how to adjust the idle speed on a yamaha 650 v star

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Ural carburetors Installation and idle adjustment

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Filed Under (Ural) by admin on 02-11-2010

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1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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Adjusting the Pekar K68 for Dnepr or Ural

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

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1. Make sure the ignition timing is correct 2. Adjust the valves as necessary to ensure proper operation 3. Run the engine to warm it up a bit 4. Adjust the float setting. To do this, remove the carburetors (leave the throttle cables attached), remove the bowl and turn the carburetor upside down (fuel will spill). The float should look like this: Adjust as necessary by bending the float support (#37 in Figure 1). Reinstall Installation and idle adjustment 1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns. * Starting using the K68′s (cold weather) 1. Verify fuel flow. Apply choke (pull 52 in Fig1). 2. Using the ticklers (13) allow fuel to enter the bowl until fuel drains from (14) 3. With the ignition off, kick 1 or 2 times 4. Turn ignition on, and as soon as engine is warmed up (maybe sooner) push choke mechanisms to open choke Idle Adjustment (engine running and warm) 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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YAMAHA V-Star 650 BIG AIR KIT REMOVAL AND INSTALLATION MANUAL

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

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Remove fuel tank and air filter assembly per Yamaha service manual procedures. 2. Remove the air silencer box under the tank. 3. Install supplied BA-2410-00 Needle/Jet kit according to the instructions in the jet kit package being sure to use the Jets and Needle Slot setting called out for the external BAK filter assemble. 4. Reinstall the air silencer box under the tank. 5. Remove the rubber boot from the stock air box. It is glued-in from the factory, but will come loose if gently persuaded. See photo #1 Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Barons bears no responsibility on installation costs associated with this product. © 2010 Barons Custom Accessories 7401 Slater Ave. Huntington Beach, CA 92647 (714)274-4065 – Ph. (714)848-0718 – Faxwww.baronscustom.comtech@baronscustom.com Page: 2 BA-2011-00/03/06/07/13/13B BIG AIR KIT – YAMAHA V-Star 650 6. Install the stock rubber boot into your new Baron air filter backing plate with the supplied glue. Squeeze glue liberally into sealing groove in stock rubber boot. See photo #2 Allow glue to set up and dry prior to mounting onto bike

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YAMAHA V-STAR 650 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 28-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. This Exhaust system is specifically designed for California models, before continuing be sure it is the correct system for your application. 2. Loosen clamp that connects muffler to front head pipe. 3. Remove cylinder exhaust bolts from rear head pipe that connects rear head pipe to cylinder (save for re- use). 4. Remove bolts that connect mufflers to mounting bracket. Remove complete system. Note: Assistance may be required. Page 1of 4 Y411IN Rev. 1.0 YAMAHA V-STAR 650 CRUZER EXHAUST SYSTEM, CA Model Part #31505 Tools required for installation: 1/2”, 12mm & 10mm wrenches 5mm, 6mm Allen wrenches 5/16″ nutdriver / flat blade screwdriver VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. 2. Install mounting bracket (stamped 370-P) in the original muffler mounting position, using two 8mm bolts (supplied)(Figure 1). 3. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside (Figure 2). Place each heat shield on a non abrasive surface such as a blanket or carpet. Lay each head pipe/muffler onto its respective heat shield (Figure 3). 4. Loosely install each hose clamp by feeding tail end of clamp into heat shield clip (Figure 4). Take note of clamp screw head direction (Figure 3). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Note: Do not tighten yet. 5. Install T-bolt clamp onto front muffler. Slide muffler onto front head pipe. Slide dog bone shaped nut plate (supplied) inside bracket welded to backside of front muffler. Attach muffler to mounting bracket 370-P using two 5/16″ flange bolts (supplied) engaging dog bone nut plate. Leave head pipe/muffler assembly loose at this time (Figure 4). 6. Using stock Allen bolts, carefully install rear head pipe/muffler assembly into exhaust port. (Assistance may be required). Note: Do not tighten yet. 7. Slide dog bone shaped nut plate (supplied) inside bracket welded to backside of rear muffler

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Harley Davidson 6- SPEED CONVERSION KIT FOR BIG TWIN 5- SPEED TRANSMISSIONS INSTALLATION

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Filed Under (Harley Davidson) by admin on 05-03-2012

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5/16 Bolt hole boss clearance This can easily be checked with the trap door gasket. Put the gasket on the dowel pins. AII material of the boss around the hole that “sticks outside” the gasket (60 degrees forward to 60 degree backwards) must be removed (see figure A). Primary fork clearance Place the gasket on the housing and remove material as indicated for clearing the shifter fork (see figure B). WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® INSTALLATION INSTRUCTIONS FOR 6 SPEED CONVERSION KIT AND 6 SPEED BUILDER KIT speed transmission. Also make sure you have a 1990 or later Factory Service Manual available. Tools The conversion kit should only be used in new or low milage transmissions. If gears or bearings of a used Gear set Removal Refer to the Factory Service Manual Section for Mainshaft and Countershaft removal. When you get to the point of actually sliding the gear set out make sure you properly mark the 5th gear set as described in the Factory Service Manual (for used transmissions only). Further follow the factory removal procedure. Clearance Checks The 6 Speed conversion and builder kit will fit in most OEM or aftermarket transmission housings without may be needed. The following clearances must be checked before assembling the 6 speed transmission. 28-05-2008 We recommend the kits are installed by a qualified mechanic with knowledge of the Harley-Davidson 5 needed are the same as used for a 5 Speed transmission. 5 speed transmission are worn, new ones must be installed, or better, the builder kit should be used. any modification of the housing. However due to casting differences, in some instances some modification
WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® Pillow block clearance (right side) Make sure there is clearance between the pillow block and the housing. Any clearance is O.K. (see figure C). Fork shaft support clearance Again use the gasket as the template and remove the material as indicated (see figure D). Shift drum end play The end play of the shift drum must be checked prior to final installation. Install the shift drum. Measure the end play with feeler gauges at the right pillow block (see figure E). End play should be between .004″ and .010″, some 1/2″ X 7/8″ 0.008″ thick shims are included to adjust the end play

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Yamaha V-Star 650 Rear Lowering Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 18-10-2010

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INSTALLATION PROCEDURE 1. Secure motorcycle to a bike lift and raise the motorcycle. 2. Remove stock rear shock from the motorcycle per standard Yamaha shop manual instructions. 3. Place the shaft of the shock in V” blocks and secure this in a vice or press, applying firm pressure to the V” blocks to trap the shaft so it will not turn. Unscrew the upper shock mount eyelet from the shaft. NOTE: The upper mount is a standard thread so you will rotate the mount counter-clockwise to unscrew it. 4. Next, screw the New LA Choppers Shock Mount onto shock shaft using Loctite. 5. Re-install shock spring, making sure it is locked in place with the retaining ring prior to slowly releasing the spring compressor. Allow shock spring to expand against the retaining ring and machined washer. 6. Reinstall shock onto the motorcycle per standard Yamaha shop manual instructions. WARNING: Installing a lowering kit will decrease initial ground clearance. The motorcycle will be lower to the ground and care should be taken to avoid bottoming, especially over bumps or in turns. To maintain proper balanced geometry, the front and rear of the motorcycle should be lowered equally. Failure to properly install the lowering kit and operate the motorcycle after installation may result in serious injury or death to the rider. LIMITED GUARANTY: Because we cannot control the application of our products, buyer assumes risks for any and all damage caused to him or herself or any third party by virtue of any failure of these parts. Guaranty for such parts is limited to our replacement costs thereof. This guaranty is in lieu of all other guaranties or warranties express or implied, and all other such guaranties or warranties are hereby expressly disclaimed. By installation of these parts, buyer irrevocably agrees to the foregoing

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650 Yamaha V-Star InstaTrike REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 29-12-2011

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install all bolts loosely until all brackets are in place y Remove any aftermarket accessories (saddle bags, back rests, etc) before hitch installation. After installation remount accessories. NOTE: Some aftermarket accessories may not be compatible with InstaTrike. 1) Place motorcycle on a firm level surface. 2) Remove rear foot pegs and bolts 3) Attach bracket A (left) and bracket B (right) to the inside of the rear foot peg bracket and reattach rear foot pegs using new bolts provided. 4) Attach front of bracket C (left) and bracket D (right) to bottom of brackets A and B 5) Attach bracket E (left) and bracket F (right) to two rear fender attachment bolts using new bolts provided 6) Attach brackets G and H to rear of brackets E and F 7) Attach bottom of brackets G and H to hitch plate. 8) Attach rear of brackets C and D to TOP of forward hitch arms. 9) Tighten all bolts. Installation Diagram Leveling stand screw jack installation 1) Thread right side screw jack into threaded hole on bracket D 2) Push motorcycle over from left side until right screw jack is touching floor. 3) Install left side screw jack on bracket C and adjust out until motorcycle will rest upright on both screw jacks. 4) Adjust screw jacks until motorcycle is level. CAUTION – Use screw jacks to hold motorcycle upright and level ONLY. Do not lift motorcycle with screw jacks. CAUTION – Use care when installing screw jacks. Be certain that motorcycle is always in a stable balanced position

V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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KTM 125 EXC, EXC SIXDAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXCSIXDAYS 300 XC, XC-W, EXC-E, EXC-ESIXDAYS OWNER'S MANUAL 2008

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Filed Under (KTM) by admin on 02-12-2010

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Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. Clutch lever The clutch lever [1] is located on the left side of the handlebars. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hand brake lever The hand brake lever [2] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see maintenance work on chassis and engine). OPERATION INSTRUMENTS » 1 2 A B
ENGLISH 6 OPERATION INSTRUMENTS » TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21″ with production tires). Afterwards the display will return to the previous display mode. Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The button is used to change between display modes. The + and – buttons are used to control various functions. SPEED display mode / H (service hours) Only the SPEED / H and SPEED / ODO display modes are activated in the condition at delivery. SPEED/H is displayed whenever the display is activated and the front wheel is not turning. It automatically changes to the SPEED/ODO display mode as soon as the front wheel starts turning. SPEED displays the speed. H displays the engine’s service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motorcycles, making the service hour counter a very practical function. SPEED / ODO display mode (odometer) The SPEED/ODO mode displays the speed and the total distance traveled. The display automatically changes to the SPEED/H display mode when the front wheel stops turning. + button no function – button no function briefly press buttonchanges to the next display mode hold button 3 secs. changes to the next display mode The electronic speedometer has a number of display modes (functions) that you can also activate (reveal) (see: Activating and deactivating display modes).
ENGLISH 7 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode You can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds. + button Starts and stops the stop watch, lap time is not reset to 0 – button Stops the stop watch, stores the lap time and restarts the stop watch again. The time is reset to 0. A total of 10 lap times can be stored. If the lap time continues to run after you press the – button, all 10 memory locations are occupied.To clear all of the stored lap times, hold the button for 3 seconds in the SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press buttonChanges to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures SPEED / CLK (time) display mode CLK displays the time in hours, minutes and seconds. + button no function – button no function briefly press buttonchanges to the next display mode hold button 3 secs. set the clock menu To set the clock, see „Setting the clock”. Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deactivated by pressing the – button. Press and hold the button 3 seconds to store the settings. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode. + button activates the blinking display – button deactivates the blinking display briefly press buttonchanges to the next display without changing any settings hold button 3 secs. starts the SETUP stores the settings and changes to the SPEED/H mode

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2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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