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Ktm 625/ 640/ 660 LC4's and some 640 Adventures Removal and Installation Manual

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Filed Under (KTM) by admin on 24-01-2012

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1. There are 3 pages of instructions here. Review all 3 first! These model bikes normally require modifications. 2. Warning: Once the triple clamp is loose, the forks can roll away from the bike . Follow step 2 carefully. 3. Block the front and rear tire securely before removing the top triple clamp, keeping the weight pushed on the front wheel so the front tire cannot move forward and the forks are forced upward, keeping the bearing in the head tube. 4. Remove the 4 bolts holding your bars tight and lay the bars forward out of the way. 5. Using Loc-tite, change the lower nuts on the under side of your triple clamp that hold your bar perches. Use the “low profile” version that we have supplied in the kit. You will need access to the Allen head bolts in the lower perch halves. Without these low profile nuts the triple clamp will not be free to turn lock to lock. There are occasions where you may have to grind on the frame bracket to allow a little extra clearance for even the low profile nuts (see photo). Because the bars are rubber mounted, this clearance varies from bike to bike. Turn the triple clamp lock to lock and be sure you have clearance. You must change them now, as later you won’t have room to do so. 6. Now remove the top triple clamp taking note of how tight the main nut is, so you can re-tighten to the exact amount. 7. Remove the tin bearing shroud (cover) and rubber seal. The lips of the seal face downward for correct installation. 8. The new shorter bearing shroud will replace the stock tin shroud, giving the frame bracket more room to seat. 9. Grease your bearings while you have them exposed. (Keep the grease off the area where our frame bracket mounts). 10. Only if your model is equipped with one, you will need to cut off the upper portion of the square steering lock receiver box (see photo). The steering lock stays functional as the lock-pin still engages the lower the portion of the box. Mark and cut the top of the box off. You must cut enough to allow our frame bracket to drop down far enough so the entire bracket grabs the head tube. If you don’t allow the frame bracket enough clamping surface it will come loose. The upper edge of the frame bracket should be level with the step where your stock bearing seal seats. (See photo). 11. Install the frame bracket so it matches the clamping area on your head tube, but do not tighten it yet. Do not remove the paint on the frame where the frame bracket fits. The paint is calculated as part of the correct dimension. On most LC4′s you will need to grind the weld at the back of the head tube, so the bracket can drop all the way down flush. Each bike is a little different; some require a lot of grinding and some very little. Try to remove the weld while retaining the original diameter of the head tube where our bracket will clamp. It is essential for the frame bracket to clamp to a symmetrical, round head tube. When you’ve removed the majority of weld the finished removal should be done with a file for precision clearance, without touching the area where the clamp will seat

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2008 Vespa GTS 250 Garmin Zümo 660 Installation Manual

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Filed Under (Vespa) by admin on 28-10-2010

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A. Remove wind screen B. Remove riding mirrors C. Carefully pry off the Piaggio plate (note the glove as protection) D. Remove the screw behind it E. Remove the front top screw just below the headlight F. Do NOT remove this screw G. Remove the two screws on the bottom side to the left and right H. Remove the cover Step 2 – extending the hole By carefully using a file of knife make a small crater in the front end of the hole where the wind screen passes through the cover. This will allow you to tighten the mechanism while not damaging the cables. Step 3 – finding a path for the cables Now as the cable will not easily pass through the interior of the Vespa a bit of help is needed. A. Using an old cable/wire from the top side allows you to find a path down to the glove compartment. B. Securing the cabling to the old cable

ROAD TECH ZUMO 660 GLOBAL POSITIONING SYSTEM (GPS) FAIRING MOUNTING KIT INSTALLATION

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Filed Under (Tips and Review) by admin on 27-10-2010

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1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. Remove the outer fairing and windshield. Refer to the service manual. is05900 Figure 1. Road Tech Zumo Drilling Template Placement 3. See Figure 1. Obtain the drilling template from the kit. 4. Position the template on the back side of the inner fairing, in the upper left corner above the fuel gauge, aligning the template to the top of the inner fairing and the plastic rib as shown. 5. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing per the template. 6. See Figure 4. Position the gasket (2) and GPS mount (1) onto the face of the inner fairing, aligning the upper hole in the mount with the hole drilled in the previous step. 7. Temporarily install one of the screws (4) through the upper hole to help align the GPS mount. 8. See Figure 2. Mark the location of the lower mounting hole on the face of the inner fairing, using the GPS mount and gasket as a template. Mark the location of the wire routing hole using the guide hole (3) in the gasket as a template. 9. Remove the screw, GPS mount and gasket from the inner fairing. 10. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing in the lower mounting location. Drill an 11/16 (17 mm) diameter hole through the inner fairing in the wire routing location. 1 2 3 is06149 1. Gasket 2. Wire routing guide hole and ribs 3. Guide hole Figure 2. Remove Gasket Ribs and Guide Hole 11. See Figure 2. Remove the wire routing guide hole and four ribs (2) from the gasket (1). 12. See Figure 4. Install the GPS mount and gasket to the inner fairing with screws (4) flat washers (5) and locknuts (6). Tighten to 50-60 in-lbs (5.6-6.8 Nm) 13. Obtain cradle with harness from GPS system kit. NOTE The fuse holder on the harness must be opened to fit through the hole. 14. Insert harness through the 11/16 inch (17 mm) diameter hole drilled earlier. 15. Insert the split grommet into the 11/16 inch (17 mm) diameter hole around the harness. Installing the Cradle 1. See Figure 4. Install four bushings (H) from the GPS system kit and insert them into the back of the cradle mounting holes. 2. Position the cradle to the GPS mount. Direct the harness out through the slot (G) of the mount. 3. Insert a button head screw (3) through one of the holes in the cradle and into the corresponding hole in the GPS mount, but do not fully tighten

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Harley-Davidson Camshaft TC, EVO, Shovelhead, XL EVO, Iron Head, XR Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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EVO Black Widow PP8833-2 – 29 55 62 25 264 267 54 103 109 105.8 0.600 0.602 EVO Black Widow PP8826-2 – 27 61 63 29 268 272 56 107 107 107.0 0.602 0.602 EVO Black Widow PP8817-2 – 254 254 0.590 0.590 EVO Carl’s Speed Shop CM4 – 28 44 52 20 252 252 48 98 106 102.0 0.495 0.495 EVO Carl’s Speed Shop CM495F Y 19 47 50 16 246 246 35 104 107 105.5 0.495 0.495 0.179 0.168 EVO Carl’s Speed Shop CM580 – 19 47 50 16 246 246 35 104 107 105.5 0.580 0.580 0.194 0.163 EVO Carl’s Speed Shop CM612 – 36 60 68 28 276 276 64 102 110 106.0 0.612 0.612 0.277 0.235 88 EVO Carl’s Speed Shop CM660 – 38 62 68 28 280 276 66 102 110 106.0 0.660 0.660 0.314 0.277 90 EVO Carl’s Speed Shop CM774 – 284 284 0.784 0.784 0.277 0.236 EVO Carl’s Speed Shop CM780F – 34 70 74 30 284 284 64 108 112 110.0 0.774 0.774 103 EVO Crane EVR0020 – 31 64.5 77 23 275 280 54 107 117 112.0 0.608 0.589 88 EVO Crane Fireball 2000 Y -12 22 20 -10 190 190 -22 107 105 106.0 0.490 0.490 0.026 0.032 EVO Crane Fireball 300 Y 12 34 41 15 226 236 27 101 103 102.0 0.490 0.490 4000 EVO Crane Fireball 310 Y 16 40 43 19 236 242 35 102 102 102.0 0.490 0.490 1500 4500 75 EVO Crane Fireball 316 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane Fireball 326 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H286 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane H290 – 17 43 45 23 240 248 40 103 101 102.0 0.581 0.581 1800 5200 EVO Crane H296 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H304 – 24 50 55 25 254 260 49 103 105 104.0 0.600 0.600 2500 5800 EVO Crane H306 – 28 54 69 23 262 272 51 103 113 108.0 0.500 0.510 0.224 0.195 3000 6000 EVO Crane H310 – 23 63 68 28 266 276 51 110 110 110.0 0.550 0.550 0.229 0.229 3000 6500 88 EVO Crane H314 – 26 54 65 21 260 266 47 104 112 108.0 0.600 0.600 2800 6000 EVO Crane HEV0042 – 27 59 71 23 266 274 50 106 114 110.0 0.600 0.576 0.226 0.194 3000 6000 100 116 EVO Crane HEV0067 – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 0.128 0.113 EVO Crane HEV0098 – 36 62 72 34 278 286 70 103 109 106.0 0.650 0.650 0.171 0.156 96 EVO CycleRama CR-E550 – 24 52 53 23 256 256 47 104 105 104.5 0.550 0.530 EVO CycleRama CR-E581 – 22 46 53 23 248 256 45 102 105 103.5 0.581 0.550 EVO CycleRama CR-E600A – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 EVO CycleRama CR-E600B – 23 51 54 22 254 256 45 104 106 105.0 0.600 0.550 EVO CycleRama CR-E617 – 22 50 50 22 252 252 44 104 104 104.0 0.617 0.617 EVO CycleRama CR-E630 – 18 60 63 13 258 256 31 111 115 113.0 0.630 0.630 EVO CycleRama CR-E660 – 27 59 71 23 266 274 50 106 114 110.0 0.660 0.660 3500 6500 140 EVO Dave Mackie DM500 Y 22 38 52 12 240 244 34 98 110 104.0 0.500 0.500 0.189 0.138 EVO Dave Mackie DM500X Y 25 40 55 20 245 255 45 98 108 102.5 0.500 0.500 0.208 0.178 EVO Dave Mackie DM530 – 28 42 55 15 250 250 43 97 110 103.5 0.530 0.530 0.221 0.141 EVO Dave Mackie DM580 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 113 EVO Dave Mackie DM581 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 EVO Dave Mackie DM595 – 21 49 57 14 250 251 35 104 112 107.8 0.595 0.595 0.192 0.150 EVO Dave Mackie DM635 – 20 56 59 18 256 257 38 108 111 109.3 0.635 0.635 0.194 0.176 EVO Edlebrock 1740 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 0.176 0.203 EVO Edlebrock 1741 – 20 46 52 22 246 254 42 103 105 104.0 0.600 0.600 0.183 0.187 EVO Head Quarters HQ-23 – 19 47 52 24 246 256 43 104 104 104.0 0.600 0.530 EVO Head Quarters HQ-24 Y 20 36 52 19 236 251 39 98 107 102.3 0.500 0.500 EVO Head Quarters HQ-25 – 18 38 42 14 236 236 32 100 104 102.0 0.550 0.550 EVO Head Quarters HQ-26 – 20 54 53 22 254 255 42 107 106 106.3 0.600 0.530 89 EVO Head Quarters HQ-27 – 26 60 70 24 266 274 50 107 113 110.0 0.650 0.575

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2007 Harley-Davidson VRSC Family: Specifications

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Length (mm) 2455 2460 Overall Height (mm) 1100 1120 Seat Height – laden (mm) 2 660 660 Ground Clearance (mm) 127 127 Rake (steering head) 34° 34° Fork Angle 36° 36° Trail (mm) 115 115 Wheelbase (mm) 1715 1715 Fuel Capacity (litres) 18.9 18.9 Oil Capacity w/filter (litres) 4.3 4.3 Dry Weight (kg) 292 287 Engine 3 Liquid-cooled, Revolution® Liquid-cooled, Revolution® Displacement (cu. cm) 1130 1130 Bore x Stroke (mm) 100 x 72 100 x 72 Compression Ratio 11.3:1 11.3:1 Fuel System Electronic Sequential Port Fuel Injection (ESPFI) Electronic Sequential Port Fuel Injection (ESPFI) Exhaust System Chrome, slash-cut duals Chrome, straight-shot dual pipes Type Dunlop® Harley-Davidson Series, radial Dunlop® Harley-Davidson Series, radial Front D208F 120/70ZR-19 60W D208F 120/70ZR-19 60W Rear D419 240/40R-18 79V D207 180/55ZR-18 74W Machined slotted disc Machined slotted disc 19 x 3 in. 19 x 3 in. Machined slotted disc Machined slotted disc 18 x 8 in. 18 x 5.5 in. Primary Drive Gear, 64/117 ratio Gear, 64/117 ratio Final Drive Belt, 30/72 ratio Belt, 30/72 ratio Clutch 9-plate, wet 9-plate, wet Transmission 5-speed 5-speed 1st 10.98 10.98 2nd 7.38 7.38 3rd 5.88 5.88 4th 5.10 5.10 5th 4.57 4.57

How To Adjust the Accelerator Pump On the 40mm Mikuni Carburetor

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Filed Under (Yamaha) by admin on 21-01-2012

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1) The “blue” colored screw in the image is the duration adjustment screw. Underneath the head of the screw is a lock nut and the bracket arm that the screw is threaded into. To decrease the amount of fuel squirted the adjustment screw is turned “clockwise” or in. To increase the amount of fuel squirted the adjustment screw is turned “counter clockwise” or out. To get the max, amount of decrease remove the screw and take the lock nut off of the screw. Then replace the screw into the cam arm, then replace the lock nut underneath the arm on the screw. this gives you another 3/32″ of an inch in which the screw can be screwed in.
2) Turn the adjustment screw fully clockwise or IN. Start your engine, Blip your throttle open, if the engine stutters, (hesitates), it is not getting enough fuel so turn the screw counter clockwise to increase the amount of fuel squirted from the accelerator pump into the carburetor. Keep blipping the throttle and adjusting the screw till the carburetor starts to cough. Stop here and turn the screw back in till the coughing stops. Tighten down the lock nut. This should give you the best throttle response with the least amount of coughing and backfiring out the carburetor. Timing Adjustment Screw This is the “Green” colored screw just above the Blue duration adjustment screw. The” Mucker” said it best,,,,, This upper screw adjusts the “timing” of the squirt. By altering it’s setting, you can advance or delay the onset of the fuel squirt. But probably, it won’t have to be touched

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Aprilia PEGASO 650 Technical specifications

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

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Engine Single-cylinder four-stroke with light alloy cylinder. Liquid cooling with three way pressurised circuit. Single overhead cam with chain timing drive; four valves. Anti-vibration balancer shaft. Euro 3. Fuel Unleaded fuel. Bore and stroke 100 x 84 mm. Total displacement 660 cc. Compression ratio 10:1. Max. power at crankshaft 48 HP (35 kW) at 6,000 rpm. Max. torque at crankshaft 6.01 kgm ( 59 Nm) at 5,000 rpm. Fuel system Integrated electronic engine management system. Electronic fuel injection. 44 mm throttle body. Ignition Electronic. Starting Electric starter. Alternator 290 W Lubrication Dry sump with oil pump. Gearbox 5 speed. Transmission ratios: 1st 12/30 2 nd 16/26 3rd 20/23 4th 22/20 5th 26/20 Clutch Multi-plate in oil bath. Cable operated. Primary drive Spur gears. Transmission ratio: 36/75. Final drive Chain. Transmission ratio: 15/44. Frame Steel, open cradle, single spar frame. Front suspension 45 mm fork. Wheel travel 140 mm. Rear suspension High strength steel swingarm. Aprilia Progressive System (APS) rising rate linkages. Sachs hydraulic monoshock with adjustable rebound and preload. Wheel travel 130 mm. Brakes Front: stainless steel floating disc, ∅ 320 mm, four piston caliper. Rear: stainless steel disc, ∅ 240 mm, two piston caliper. Wheels Alloy wheels with twinned spokes. Front: 3.50 x 17″. Rear: 4.50 x 17″.

Aprilia PEGASO 650 FACTORY – Technical specifications

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

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Engine Single-cylinder four-stroke with light alloy cylinder. Liquid cooling with three way pressurised circuit. Single overhead cam with chain timing drive; four valves. Anti- vibration balancer shaft. Fuel Unleaded fuel. Bore and stroke 100 x 84 mm. Total displacement 660 cc. Compression ratio 10:1. Max. power at crankshaft 48 HP (35 kW) at 6,000 rpm. Max. torque at crankshaft 6.01 kgm ( 59 Nm) at 5,000 rpm. Fuel system Integrated electronic engine management system. Electronic fuel injection. 44 mm throttle body. Ignition Electronic. Starting Electric starter. Alternator 290 W Lubrication Dry sump with oil pump. Gearbox 5 speed. Transmission ratios: 1st 12/30 2nd 16/26 3rd 20/23 4th 22/20 5th 26/20 Clutch Multi-plate in oil bath. Cable operated. Primary drive Spur gears. Transmission ratio: 36/75. Final drive Chain. Transmission ratio: 15/44. Frame Steel, open cradle, single spar frame. Front suspension 45 mm fork. Wheel travel 140 mm. Rear suspension High strength steel swingarm. Aprilia Progressive System (APS) rising rate linkages. Sachs hydraulic monoshock with adjustable rebound and preload. Wheel travel 130 mm. Brakes Front: FTE stainless steel floating disc, ∅ 320 mm. Four piston radial caliper with radial master cylinder. Rear: stainless steel disc, ∅ 240 mm. Floating caliper

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YAMAHA FJR1300N OWNER'S MANUAL

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

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3-2 3 EAU03034 Indicator and warning lights EAU04121 Turn signal indicator lights “” a n d “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU00061 Neutral indicator light ” ” This indicator light comes on when the transmission is in the neutral position. EAU00063 High beam indicator light ” ” This indicator light comes on when the high beam of the headlight is switched on. EAU03201 Oil level warning light ” ” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Set the engine stop switch to ” ” and turn the key to “ON”. 2. Shift the transmission into the neu- tral position or pull the clutch lever. 3. Push the start switch. If the warning light does not come on while push- ing the start switch, have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a mal- function. EAU03192 Engine trouble warning light ” ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this oc- curs, have the Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Set the engine stop switch to ” “. 2. Turn the key to “ON”. If the warn- ing light does not come on, have a Yamaha dealer check the

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YAMAHA YZF-R1R/ YZF-R1RC OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 03-12-2010

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1. Right turn signal indicator light “” 2. Fuel level warning light “” 3. Oil level warning light “” 4. Neutral indicator light “” 5. Engine trouble warning light “” 6. High beam indicator light “” 7. Left turn signal indicator light “”
INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU04895 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5seconds. If this occurs, have a Yamaha dealer check the motor- cycle. EAU00061 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU04896 Engine trouble warning light “” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. (See page 3-7 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. EAU00063 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on

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