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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

KTM Starter Gear Maintenance Instructions

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Filed Under (KTM) by admin on 26-11-2010

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Checking the electric starter motor for wear -Check Bendix 1 for smooth operation and signs of wear. -Check the sprocket of the electric starter for wear and radial clearance. -Replace O-ring 2 of the electric starter. -Replace gasket 3 . -Check starter idler gear 4 for smooth operation and wear, check that the bearing bushings are seated firmly. Electric starter motor – checking for and adjusting play -Mount the electric starter and the starter idler gear. -Mount the tighten cover 5 . -Move starter idler gear 4 back and forth in the direction of rotation, the maximum play may not exceed half the width of a tooth. -If play is larger, cover 5 must be removed and as many shims 6 with a thickness of 0.10 mm as necessary must be added to eliminate all play. Then remove one shim again. -Check the play again; the maximum play may not exceed more than half of the width of a tooth. 1 2 3 4 5 4 5 6

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Honda 2007-2010 Rancher 420 ATV Rear Bumper Installation

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Filed Under (Honda) by admin on 22-12-2011

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Honda Rancher 420 ATV Rear Bumper (2007-2010) Installation Instructions 1. Attach top bumper attachments to top rack. 2. Attach the rear bumpers lower attachment point to vertical bars

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HONDA 420 RANCHER 2×4/4×4 2007-2009 CLUTCH KIT INSTRUCTIONS

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Filed Under (Honda) by admin on 22-12-2011

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Remove key from the ignition switch. Remove the side panels from both sides. Remove both foot wells. 2. Drain coolant. Remove the oil drain plug from the motor; if you carefully drain it into a clean container you should be able to reuse it. 3. Disconnect shift motor (on electric shift models only). Remove coolant hoses. 4. Remove the bolts that mount the front differential to the frame, no other parts need to be removed. Carefully slide the front differential towards the front of the machine; you might need to lift up slightly to get the differential to move. Remove the drive shaft. Remove o-ring on output shaft (on motor). 5. Remove the fuel pump. 6. Loosen the front crankcase cover bolts, keep track of each bolt length and location. Slowly remove the crankcase cover. Carefully watch for o-ring shims and dowel pins that may fall out. 7. Unstake the nut holding the clutch on and remove nut. Using Honda tool #07933-HB3000A thread the large part of the tool into the center of the clutch. Tighten the center bolt on the tool while holding the large part of the tool with a wrench. This will pull the clutch off the machine. Place the clutch on a clean work surface. EPI performance.com
8. Using the c-clamps push down slightly on the outside cover and remove the four e-clips. Keeping track of which way they come off, remove the round metal plates one at a time. This will allow you to see the complete spring. Remove one end of each spring using a spring tool or needle nose pliers and then remove springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the hole. Install the metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up. Slide the clutch into the machine. The Sprague clutch is marked “outside” when installing make sure this is facing out. Torque clutch nut to 87 ft/lbs. 9. Clean the gasket surface on the motor and on the cover. Put a thin layer of Honda Bond or Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase cover. Carefully install crankcase cover, do not force cover on. Torque bolts to 9 ft/lbs. 10. Install the fuel pump. 11. Install the o-ring on the output shaft (on motor) and install the drive shaft. Carefully slide the front differential back into place and mount to the frame. Install the coolant hoses. Refill your engine coolant to the proper level according to your owner’s manual. 12. Install the oil drain plug. Refill your engine to the proper level according to your owner’s manual. You can reuse your oil if it is clean and was drained into a clean container. Only use manufactures recommended oil. 13. Be sure to double check coolant and oil levels and to look for any leaks after the machine has run for a few minutes. 14. Go out and ride your machine. If your performance doesn’t seem right double check to make sure everything has been done properly. 15. EPI is constantly testing our products. Sometimes there is a need to contact the user with new technical information. To ensure that you are receiving this information visit our web site EPIperformance.com to register your clutch kit.

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2000 Honda Rancher ATV Winch Mounting Kit REMOVAL AND INSTALLATION

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Filed Under (Honda) by admin on 13-01-2012

Begin by removing the front fascia and front skid plate on the vehicle as shown in figure 1. Save the fasteners as they will be used later to re-install the front fascia and skid plate. 2. Remove the 8mm bolts on both sides located inside the front tires and on the ends of two horizontal tubes on the front tube frame as shown in figure 2. 3. Place the mounting plate (A1) inside the front tube frame. The tabs with the slotted holes facing down. The slotted tabs should align where the
two 8mm bolts were removed in step 2. Reinstall these two bolts at this time thighten to just fingertight. Install the two 1/4-20 u-bolts (B3) and locking hex nuts (B1) and flat washers (B7) at thism time see figure 3, do not tighten down at this time. so the plate can be adjusted for position see figure 2. 4. Place the rear support bracket (A4) into position
and attach with the two 5/16-18 x 3/4 hex cap screws (B6), flat washer (B5) and locking nut (B4). Adjust the position of the support bracket so that it comes in contact with the frame tubes and tighten the fasteners see figures 3 and 4.
Make sure the support bracket maintains contact with the rear frame tubes and tighten down the two front 8mm mounting bolts. Tighten the bolts to a recommended torque of 12 ft-lb (17 N-m). 5. Attach the fairlead bracket support (A2) to the front frame tubes see figure 5. The support bracket attaches behind the front tubes. Space the bracket away from the tubes using the spacer brackets (A3). Attach the brackets using the 1/4- 20 u-bolts (B2), lock nuts (B1) and flat washers (B7). Before tightening the u-bolts make sure the bracket is in the correct position by fitting the front
fasica into postion and checking location. Tighten the nuts to a recommended torque of 7 ft-lb (10 N-m). NOTE: If this kit is being installed on a 00 to 03 Honda the wider fairlead bracket (A2) will need to be used. This will require the use of the
wider u-bolts (B3). The spacer brkts (A3) will not be required when installing the wider fairlead brkt

HONDA ATV Carburetor Repair Kits Installation

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Filed Under (Honda) by admin on 21-12-2011

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ATV Carburetor Repair Kits Complete kits to rebuild one OEM carburetor. Each kit contains necessary gaskets/o-rings, needle valve or needle valve set, and jets. Made in Japan. Note: Check all parts before installation. Honda Model Year Order No AT C70 78-85 025-001 AT C90 70-71 025-003 ATC90K1/K2/K3 72-75 025-003 AT C90 76-78 025-003 TRX90 Fourtrax 90 93-98 025-084 ATC110 79-83 025-005 ATC110 84-85 025-061 ATC125M 84-85 025-062 TRX125 Fourtrax 85-86 025-050 TRX125 Fourtrax 87-88 025-063 ATC185 1980 025-009 ATC185S 81-83 025-009 AT C200 81-82 025-008 AT C200 1983 025-009 ATC200E Big Red 82-83 025-064 ATC200ES Big Red 1984 025-064 AT C200M 84-85 025-064 AT C200S 84-86 025-065 AT C200X 83-85 025-012 AT C200X 86-87 025-014 TRX200 Fourtrax 200 90-91 025-066 TRX200D Fourtrax 200 Type II 1991 025-066 TRX200D Fourtrax 200 Type II 92-93 025-067 TRX200D Fourtrax 200 Type II 94-97 025-068 TRX200SX Fourtrax 87-88 025-069 ATC250R 81-82 025-017 ATC250R 83-84 025-018 AT C250R 1985 025-019 ATC250ES Big Red 85-87 025-029 AT C250SX 1985 025-070 TRX250 Fourtrax 250 1985 025-071 TRX250 Fourtrax 250 86-87 025-072 TRX250EX Sportrax 250EX 01-04 025-085 TRX250R Fourtrax 250R 86-87 025-060 TRX250R Fourtrax 250R 1988 025-073 TRX250X 91-92 025-074 TRX300 Fourtrax 300 1988 025-075 TRX300 Fourtrax 300 91-92 025-076 TRX300 Fourtrax 300 93-95 025-078 Honda Model Year Order No TRX300EX Fourtrax 300EX 93-98 025-081 TRX300FW Fourtrax 300 4×4 1988 025-075 TRX300FW Fourtrax 300 4×4 91-92 025-076 TRX300FW Fourtrax 300 4×4 93-95 025-078 AT C350X 1985 025-035 TRX350 Fourtrax 4×4 86-87 025-079 TRX350FE Fourtrax Rancher 4×4 ES 00-03 025-082 TRX350FM Fourtrax Rancher 4×4 00-03 025-082 TRX350TE Fourtrax Rancher ES 00-03 025-082 TRX350TM Fourtrax Rancher 00-03 025-082 TRX350D Fourtrax Foreman 4×4 87-89 025-079 TRX400FW Fourtrax Foreman 95-00 025-080 TRX450ES Fourtrax Foreman ES 98-01 025-083 TRX450FE Fourtrax Foreman ES 02-03 025-083 TRX450FM Fourtrax Foreman S 02-03 025-083 TRX450S Fourtrax Foreman S 98-01 025-083 TRX500FAFourtrax Rubicon 01-04 025-086

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HARLEY DAVIDSON STARTER SOLENOID REPAIR KIT

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1. Remove, but do NOT discard, bolt washer 1 and 4 (fig. 1). 2. Remove, but do NOT discard, nut washer 2 (fig. 1). 3. Remove, but do NOT discard, nut washer 3 from shortest copper bolt on cap (fig. 1). 4. Gently remove solenoid cap. 5. IMPORTANT!: Snip wire 5 as close as possible to large copper bolt (fig. 2). 6. Discard old copper bolt and cap. 7. Replace old plunger 6 with new plunger provided in kit. 8. Guide small bolt 7 through hole in new cap as shown (fig. 3). 9. Solder cut wire 5 to new copper bolt terminal 8CAUTION!: Solder wire to terminal, so as not to interfere with contact of plunger to terminal. 10. Install new cap. 11. Re-assemble nuts, bolts and washers 1 2 3 4 as shown (fig. 1). Replace worn parts with those provided in kit.

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Honda Motorcycle Na vigation Kit

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Filed Under (Honda) by admin on 28-11-2010

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Honda Motorcycle Na vigation Kit Honda Motorcycle Navigation Kit G e n e r i c A c c e s s o r i e s 2 0 0 8 For your peace of mind Honda Genuine Accessories are carefully designed, researched and stringently test ed tot he highest standards. And since they’re all Honda approved you’llknowthat they’rejustastoughand well made as your Honda motorcycle. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice. y e a r w a r r a n t y GENUINE ACCESSORIES Honda Motorcycle Navigation Kit Model Part Number Description RRP Remarks NAKED CBF 600 08A 40MER800B CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY CBF 600 08A 40MER800A CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY ON/OFF XL700V 08A 40MFF800 * CONTAINS NA VI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EARPH ONE, MANUAL, 08A 30MFF800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY XL 1000V 08A 40MBT800 CONTAINSNAVI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EAR PH ONE, MANUAL, 08A 30MBT800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY TOURERS/SPORT TOUR ERS DN-01 08A 40MEH800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, AND BATTERY -CONTAINS 08A 30MEW800 ADDITIONALSTE ERIN G HANDLE C LAMPS FORV ISU AL INTE GRAT ION OF THE COMPONENT NT700V 08A 40MEW800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, BATTERY

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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Honda GL1000/1100 starter motor Removal/ Over haul Manual

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Filed Under (Honda) by admin on 08-04-2011

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1. Remove the three long bolts that hold the sections together and separate them. Be careful as there are a series of flat thrust washers on each end of the armature (located in the middle section). 2. The end cap basically performs no function other than to cover the brush plate and commutator area as well as center the armature shaft in a pressed in bushing located in the end of the cap. 3. The drive end contains the reduction gearing and if need be, can be disassembled to replace the bearing. This is extremely unlikely. The shaft should turn freely and normally only requires a cleaning and grease application. If the bearing in fact needs replacing, simply remove the “C” clips on either end, drive out the bearing and reinstall with an appropriate size replacement. Any decent auto parts / industrial supply should be able to supply the correct bearing. 4. Remove the brush plate from the end of the center section by removing the screw at the one brush connection. Before removing the brushes, note that one of them has an insulating sleeve over the braided wire. The replacement must go in the same brush holder. Remove the brushes and replace if necessary and clean the brush plate. ** Brake Cleaner is a good general cleaner for this entire job. 5. Remove the thrust washers from brush plate end of the armature. Count them and ensure they go back on the correct way. 6. The end of the center section that had the drive end on it has a circular plate covering it with a short splined shaft protruding through the plate. Drive the plate out by tapping the opposite end of the section on the shaft – just lightly with a rubber hammer or piece of wood to protect the shaft. Once the plate is out, remove the armature from the section. You will find more thrust washers at this end. Make sure they go back on correctly. 7. In the center of the center section there are four large Philips screws. These hold in the field coils found within the housing. Using an “impact driver”, loosen the four screws that go around the circumference of the center section and remove them. Remove the 10mm nut for the battery connection and the accompanying fiber insulating washers. With the screws and nut removed, the entire field coil assembly should withdraw entirely from the housing. There will be four (4) metal plates that the screws mounted into come falling out. They are easily replaced into the field coils when you slide it back into the housing. Do not be alarmed that you suddenly have four loose metal parts. 8. With everything out of the housing, thoroughly clean everything using the Brake Cleaner. Although the cleaner will dry without leaving a film, it is suggested that the components be dried with compressed air. 9. Get some extremely fine steel wool (“000″ of even “0000″ is better) and gently clean the metal surfaces or bars of the armature and the commutator. Blow with compressed air. 10. Using a volt/ohmeter, test for continuity between pairs of armature bars (the long ones). There should be continuity between the pairs around the entire circumference.

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