronic advance Ignition Timing 8.4° BTDC (idle speed) Sparkplug Type IMR9E-9HES (NGK); VUH27ES (DENSO) Starter Electric Battery Capacity 12V/11.2Ah (YTZ14S) ACG Output 570W Headlights H7x2 (55Wx2) Tail-light 5Wx2,STOP LIGHT 21W( 21/5W+5Wdual-light) DRIVETRAIN Clutch Wet multi-plate, hydraulic, dual Clutch Operation Hydraulic Transmission Type Constant mesh 6-speed Primary Reduction 1.738 (73/42) Gear Ratios 1 2.4666 (37/15) 2 1.7894 (34/19) 3 1.4090 (31/22) 4 1.1600 (29/25) 5 1.0322 (32/31) 6 0.9393 (31/33) VFR1200F 03/05/10 10 10 Final Reduction 2.7061 Final Drive Shaft FRAME Type Diamond; aluminium twin-spar CHASSIS Dimensions (LWH) 2250  740 1220mm Wheelbase 1,545mm Caster Angle 25.5° Trail 101mm Turning Radius 3.5m Seat Height 815mm Ground Clearance 125mm Kerb Weight 277kg Loaded Weight 473Kg SUSPENSION Type Front 43mm cartridge-type telescopic fork with stepless preload adjustment, 120mm axle travel RearPro-Link with gas-charged damper, VFR1200F 03/05/10 11 11 25-step (*stepless remote-controlled hydraulic) preload and stepless rebound damping adjustment, 130mm axle travel WHEELS Type Front 5-spoke hollow gravity Die-cast aluminium Rear7-spoke gravity Die-cast aluminium Rim Size Front 17M/C  MT3.50 Rear 17M/C  MT6.00 Tyre Size Front 120/70 ZR17M/C (58W) Rear 190/55 ZR17M/C (75W) Tyre Pressure Front 250kPa Rear 290kPa BRAKES Type Front 320mm dual floating hydraulic disc with two 6-piston callipers, C-ABS and sintered metal pads Rear276mm hydraulic disc with 2-piston calliper, C-ABS and sintered metal pads All specifications are provisional and subject to change without notice. * Please note that the figures provided are results obtained by Honda under standardized testing conditions prescribed by WMTC. Tests are conducted on a rolling road using a standard version of the vehicle with only one rider and no additional optional equipment. Actual fuel consumption may vary depending on how you ride, how you maintain your vehicle, weather, road conditions, tire pressure, installation of accessories, cargo, rider and passenger weight, and other factors

BMW K 1100 LT/ RS Repair And Installation Manual

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

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Transmission cover to transmission 9 Machine screw for neutral stop 13 Stud bolt, selector shaft 17 (Loctite 243) Transmission to intermediate flange 16 Frame mounting to transmission 45 Bearing mount to transmission 41 (Loctite 243) Starter motor to transmission 9 Positive lead to starter motor 5 Fixed bearing of swinging arm to transmission 9 Swinging arm bearing journal (loose bearing) 7,5 Locknut of bearing journal 41 Fixed bearing rear wheel drive in swinging arm 150 (clean thread + Loctite 2701) Bearing pin, loose bearing rear wheel drive in swinging arm 7 (clean thread + Loctite 2701) Locknut, loose bearing rear wheel drive in swinging arm 105 (clean thread + Loctite 2701) Suspension strut to frame/rear wheel drive 51 Brake caliper 32 Hinterradschraub en 105 Exhaust to cylinder head 21 Silencer to holder/footrest plate 9 Front silencer to transmission 12 Footrest plate to transmission 15 31 Front fork Oil filler plug 10 Oil drain plug 3,5 Spring support bearing 20 Locking tube 65 Hexagon nut 65 Clamping screws of fork bridges 15 Bottom screw fitting 47 Handlebar clamp block 22 Fork stabilisor

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A750 Transmission Solenoid Identification Automatic Transmission/ Transaxle

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Filed Under (Toyota Manuals) by admin on 19-09-2011

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Provided below isachartlisting the Repair Manual name of each solenoid used in the A750 transmission, as well as the part name description provided in the electronic parts catalog. REPAIR MANUAL SOLENOID NAME PARTS CATALOGP ART DESCRIPTION S1 3WayTransmission Solenoid S2 Transmission Solenoid#3 SL1 Clutch Control Solenoid#1 SL2 Clutch Control Solenoid#2 SLT Line Pressure Control Solenoid SLU Lock UpControl Solenoid SR

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION INSRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

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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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HARLEY DAVIDSON CHROME TRANSMISSION HARDWARE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cable, negative (-) cable only. NOTE The starter does not need to be removed to install this kit. 2. Remove exhaust system only if needed to access transmission top cover hardware. Refer to Service Manual for instructions. NOTES Replace existing zinc hardware with chrome-plated hardware one at a time so the transmission top and side covers do not need to be replaced. 3. Remove and discard existing six 1/4-20 x 1 in. hex socket- head screws and washers from top transmission cover. Install six chrome hex socket head screws (1) and washers (2) on top transmission cover (3). Tighten to 84-108 in-lbs (9.5-12.2 Nm). 4. Remove and discard existing two 1/4-20 x 1 in. hex socket head screws and washers from side transmission cover. Install two chrome hex socket head screws (1) and washers (2) on side transmission cover (5). Tighten to 84- 108 in-lbs (9.5-12.2 Nm). 5. Remove and discard existing four 1/4-20 x 1-1/2 in. hex socket head screws and washers from side transmission cover. Install four chrome hex socket head screws (4) and washers (2) on transmission side cover (5). Tighten to 84- 108 in-lbs (9.5-12.2 Nm). 6. Install exhaust system if previously removed. Refer to Service Manual for instructions. 7. Connect negative (-) battery cable

HARLEY DAVIDSON ENGINE/TRANSMISSION INTERFACE AND TOP COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 1 4 3 2 is03621 1. Transmission top cover screw (3) 2. Upper and lower rear bearing housing screw (2) 3. Upper front bearing housing screw 4. Lower front bearing housing screw Figure 1. Interface Cover Installation 2. See Figure 1. Remove the two rear bearing housing screws (2) from the side of the transmission case. 3. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 4. See Figure 2. Obtain the rear interface mounting bracket (1) from the kit. 5. Apply a few drops of Loctite 243 (Blue) to the threads of the two bearing housing screws removed in Step 2. Install the rear interface mounting bracket to the bearing housing with the screws, and tighten to 13-18 ft-lbs (17.6-24.4 Nm) . 6. See Figure 1. Remove the upper front bearing housing screw (3) from the side of the transmission case. Loosen the lower front bearing housing screw (4). 7. See Figure 2. Obtain the front interface mounting bracket (2) from the kit. 8. Apply a few drops of Loctite 243 (Blue) to the threads of the upper front bearing housing screw removed in Step 6. Hook the slot in the front interface mounting bracket under the loosened lower screw head. Install the bracket to the bearing housing with the upper screw, and tighten both screws to 13-18 ft-lbs (17.6-24.4 Nm) . 9. See Figure 1. Remove and retain the three socket head cap screws (1) that fasten the right side and left front corner of the transmission cover. 10. Remove and retain the screw fastening the rear brake line P-clamp to the rear fork bracket. 11. See Figure 2. Obtain the right rear interface cover (3), two chrome 1/4-20 screws (6) and two flat washers (7) from the kit. 12. From the rear of the motorcycle, bring the right rear interface cover into position behind the rear exhaust pipe, over the bearing housing. The hole in the top surface of the cover should be positioned over the right rear transmission top cover hole. 13. Loosely fasten the interface cover to the rear interface mounting bracket with the two chrome screws and flat washers. 14. Obtain the chrome top interface cover (4) from the kit. 15. Position the top interface cover over the transmission top cover, overlapping the tab at the top front of the chrome right rear interface cover

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