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Kawasaki KZ 900/ KZ 1000 Piston Kits Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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075CC 72MM KZ 900: Resleeving and bore crankcase ROAD 10.5:1 MTC-K1075 KZ 1000: 2mm oversize 2.834 In KZ 1000: Cylinder boring DRAG 12.5:1 MTC-K1075H TURBO 9.0:1 MTC-K1075T 1135CC 74MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1135 KZ 1000: 4mm oversize 2.913 In DRAG 12.5:1 MTC-K1135H TURBO 7.8:1 MTC-K1135T 1197CC 76MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1197 KZ 1000: 6 mm oversize 2.992 In DRAG 12.5:1 MTC-K1197H TURBO 7.8:1 MTC-K1197T 1261CC 78MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1261 KZ 1000: 8mm oversize 3.070 In DRAG 12.5:1 MTC-K1261H TURBO 7.8:1 MTC-K1261T 1327CC 80MM Big block required bore crankcase ROAD 10.5:1 MTC-K1327 KZ 1000: 10mm oversize 3.149 In DRAG 13.5:1 MTC-K1327H TURBO 7.8:1 MTC-K1327T 1428CC 83MM Big block required bore crankcase ROAD 10.5:1 MTC-K1428 KZ 1000: 13mm oversize 3.267 In DRAG 13.5:1 MTC-K1428H TURBO 7.8:1 MTC-K1428T 1500CC 85MM Big block required bore crankcase DRAG 13.5:1 MTC-K1500H KZ 1000: 15mm oversize 3.346 In TURBO 7.8:1 MTC-K1500T

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

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TRIUMPH 750 BIG BORE CYLINDER AND PISTON SET FOR 650 TWINS INSTALLATION

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

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Step 1. Unpack your big bore kit and inspect the contents. There should be the following: 1. Cylinder x l 2. piston with wristpin x 2 3. Hepolite piston ring set x l 4. Special big bore head gasket Step 2. Thoroughly wash the cylinder bores with soap and water. Do not use solvent! Dry bores with air or a lint free towel and let completely air dry. This step is most important and will greatly extend the life of the pistons. Step 3. Following the procedure outlined in your service manual, drain the fuel tank, remove the exhaust system, fuel tank and carburetors. Have a catch basin handy to capture any fuel that may spill from the carburetors, as fuel is highly flammable and can be ignited by a dryer pilot light etc. from a long distance. Clean up any spilled fuel immediately and dispose of away from any source of ignition. Store the fuel tank in a well vented area, outdoors is best, in the event your fuel taps should leak. Step 4. Remove the rocker boxes by slacking the 9 head bolts a little at a time in a star pattern. Remove the 6 nuts at the front and back of the head. Remove the 4 corner rocker box bolts. Remove the head bolts and rocker boxes. Remove the push rods. Examine the push rods to insure they are straight and the ends are tight. Replace any suspect push rod. Step 5. Remove the cylinder head. Now would be a good time for guide and valve renewal. This is best left to an expert. More cylinder heads have been ruined by auto machine shops than by hard use. If you do not have a qualified shop in your area please call for a referral. Step 6. Remove the push rod tubes and the cylinder base nuts. Clip rubber bands around the top of the lifters to keep them from dropping into the crankcase. Have a few lint free rags handy. Bring the pistons to the top of the stroke and begin lifting off the cylinder. If the cylinder is hard to lift off, thread a nut on one of the base studs and use a tire lever to pry against the bottom fin close to its base using the stud as a fulcrum. After partially raising the cylinder stuff the crankcase mouth with rags to keep any carbon or broken rings from entering the crankcase. These will remain in place until step 12. Step 7. Leaving the rags in the crankcase remove the wrist pin circlips from the pistons and discard. Heat the piston and gently push the wrist pin out. Do not use force as this can damage the connecting rod or its bearings. Be sure to account for all the clips as one left in the crankcase can do extensive damage. Step 8. Clean all gasket surfaces to remove any traces of the old gaskets. Use Pennatex gasket remover if needed. Be very careful not to scratch the gasket surface or to allow any gasket particles to enter the crankcase. Even a small bit of gasket can stop the oil pump from working! Step 9. Note the direction and location of the lifters. These must be replaced in the same position as when removed. Remove the lifter blocks from the old cylinder. Start by removing the small retaining bolts and washers. The lifter blocks are extremely fragile and are easily broken. They are also very expensive so great care must be taken in this step! Triumph special tool 222-616008 is advisable here. Apply pressure to the center of the block only. Do not press against the tangs that locate the lifter! A tool can be fabricated using two dowels to locate in the lifter holes. Step 10. Clean and examine the lifters and camshaft faces. Clean the lifter blocks and remove the sealing oring under the locating flange. Replace these with the new orings in the gasket set. Apply a smear of gasket sealant to the lifter block oring and press into the new cylinder. Be sure the lifter block is parallel with the bores and the grooved block is on the exhaust side. Apply a small amount of assembly oil to the lifters and replace in the exact position they came from

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S&S Connecting Rods Installation Instructions

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Filed Under (S&S) by admin on 29-10-2010

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1. Female rod crankpin end to mainshaft nuts – .030″ minimum clearance recommended. A. Install sprocket shaft and crankpin in driveside flywheel. Snug nuts only. Do not torque to final specs. B. Slide connecting rods and bearings over crankpin. C. Rotate rods on crankpin, and observe clearance between rod and sprocket shaft nut. D. If additional clearance is needed, remove material from sprocket shaft nut. Do not remove material from connecting rod. E. Repeat procedure for camside flywheel and pinion shaft. 2. Female rod crankpin end to inner flywheel rim – .060″ clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between crankpin end of female rod and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 3. Wristpin end of both female and male rods to flywheel edge -.060″ minimum clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between wristpin end of both rods and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 4. Wristpin end to crankcase and cylinder – .060″ is recommended in these areas. A. With the camside flywheel and rods mocked up, install the assembly in the right crankcase half with pistons (less rings) and cylinders in place. B. Rotate flywheel through one full revolution and check for rod to crankcase and cylinder spigot contact on both the front and rear of each cylinder. C. File or grind crankcase or cylinder spigot as needed to achieve .060″ clearance. Do not remove morematerial than needed. D. Repeat for left crankcase half. NOTE: Whenever clearancing is performed in any of these areas, do not remove any material from the connecting rods as clearancing on the rods may unnecessarily weaken them. Make adjustments to the point of contact on the mainshaft nut, flywheel rim, crankcase, cylinder spigot, etc. Connecting rods weakened by clearancing may fail causing serious engine damage.

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1992 Toyota Cressida Vehicle Wiring Chart and Diagram

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Filed Under (Toyota Manuals) by admin on 18-06-2011

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Listed below is the vehicle specific wiring diagram for your car alarm, remote
starter or keyless entry installation into your 1992 Toyota Cressida . This
information outlines the wires location, color and polarity to help you identify the
proper connection spots in the vehicle. Please be sure to test all of your wires
with a digital multimeter before making any connections. More information on
using a multimeter and testing wires please see our Technical Support Area.

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YAMAHA CRANKSHAFT LOWER END REMOVAL AND INSTALLATION TOOLS

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Filed Under (Yamaha) by admin on 08-01-2012

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90 LOWER END REMOVAL & INSTALLATION TOOLS SHOP EQUIPMENT & TOOLS 35-8399 35-8513 35-8516 35-8508 35-8504 35-8507 YAMAHA CRANKSHAFT PROTECTORS Sold each. 35-8504 YM-4063-A, XV750/920 Virago, XT550, YFP350, YFM660R Raptor 35-8399 YM-1382, XT250/XT350, RZ350, YFP350, YFZ350 35-8507 YM-33282, XV500 Virago, XZ550 Vision, XVZ12/13 Venture & Venture Royale, VMX12 V-Max 35-8508 YM-38145, XV750/XV1000 Virago YAMAHA CRANKSHAFT INSTALLATION SET Sold as a set. Consists of the following: Qt1-Installing Pot, Qt1-Pot Spacer, Qt1-Bolt. 35-8509 YU-90050 Crankshaft Installation Set OPTIONAL POT SPACERS 35-8513 YU-90070-A, XV750/920 Virago, XT550, TT600 35-8515 YU-91044, YFM350, SRX600, XT550/600 35-8516 YU-1202, SR500, TT/XT500 CRANKCASE PRESSURE TESTER An accurate method for checking possible air leaks on two-stroke engines. Complete with air pressure gauge, pump-up bulb and all fittings and adapters for single and multi-cylinder two-cycle engines. 35-5962 Crankcase Pressure Tester CRANKSHAFT INSTALLING JIG TOOL Supports and centers crankshaft webs while assembling two-stroke engine cases and rebuilding crankshafts. Prevents rod misalignment. Adjustable tang ends. 35-9804 Crankshaft Installing Jig Tool CRANKCASE SEPARATOR TOOL This tool will work on most two and four stroke engines that have a vertically split crankcase. Moveable fingers allow a multitude of bolt patterns to be used so it will work on a variety of models. Includes 6mm and 8mm mounting bolts, center pulling bolt and a three leg frame that is appropriate for many applications. 35-9642 Crankcase Separator Tool 35-9637 Replacement 6mm and 8mm mounting bolts. Each

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

2005 SUZUKI SV1000 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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TIRE PRESSURE FUEL + OIL COLD INFLATION TIRE PRESSURE FRONT REAR SOLO RIDING ITEM Fuel type kPa 250 250 DUAL RIDING kPa 250 290 NOTE E-03, 28, 33 The others E-33 The others Fuel tank Engine oil type Engine oil capacity SPECIFICATfON Use only unleaded gasoline of at least 87 pump octane (R12 + M12) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% etha- nol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. 16 L (4.2/3.5 USnrnp gal) 17 L (4.513.7 USIlmp gal) * SAE 10W-40, API SFlSG or SHISJ with JASO MA kgf/cm2 2.50 2.50 Change Filter change Overhaul psi 36 36 kgflcrn2 2.50 2.90 2 700 rnl (2.912.4 USllmp qi) 2 900 ml (3.112-6 US/lmp qt) 3 300 ml (3.U2.9 USllrnp qt) psi 36 42 CRANKCASE-CRANKSHAFT BEARING SELECTION Select the specrffed bearings from the crankcase bore I. D. code. The crankcase bore I.D. code (A) “A, “6″ or “C”, is stamped on the inside of each crankcase half. Bearing selection table Bearing thickness I.D. code @9 A B C Bearing must be replaced as a set. I.P. specification 52.000 – 52.006 mrn (2.0472 – 2.0475 in) 52.006 – 52.01 2 mm (2.0475 – 2.0477 in) 52.01 2 – 52,018 mm (2.0477 – 2.0479 in) Color (Part No.) Green (1 2229-1 6GOO-OAO) Black (1 2229- tGG00-OBO) Brown (I 2229- 16GOO-OCO) Color code 9 Bearing Green Black Brown Thickness 1.999 – 2.002 mrn (0.0787 – 0.0788 in) 2.002 – 2.005 mm (0.6788 – 0.0789 in) 2.005 – 2.008 rnm (0.0789 – 0.0791 in) FI SYSTEM WIRING DIAGRAM I ECM TERMINAL (For KCModel) ‘& ECM TERMINAL (For K5-Model) FAIL-SAFE FUNCTION & FI system is provided with fail-safe function ta allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition

AIR / HYDRAULIC MOTORCYCLE LIFT REMOVABLE INSPECTION PLATE

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

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For best service, you should incorporate an oiler, regulator, and inline filter, as shown in the diagram on the next page. Hoses, couplers, oilers, regulators, and filters are all available at Harbor Freight Tools. NOTE: If an automatic oiler is not used, put 3-5 drops of pneumatic Tool Oil (not included) in the Motorcycle Lift’s Quick Coupler (38A) before each use. (See Figure B, next page.) To Check The Level Of Hydraulic Oil: 1. The Motorcycle Lift already contains some hydraulic oil in its Hydraulic Pump Reservoir (32P). Even so, it is recommended that you check the oil level in the Reservoir and, if necessary, top off the Reservoir with the proper amount of 15/40 hydraulic oil (not included). (See Assy. Diagram, page 15.) 2. Make sure to screw the two Adjusting Screws clockwise enough to lift the two Caster Wheels (14) off the floor so as to provide stability for the Motorcycle Lift. (See Figure A.) 3. To check the level of hydraulic oil, remove the Sliding Plate (36) from the Platform (35) to expose the Hydraulic Pump Reservoir (32P). (See Assy. Diagrams, pages 13 and 15.) 4. Remove the rubber Filler Plug (33P) located on the top of the Reservoir (32P). If necessary, top off the Reservoir with hydraulic oil. (See Assy. Diagram, page 15.) 5. Connect the air compressor’s hose to the to the Air Motor assembly. Then turn on the air compressor and set its regulator at 120 PSI. (See Assy. Diagram, page 14.) 5. Insert the Lift Foot Pedal (11) onto the Pump Piston Spindle (9), and slowly pump the Lift Foot Pedal until a slight amount of hydraulic oil begins to leak out of the Reservoir (32P). Discontinue pumping the Lift Foot Pedal. Then, replace the Filler Plug (33P) on the top of the Reservoir. (See Assy. Diagram, page 15.) REGULATOR OILER FILTER TO QUICK COUPLER (38A) OF MOTORCYCLE LIFT FIGURE B 6. Insert the Release Foot Pedal (10) onto the Release Valve Spindle (5). Pump the Lift Foot Pedal (11) until the Platform (35) of the Motorcycle Lift reaches its maximum height. Then press down slightly on the Release Foot Pedal until the Platform is fully collapsed to the floor. Repeat this procedure several times to ensure the Motorcycle Lift is operating properly. (See Figure E, page 10.)

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