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BMW Motorcycles All R1100 Models- Cylinder Head Gasket

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Filed Under (BMW) by admin on 16-11-2010

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Situation: All R1100 models produced from calendar week 18 (April 28, 1997) onwards will be equipped with head gaskets of Multi-Layered Steel (MLS) technology. Service Information: The MLS cylinder head gasket can be used in place of all earlier gaskets, on all R1100 models, without any modifications. Part Number: MSL cylinder head gasket for all R1100 models. P/N: 11 12 1 341 173 Note: The MLS cylinder-head gasket is applicable to R1100 models only. If it becomes necessary to replace cylinder-head gaskets on R850 R models, the conventional gasket, P/N 11 12 1 342 082, must be used. Warranty Processing: If your retail center has any quantity of the conventional head gasket for the R 1100 models, P/N: 11 12 1 342 127, in stock, please file a warranty claim using the information below. If your retail center has the engine gasket set, P/N: 11 00 1 341 901 in stock , please make sure that the new style MLS gaskets are used in place of the conventional head gasket supplied in this set. All current BMW NA inventory of P/N 11 00 1 341 901 will have the MLS head gasket included. Defect Code: 00 11 01 00 00 Frame Number: 4990150 Warranty Type: 2 Warranty Stage: 1 Very truly yours,

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Harley-Davidson V-Rod Destroyer Indy Series Exhaust REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 24-10-2010

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STOCK EXHAUST SYSTEM REMOVAL (DESTROYER) 1. Remove both collector bolts. 2. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 3. If the Racepak is installed, remove both O2 and EGT sensors from the front and rear head pipes. 4. Carefully remove complete exhaust from the motorcycle. STOCK EXHAUST SYSTEM REMOVAL (V-ROD) 5. Loosen clamp bolt at front of the collector using a 13mm socket. 6. Remove muffler bracket bolt using a 13mm wrench. 7. Carefully remove muffler and collector assembly from motorcycle. 8. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 9. Carefully remove head pipes from motorcycle. 10. Remove the stock exhaust flanges and circlips from both the front and rear head pipes. If the circlips are bent or twisted they should be replaced, Harley-Davidson part number #65045-01 We also recommend replacing the stock exhaust gaskets, Harley-Davidson part number #65109-01 INDY SERIES EXHAUST SYSTEM INSTALLATION 1. Identify front head pipe #7-8002. Install the stock flange and circlip. Install the exhaust gasket and front header pipe, leaving the flange nuts hand tight. 2. Repeat the above step for the rear head pipe #7-8006. 3. Slip the megaphone/collector assembly onto the head pipes, secure with the four springs supplied using the spring puller tool. 4. Rotate the exhaust so there is adequate clearance in all places. 5. Tighten the cylinder head flange nuts for both the front and rear head pipes. 6. Tighten both the EGT and O2 plugs on the front and rear head pipes. 7. Clean all fingerprints from the exhaust using a contact cleaner (or other non flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. 8. You are now ready to start the motorcycle.

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HARLEY DAVIDSON SCREAMIN' EAGLE MECHANICAL COMPRESSION RELEASE FIX- TURE

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Filed Under (Harley Davidson) by admin on 04-02-2011

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DRILLING AND TAPPING PROCEDURE Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b) NOTE Perform the following procedure on both the front and rear cylinder heads. Tool Setup NOTE Due to slight manufacturing differences, it may be necessary to tap the fixture into place with a rubber mallet. Do NOT use excessive force. 1. Align the fixture’s locating pins with the 3/8 inch tooling holes in the head and install the fixture on the head. 2. See Figure 1 and Figure 6. Secure the fixture (1) to the head with two 5/16-18 socket head cap screws (2) and washers (9) included in the kit. Install the screws in the holes marked “F” when modifying the front head or in the holes marked “R” when modifying the rear head. Tighten screws to 80 in-lbs (9 Nm) . 3. See Figure 3 and Figure 6. Install the drill bushing (3) in the bore marked “FRONT” when modifying the front head or in the bore marked “REAR” when modifying the rear head. 4. Tighten drill bushing set screw to 50 in-lbs (5.6 Nm) . 5. See Figure 2 and Figure 6. Install collar stop (4) onto the 1/2 inch diameter shank of the step drill bit (5). Secure the collar stop with the set screw 3.900 inches (9.90 cm) from the beginning of the 3/4 inch diameter step of the drill bi

HARLEY DAVIDSON DERBY COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits are designed for installation on all 1999 and later 1340 Evolution and Twin Cam equipped models.INSTALLATION For models equipped with left side exhaust pipe: 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) NOTE Remove clutch inspection (derby) cover with motorcycle upright, not on side stand. If cover is removed with motorcycle on side stand, primary fluid will leak out of primary chaincase. 1. On models so equipped, remove the left-side passenger footboard. Using a T27 TORX® drive head, remove the derby cover from the primary chaincase. Discard the derby cover and fasteners. NOTE The gasket between the clutch inspection cover and the chaincase cover must be removed and all oil must be wiped from the gasket and groove in chaincase cover each time the cover is removed. 2. Remove the gasket from the groove in the chaincase cover and mounting surface. 3. Inspect gasket for tears or damage. Replace as required with gasket 25416-99C (sold separately). NOTE If installing the Derby cover on a 2006 and later Dyna, 2007 Softail, or 2007 Touring model, the original equipment gasket must be discarded and replaced with Derby Cover Gasket 25416-99C (sold separately). 4. To avoid punching holes in the clutch inspection cover gasket or enlarging the existing holes, install the new derby cover and gasket as follows: a. Align the triangular shaped hole in the gasket with the top hole in the derby cover. Be sure the rubber molding and the words “towards clutch” face the motorcycle. b. See Figure 2. Place a washer (2) from the kit onto the threads of one of the new screws (3). Insert the screw threads through the top hole in the derby cover, and carefully thread it all the way through the triangular shaped hole in the gasket. Do not push the screw through the hole. c. Hang the derby cover on the primary chaincase cover flange by starting the top cover screw. d. Start the remaining four screws and washers. 5. Install gasket (part number 25416-99C) and derby cover (1) on primary chaincase cover using screws and washers from the kit. Tighten screws to 84-108 in-lbs (10-12 Nm) in the sequence shown in Figure 1

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Harley Davidson Sportster Straightshots HS Slip-on Exhaust system

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Filed Under (Harley Davidson) by admin on 19-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Loosen, but do not remove, the two head pipe mounting nuts from each flange located at the cylinder head. 3. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 4. Loosen the clamp holding the mufflers onto the head pipes. Page 1 of 4 D480IN Rev. 1.0 Sportster Straightshots HS Slip-on Exhaust system Part #16819 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: 1/2″ combination wrench 3/8″ drive ratchet and 9″ extension 9/16″ and 1/2″ sockets 5/16″ Nutdriver/flat blade screwdriver 5. Remove the two bolts from each muffler which attach the mufflers to the mounting bar. 6. Remove the mufflers by sliding them off the head pipes. 7. Remove the clamp from the nose of each muffler (these will be re-used when installing the new mufflers). 8. Remove the gaskets from the crossover ports on the stock mufflers. Inspect the gaskets and replace if damaged or worn (H-D part #65927-00). 9. Install crossover gaskets onto mounting bar on motorcycle. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Remove mufflers and heat shields from protective packaging. 2. Slide the nut plate inside the bracket that is welded to the backside of each muffler body and attach the muffler bodies to the mounting brackets (stamped 379-P) using four 5/16″ x 5/8″ flange head bolts (supplied). Leave them loose at this time (Figure 1). 3. Slide stock exhaust clamp onto nose of each muffler. 4. Slide mufflers onto head pipes and align crossover port with gasket on mounting bar (Figure 2). Press into place on gasket. 5. Attach the muffler brackets to the stock mounting bar using four 5/16″ x 3/4″ hex head bolts, washers, and nuts (supplied). Leave them loose at this time (Figure 3). 6. Tighten cylinder port exhaust flange nuts on front and rear cylinders. 7. Install and tighten the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 8. Align muffler and bracket so they sit level. Tighten the muffler mounting bolts and the bracket mounting bolts. 9. Tighten the clamp holding the muffler onto the head pipe.

HARLEY DAVIDSON LOCKING GLOVE BOX DOOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION 1. Unsnap the original equipment (O.E.) left-side glove box door, and unfasten the tether by bringing the aglet end (see Figure 1, B) out through the retaining hole. Always wear proper eye protection when drilling or grinding. Flying debris could cause serious eye injury. (00402e) 2. Using an 3/16 inch (5 mm) bit positioned in the center of each snap, drill out the four plastic snaps surrounding the glove box opening. NOTE The glove box door, hinge and frame assemblies are side- specific. The assemblies install so that the tether retaining hole (C) in the door frame is to the inboard side. 3. Obtain the new left-side glove box door, hinge and frame assembly (1), a lock (2) and a tether assembly (8) from the kit. Remove the nut (3) from the lock. 4. Insert the lock through the hole in the glove box door as shown. Assemble the tether over the lock threads with the tab (A) on the inboard side of the lock, same as the retaining hole in the door frame. Tighten securely. 5. Open the left-side door, and position the door assembly at the glove box opening, lining up the holes. 6. Insert a screw (9) through each of the holes in the door frame and glove box. Install a hex nut with washer (10) onto the threads of each screw. Tighten finger-tight. NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the gaskets to the glove box door frame. 7. Clean the glove box door frame with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. NOTE The glove box gaskets are side-specific. With the paper backing facing the door frame, the oblong hole at the top of the gasket is to the outboard side. 8. Obtain the left-side gasket (6) and a hinge gasket (7) from the kit. Install the gaskets to the glove box door frame. a. The gasket liner on the large gasket is split to aid alignment. Peel one half of the liner from the adhesive backing of the left-side gasket. b. Using the frame edges and screw heads as a guide, carefully position the gasket to the glove box door frame and press firmly into place. c. Peel the remaining half of the liner from the gasket backing, and carefully position the rest of the gasket to the door frame. Press firmly into place. d. Apply steady pressure for a few seconds at all areas of the gasket to verify proper adhesion. e. Peel the liner from the hinge gasket. f. Carefully position the gasket to the door frame above the hinge, and press firmly into place.

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YAMAHA VIRAGO 700/ 1100 2 into 2 EXHAUST SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8″ x 1″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16″ x 1 1/4″ bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time

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2009 Daytona 675 Motorcycle Race Kit Manual

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Filed Under (Triumph) by admin on 29-10-2010

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1. Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Position a piece of solder (with a diameter approximately 1.3 mm) on the four squish surfaces of each piston. Position the solder in line with the corresponding squish surfaces on the cylinder head and hold in place with a small amount of grease. 3. Refit the cylinder head with the head gasket. 4. Slowly turn the engine over, by hand, to compress the solder to the same height as the squish clearance. 5. Remove the cylinder head and head gasket. 6. Measure the compressed thickness of the solder. The squish clearance must be a minimum of 0.65 mm. If the thickness of the solder is less than 0.65 mm repeat steps 2 to 6 with a thicker head gasket until the squish clearance is at an acceptable level. NOTE •In some cases, it may be necessary to use a standard cylinder head gasket to achieve the correct squish clearance. 7. Fit the chosen cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Warning Running the engine at less than the minimum recommended squish height can lead to the pistons contacting the cylinder head, causing major engine damage. This could cause loss of motorcycle control and an accident. Triumph Designs Ltd 2009. Camshaft, Valve Spring & Camshaft Sprocket Kits Parts Supplied Camshaft, Inlet – A9618055 Camshaft, Exhaust – A9618056 Valve Spring Kit – A9618086 Camshaft Sprocket Kit – A9618095 Warning The Race Kit camshaft, valve Spring and camshaft sprockets must be fitted as a complete set. If they are not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.

2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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HARLEY DAVIDSON DYNA LongShot Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove both front and rear head pipe clamp bolts. 4. Remove the entire exhaust system and set it aside. 5. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips. 6. Remove the rear head pipe clamp bracket from the transmission cover. Save the bolts, two will be reused. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Locate the muffler mounting bracket (stamped 239). Mount the bracket to the engine case, to the rear of the transmission cover using the two stock bolts. Refer to figure 1. Tighten the bolts at this time. Install the mounting bar (supplied) to the transmission housing using the stock hardware. Refer to figure 1 . Note: The mounting bracket should mount flatagainst the transmission housing. Some motorcycles use a stud to mount the stock rear head pipe clamp, be sure to remove the stud from the transmission housing and replace it when mounting the bracket, this will insure that the bracket is flat against the housing. 2. Locate the muffler clamp bracket (stamped 240). Install the bracket to the outside of bracket 239, using the 5/16″x 1 1/4″ bolt and 5/16″ flat washer (supplied). Refer to figure 1. Leave the bracket loose, it will be adjusted later. 3. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the circlips and flanges from the stock system onto both the new head pipes. 5. Slide the new pipe clamp (supplied) onto the muffler end of the front head pipe. Position the clamp in the approximate mounting location on the pipe. 6. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the rear head pipe.

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