gsxr600k7 output shaft seal leaking

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Harley Davidson Twist Gear and Wide Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 11-04-2012

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Assemble triple lip output seal 705002 and output spacer 280001 together. The seal is shipped with high performance grease packed into the seal lips to ensure lubrication and exclude dust & water. (Caution: Only high temperature grease should be used, grease is better than oil, never install the seal dry.) Slide the quad ring and seal/spacer assembly onto the transmission output shaft, then slide tool JE300001 ( TwistGear TM ) or JE300002 ( WideGear ) onto the shaft and finally tighten the nut until the tool drives the seal flush with the case. Do not attempt to install the main drive seal without the JE tool or the seal will be damaged, and the seal performance will be compromised (the JE seal is wider around the shaft for the third sealing lip, which will be damaged if a tool is pressed against it.) It is best that a new JE spacer be used each time a new seal is installed for quick break-in of the main lip seal surface. Counter Shaft Assembly Note the order and orientation of the gears on the counter shaft when it is removed from the trapdoor. Disassemble the counter shaft and transfer the parts to the TwistGear TM counter shaft. Note that the TwistGear TM counter shaft assembles in different order than the OEM counter shaft. Two washers are required in the position as shown in figure 1 (see arrow) before the retainer ring is installed. The second washer is included in the kit.

TOYOTA TACOMA TRANSMISSION TO ATLAS TRANSFER CASE

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Filed Under (Toyota Manuals) by admin on 20-09-2011

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Remove the stock transfer case from the stock tailhousing adapter. The stock tailhousing is retained along with the stock rubber crossmember support. Once the transfer case is removed, you’ll see a seal located in the stock tailhousing. This seal must be removed and discarded. Some tailhousings also had a bearing which also must be removed. Install the new oil seal into the large end of the seal adapter. The sealing lip should be facing down. The small end of the seal adapter has the same O.D. (outside diameter) as the old seal that was just removed from the stock tailhousing. The seal adapter is a press-fit into the stock tail and should now be installed. The kit comes with a new spud shaft which fits over the stock Toyota transmission 26 spline output shaft. This spud shaft has a Jeep 23 male spline on the opposite side which fits into a standard 23 spline Atlas case. When installing the spud shaft into the Toyota transmission, the spud shaft does not seal onto the new seal just previously installed. The seal contacts seal off of the Atlas input shaft. The adapter plate should now be installed onto the Atlas transfer case. The adapter plate indexes off of the Atlas front retainer

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RACE TECH SUSPENSION SERVICE TOOLS

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Filed Under (Tips and Review) by admin on 01-12-2010

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SHOCK SEAL BULLET TOOL “Bullet Tools” make seal head installation onto shafts quick and easy. 35-8677 TSSB12512.5 x 10mm Shock Seal Bullet 35-8678 TSSB1414 x 12mm Shock Seal Bullet 35-8679 TSSB1616 x 12mm Shock Seal Bullet FORK CAP WRENCH 46/50MM Black Oxidized steel construction for superior strength. Multiple applications (46/50mm): Honda CR250 (97-00), Suzuki RM125/250 (96-00), and removes compression adjuster assembly on Suzuki RM125/250 (98-00). Sold each. 35-8670 TFCW4650 Fork Cap Wrench SHAFT HOLDING TOOL Holds fork damping rods, cartridges, shock shafts, etc. while servicing. (aluminum) 35-8672 TFSH10 Shaft Holding Tool 10, 12, 12.5, & 14mm (Dampning Rods) 35-8673 TFSH14 Shaft Holding Tool 14, 16, & 18mm (Shock Shafts) 35-8674 TFSH20 Shaft Holding Tool 20, 24, & 29mm (20 & 25mm Fork Cartridges) 35-8675 TFSH32 Shaft Holding Tool 32 & 35mm (28 & 32mm Fork Cartridges) ULTRA SLICK SEAL GREASE Race Tech Ultra-Slick Grease provides maximum lubrication and minimum friction for all seal and bushing needs. Available in 1 oz. container. 35-8682 Ultra Slick Seal Grease SHOCK SEAL HEAD SETTING TOOL Allows easy removal and installation of all 40 – 46mm integral shock seal head assemblies. 35-8676 TFSH32 Shock Seal Head Setting Tool SAG MASTER™ The Sag Master is a tool that makes measuring “Race Sag”a snap because you read it directly. No more subtracting! Also useful in determining proper spring rates and monitoring linkage and seal drag. Comes with complete instructions and, doubles as a tape measure. 35-8681 TSSM01 Sag Master Race Sag Setting Tool FORK SPRING COMPRESSOR TOOL This unique fork spring compressor is designed to work on most current sport bikes and road racers. It allows the spring to be compressed while the fork cap is removed from the rod. It can be used on or off the bike on most models. 35-8680 TFSC01 Fork Spring Compressor Tool

Honda / Acura Crank Shaft Seal Kit installation

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Filed Under (Toyota Manuals) by admin on 17-11-2011

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Due to the close proximity of transversely mounted engines to the shock tower, this essential tool is crucial for the
proper installation of Cam Shaft Oil Seals. Comes equipped with an exclusive expansion guide ensuring damage free installation. Applicable: Most Toyota 4 cylinder & some Mazda engines. This Special Bonus Kit was designed for the proper installation of Pulley Crank Shaft oil seals, situated within confined areas on most 4, 6 & 8 cylinder Toyota / Lexus, Nissan, Mitsubishi, Mazda and Infiniti engines. Application includes Cam Shaft oil seal installation of Toyota / Lexus 2.5L, 2.8L, 3.0L, 3.4L, 4.0L & 4.3L engines. The step bolts screw into the cam or crank shaft end. The press nut w/ washer allows for an even ressing force, seating the oil seal into the engine case every time

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HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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AJS DISMANTLING AND REBUILDING FULL-WIDTH FRONT WHEEL HUBS INSTALLATION

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

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Removal of the Brake-side Bearing Cup The bearing cup (5) is located endwise by a circlip (1), and between the cup and circlip arc an oil-seal retaining washer (4), oil seal (3), and oil-seal cup washer (2) Before these parts can be removed from the hub the bearing cup must be moved inwards for a very short distance (3/16-inch) so that the circlip can be withdrawn. (n) Gently heat the hub shell. (i) Place a soft metal rod (e.g. brass) against the oil-seal cup washer (2) and apply pressure with a hand press or hammer blows. It is only necessary to move the bearing cup (5) inwards about 1/16-inch. (j) Extract the circlip by inserting a narrow pen-knife blade under one end of the circlip; lift it upwards and outwards and prise the clip out of its groove. (k) Remove the oil-seal cup washer (2), oil seal (3) and oil-seal retaining washer (4). They can be hooked out with the shank of a small and narrow screw­ driver, (l) The bearing cup can now be ejected by placing a suitable rod of soft metal (e.g. brass) in the hub tunnel from the right-hand side and pressing it — with a press or hammer blows — against the bearing cup until the cup is forced out of the bearing. This must be done with care so that the cup remains square with the housing. Reassembly To facilitate replacement of the bearing cups gently heat the hub shell. Just too hot to hold is about the right temperature. (a) Place the brake-side bearing cup squarely in the hub shell — the open end faces inwards — and press it into the hub tunnel A short length of brass rod, slightly less than the outside dia­ meter of the cup, should be interposed between the cup and ram of the press, or hammer head. Press the cup in until the outer face is approximately half-an-inch below the mouth of the hub tunnel. This will allow sufficient room to allow [he circlip to be inserted into its groove. (b) Refit in the following order: oil-seal retaining washer (4), oil seal (3), oil-seal cup washer (2). (c) The circlip can now be replaced. In the interest of reliability use a new circlip, for it is possible that the existing circlip was strained when it was re­ moved. (d) Insert into the hub tunnel from the right-hand side a brass rod of suitable length, and press the bearing cup firmly against the circlip. (e) Before inserting the spindle complete with the roller races, pack them with clean and fresh grease of a suitable grade (Mobilgrease No. 4. Castrolease heavy, Energrease C3, Esso Pressure Gun Grease. Shelf Retinax Grease CD or A). (0 Insert the spindle into the hub. (g) Place the right-hand side bearing cup in the hub tunnel; the open end faces inwards, It may be necessary to re-heat the hub to allow the cup to go into position without difficulty. (h) Press the cup into position, but do not force it fully home, leave some end play on the spindle. (i) Refit in the following order: oil-seal retaining washer (6), oil-seal (7) and oil-seal cup washer (8). (j) Screw into the hub the adjusting sleeve (9) until it comes into contact with the bearing cup (5)

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Toyota Power Steering Conversion Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 04-10-2011

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Remove the stock steering box and column. Be sure to clear the area of all wiring, brake lines and fuel lines. 2. Bolt the Toyota box to the mounting bracket so that the long arm of the bracket points in the same direction as the steering column input shaft (small shaft.) To mount the bracket and box correctly, the longer end should be towards the rear of the vehicle. It may be necessary to grind on the power steering box where the two flanges protrude above the bracket. For technical help call Classic Performance Products Monday thru Friday 8:30am to 5:00pm at (714) 522-2000. Rev. 8/17/2009 3. Locate the box/bracket assembly into the frame by centering the Toyota sector shaft through the original hole in the frame. This hole will need to be elongated approximately 3/8″ to allow the sector shaft to clear the frame. Bolt the bracket directly into the mounting holes for the original steering box. 4. With the first bolt in, check the fit by reattaching the steering box. Make sure the splined shaft goes through the frame without interference. Torque down the mounting bolts to 45 lbs. 5. Attach the pitman arm to the steering box. Before this is done the steering sector must be centered. Turn the input shaft clockwise as far as it can go. Make a reference mark. Now turn the shaft counter clockwise as far it can go and be sure to count the turns. Turn the shaft back half the distance and now the box is centered. Be sure to double and triple check this procedure. Attach the pitman arm to the output shaft with the output shaft nut. Torque the bolt down to 110ft/lbs. Reconnect the stock drag link and you are on your way

1953 Toyota Ford Truck Power Steering Conversion Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 01-10-2011

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of all wiring, brake lines and fuel lines. 2. Bolt the Toyota box to the mounting bracket so that the long arm of the bracket points in the same direction as the steering column input shaft (small shaft.) To mount the bracket and box correctly, the longer end should be towards the rear of the vehicle. It may be necessary to grind on the power steering box where the two flanges protrude above the bracket. For technical help call Classic Performance Products Monday thru Friday 8:30am to 5:00pm at (714) 522-2000. Rev. 8/17/2009 3. Locate the box/bracket assembly into the frame by centering the Toyota sector shaft through the original hole in the frame. This hole will need to be elongated approximately 3/8″ to allow the sector shaft to clear the frame. Bolt the bracket directly into the mounting holes for the original steering box. 4. With the first bolt in, check the fit by reattaching the steering box. Make sure the splined shaft goes through the frame without interference. Torque down the mounting bolts to 45 lbs. 5. Attach the pitman arm to the steering box. Before this is done the steering sector must be centered. Turn the input shaft clockwise as far as it can go. Make a reference mark. Now turn the shaft counter clockwise as far it can go and be sure to count the turns. Turn the shaft back half the distance and now the box is centered. Be sure to double and triple check this procedure. Attach the pitman arm to the output shaft with the output shaft nut. Torque the bolt down to 110ft/lbs. Reconnect the stock drag link and you are on your wa

HARLEY DAVIDSON GEAR SHIFTER SHAFT COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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Models This kit fits 1982 and later Touring and FL Softail model motorcycles. Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not Sold Separately Gear shifter shaft cover Not Sold Separately Screw, set There are no Service Parts available with this kit. INSTALLATION 1. Remove the stock heel shift lever from the gear shifter shaft. 2. Install the set screw into the gear shifter shaft cover. 3. Install gear shifter shaft cover with installed set screw over the end of the gear shifter shaft. 4. Tighten the set screw until light contact is made with the shaft groove. 5. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw.