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BMW Motorcycle R 1100 RS – Rear Frame

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

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Complaint: On R 1100 RS models (above serial numbers only) with luggage racks, a crack may develop in the rear section of the frame (see drawing) if a load exceeding the permitted 11 lb. is applied to the luggage rack, or if a top case is used. Remedy: Please check all R 1100 RS models (in serial number range above) which pass through your workshops for cracks on the rear section of the frame. Cracked frames should be exchanged with the new part listed below. The new rear frame has been reinforced to use with larger loads. New Part: 46 51 2 320 698 (reinforced rear frame) Caution: Since the introduction of the rear luggage grid to accommodate the 33 liter removable top box, it is vital that this luggage grid and 33 liter top box not be installed on any of the above unless the reinforced rear frame is fitted, or a frame reinforcement kit is installed (a kit will be made available in the future to reinforce the rear frame of the above models, in order to install the 33 liter top box). The new reinforced rear frame (46 51 2 320 698) has been fitted since May 1995 production. Use of the new rear section of frame on an earlier production bike requires a new rear section of the dual seat as follows: Parts 52 53 2 325 121 Flash Green 52 53 2 325 122 Red Needed: 52 53 2 325 123 Black 52 53 2 325 120 Light Gray 52 53 2 325 211 Anthracite Warranty: Please explain to your customers that the top case can only be installed on bikes with reinforced rear frames. Claims for frame cracks which result from operation with large loads beyond specification will not be honored under the terms of the Limited Motorcycle Warranty.

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Kawasaki Teryx Dash Frame Installation Manual

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

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The BRP Dash Frame mounts in place of the factory cup holder/storage pocket. Remove the screws holding the cup holder or storage pocket from the back of the dash and remove it. Hold the Dash Frame up on your dash. The top of the frame includes a channel that your dash slips into to provide support. Press the frame firmly up and against the dash. Be sure the frame is centered and straight. Using the frame as your template drill out the two top holes using a 13/64″ drill. Each hole is located at the top corner of the frame. Alternatively, you can mark the location of the holes, then drill them out with the frame removed. Using the smaller button head bolts supplied with this kit, along with the nylock nut and rubber backed washer, mount each of the two top corners of the frame. Use caution when tightening however. The angle of the dash frame is different than the angle of your plastic dash. The two bolts are only needed to snug the frame against your dash. You should only snug the bolt up, but don’t tighten it down. Looking from the back of the dash, you’ll see that the rubber washer does not lay flat against the plastic of the dash. This is correct. Again, these bolts are only to snug the frame against your dash and should not be tightened down. Doing so could damage your dash. The supplied nuts are nylock and will not back off even though the bolt is not tightened.

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SUZUKI 2005-2006 GSX-R1000 MOTORCYCLES FRAME REINFORCEMENT BRACE INSTALLATION/FRAME REPLACEMENT

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Filed Under (Suzuki) by admin on 30-11-2010

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Bodywork removal 1. Refer to section 8 of the service manual and remove the following: a) Right and left Under Cowlings (NOTE: Two of these screws will NOT be re-installed) b) Cover, Front Lower 2. Refer to section 7 of the service manual to remove the radiator mounting bolts. It is not necessary to remove the radiator. 3. Remove the Horn and the Front Engine Cover: a) Remove the Horn. b) Refer to page 3-5 of the service manual and remove the Front Engine Cover. (NOTE: This part will NOT be re-installed) NOTE: To view a video (approximately 10 minutes in length) of the inspection and installation procedure, click here (available on January 23, 2009). Frame inspection 1. Inspecting the frame for damage: a) Inspect the frame for cracks on the left and right sides of the frame as indicated in the photos and graphic below using the Dye Penetrant test kit which will be sent to your dealership by Jan.23th. This inspection has to be done not only on the outside but also on the inside of the frame spars. b) If no cracks are detected, thoroughly clean the frame area using a clean cloth (not a shop rag) and the kit cleaner to remove the dye penetrant used for the inspection. NOTE: * Protect the surrounding areas where inspection is not required from the overspray of the Dye Penetrant. * Read and understand the instructions and handling precautions of the Dye Penetrant before applying it. * If the motorcycle is excessively dirty, prewash it with soap and water before applying the Dye Penetrant.

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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

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2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

YAMAHA ROYAL STAR VENTURE CENTERSTAND REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 31-12-2011

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Stand Installation. Locate the four mounting holes on the frame that correspond with the holes in the centerstand. Slide the front of the centerstand up into the frame and align the large bolt holes with those in the frame. Install the (2) 7/16″ x 1″ bolts with washers thru the frame and centerstand. Install the (2) 7/16″ nuts and make finger tight. (on California models the fuel tank vent canister must be removed and the hoses bypassed see note below) Pivot the rear of the centerstand up to align the (2) smaller holes in the stand with those in the frame. Insert a phillips screwdriver into one of the (2) remaining mounting holes and pry the other hole into alignment. Install one of the ¼” x ¾” bolt with a washer from the top down thru the frame and centerstand. Install the lock nut finger tight. Remove the screwdriver and install the remaining ¼”x¾” bolt washer and nut. Tighten the ¼ ” bolts securely 10-12 ft. lbs., then tighten the 7/16″ bolts securely 20-24 ft. lbs. 2. Stop Bumper Installation. Next install the centerstand-stop bumper and bracket onto the frame. Locate the bolt “A” in photo #1. Notice there is another 10 mm bolt just below it. Remove the lower bolt. Attach the bumper bracket to this hole using the longer bolt and washer supplied. The leg of the bracket with the bumper should face inward towards the center of the motorcycle. Adjust the height of the bracket to keep the pedal arm 3/8″ to ½” from the bottom of the exhaust pipe. Tighten securely. 3. Emissions Valve Relocation. You will notice that the right leg of the stand near the foot comes in contact with the emissions valve. The valve needs to be moved outward or to the right as you are sitting on the motorcycle approximately ¾”. This is done as follows: Remove the (2) 10 mm bolts holding the emission valve and bracket to the frame. See photo #2. With the hoses still attached pull the valve down to gain access to the (3) allen screws. Remove the (3) allen screws and (2) nuts holding the bracket to the valve, turn the bracket over and re-assemble the valve onto the bracket as shown in photo #3. Re-install the valve onto the frame. You may need to rotate the hose clamp clips out of the way and/or bend the entire valve bracket assembly outward slightly to gain clearance between the centerstand leg and foot. 4. Using Your New Centerstand. To put the motorcycle up onto the centerstand, hold the left handle bar and saddlebag guard rail. Using the ball of your right foot, lower the stand to the ground. Rock the motorcycle from side to side slightly until you feel both feet of the stand touching the ground. Now, put all of your weight on to the centerstand pedal (stand on it). Pull up and back on the grab rail using a rocking motion to rock the motorcycle up on to the stand. Remember it is a matter of using your body weight and leverage not lifting! 5. Getting the Bike Down off the Centerstand. Holding the left handle bar and saddlebag guardrail, firmly rock the motorcycle off the centerstand. You can also rock it off while sitting on the motorcycle.

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Honda Shadow750 ACE Installation Manual

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Filed Under (Honda) by admin on 21-11-2010

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1) Place motorcycle on a smooth level surface on its side stand. 2) Install leveling screw jacks so that motorcycle is in an upright and level position. 3) Remove saddlebags. 4) Mount bracket A ( left side ) to the 3 bolts that attach the rear fender and sub frame to the main motorcycle frame. new bolts provided 5) Mount bracket B ( right side ) to the 3 bolts that attach the rear fender and sub frame to the main motorcycle frame. new bolts provided 6) Bracket C mounts to the outside of bracket A at the rear lower hole. ( left ) 7) Bracket D mounts to the outside of bracket B at the rear lower hole. ( right ) 8) Bracket E ( left ) attaches to the outside of the motorcycle frame just under the rear foot peg and above the frame weld with the provided U-bolt. see diagram 9) Bracket F ( right ) attaches to the outside of the motorcycle frame just under the rear foot peg and above the frame weld with the provided U-bolt. see diagram 10) Bolt brackets C and D to the top rear of the receiver hitch. 11) Bolt brackets E and F to the top of the forward arms of the receiver hitch. 12) Tighten all bolts at this time. 13) Remount saddlebags and check all bolts for tightness. 1. Place your motorcycle on a smooth level surface and attach leveling jack stands. 2. Assemble axles, wheels, and fenders onto the tow-pac hitch cart. 3. Push the hitch mount into the receiver hitch. (this might bea little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bolt. 5. Align InstaTrike wheels. (initial installation only. Check periodically and realign if necessary) 6. Bolt lean stop braces to hitch. (Bolt inserts from the bottom) Be certain to replace washers/spacers in the same configuration as when you removed them.

1300 Yamaha V-Star Installation Manual

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Filed Under (Yamaha) by admin on 07-11-2010

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1) Place motorcycle on a firm level surface and secure in a upright position. 2) Remove saddle bags and saddle bag hardware (Tourer model only) Also remove rear riders pegs (Tourer model requires removal of rear footpeg offset hardware as well) 3) Attach bracket A (right) / B (left) to rear footpeg attachment point using new bolts provided. Remount footpegs/saddlebag hardware over top of brackets A/B. NOTE: Do not attach leveling stand bracket at this time 4) Attach bracket C(right) / D(left) to rear fender sub frame using new bolts provided. (Tourer model only – Saddle bag hardware mounts to the outside of brackets C/D. Brackets C/D mount between chrome side rail and saddlebag hardware.) NOTE: Brackets C/D have welded spacers which attach in toward rear fender 5) Attach top of Bracket E(right) / F(left) to rear of brackets C/D. Brackets E/F mount to the inside of brackets C/D. NOTE: Use ½ inch spacer between brackets E/F and C/D on Tourer model ONLY
6) Attach rear of brackets A/B to TOP of forward hitch arms. Attach bottom to brackets E/F to rear hitch plate. 7) Carefully tighten all bolts at this time ensuring hitch is square with motorcycle. Hitch Bracket Identification Leveling stand screw jack installation 1) Attach leveling stand brackets to brackets A and B 2) Thread right side screw jack into threaded hole on leveling stand bracket attached to bracket A sand adjust leveling jack bolt out. 3) Push motorcycle over from left side until right screw jack is touching floor. 4) Thread left side screw jack into threaded hole on leveling stand bracket attached to bracket B and adjust out until motorcycle will rest upright on both screw jacks. 5) Adjust screw jacks until motorcycle is level. 6) After InstaTrike is attached to or removed from receiver hitch, be sure to remove leveling stands and leveling stand brackets. 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.
INSTALLATION OF THE TOW-PAC HITCH CART. 1. Place your motorcycle on a smooth flat surface, like a garage floor, and install leveling stands. Install right leveling stand first. Carefully raise motorcycle off of side stand and install left leveling stand. Caution – Use leveling stands to level motorcycle ONLY. Do not raise motorcycle with stands Caution – Be certain that motorcycle is always in a stable balanced position when installing leveling stands. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bolt

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Vengeance Motorcycle Specification And Owner's Manual

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Filed Under (Vengeance) by admin on 20-11-2010

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Vengeance Maxis • Vengeance Raven • Vengeance Banshee • Vengeance Whiplash • Hotrod Drifter • Hotrod CalChop • Hotrod Teacher • Hotrod Bone Shifting Gears Starting off and changing gears requires coordination of the clutch and throttle and gearshift lever. If you don’t do things right, the amount of control you have over the bike is lessened. To start off, pull in the clutch, shift into first gear, roll on the throttle a little, and ease out the clutch. You will become familiar with the friction zone (that’s where the clutch begins to take hold and move the bike), and you add a bit more throttle. You don’t want to stall the engine, nor do you want to over-rev it. There’s a sweet spot in there; find it. Shift while traveling in a straight line. Shifting in a curve is not good practice, and something to be avoided. Become familiar with the sound of your engine, so you can tell when you should shift without looking at your instruments. When you downshift to a lower gear, you should (in one swift, smooth movement) be able to squeeze the clutch, rev the engine a little to let it catch the lower gear smoothly, and shift down. When you come to a stop in traffic, leave the bike in first gear with the clutch disengaged (just in case you want to accelerate out of there in a hurry). Who knows what may be coming up behind you. Braking Don’t ever forget: The front brake on your motorcycle can supply as much as 70 percent or more of your stopping power. The single most important thing you can learn about braking is to use that front brake every single time you want to slow down. Turning When you are riding along the road, you lean a motorcycle into a turn. Learning to lean is an essential part of riding a motorcycle. It is a normal function of the bike when you are changing its path of travel – and quite different from turning the steering wheel of your car. To get the motorcycle to lean in a normal turn, press the handlebar in the direction of the turn and maintain slight pressure on that handlebar to take you smoothly through that particular turn. In other words: press right to go right; press left to go left. Your instincts to keep the motorcycle on a smooth path while keeping it from falling over usually take care of this without you even noticing it. (Demonstrate to yourself how a motorcycle moves by pressing a handlebar slightly while traveling in a straight line. The motorcycle will move in the direction of the handlebar you pushed.) • Slow down before you enter the turn; look as far ahead as possible through the turn. • Keep your feet on the pegs, and grip the gas tank with your knees. • Lean with the motorcycle; don’t try to sit perpendicular to the road while the motorcycle is leaning over. • Keep an even throttle through the turn, or even accelerate a little bit. Checking the Bike before the Ride It’s not fun to have things go wrong on a motorcycle, but if you spend a minute before you go off on a ride, you can increase the chances that nothing will.

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HARLEY DAVIDSON TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL NOTES Refer to the service manual for more information on these generalized steps. Save all removed parts (unless otherwise noted) for installation of this kit or for motorcycle operation without the sidecar. 1. For TLE-Ultra Models: Remove both lower fairings. 2. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. 3. Remove the three right side exhaust heat shields. Some models may require removal of the right side exhaust pipes. 4. Remove stock clutch cable. 5. Remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and brake pedal. Discard cotter pin. 6. Cut the cable straps holding front oxygen sensor connector to frame bracket. 7. Remove wire harness/brake line clip from right lower frame tube. INSTALLATION New Clutch Cable Installation 1. Refer to the service manual and follow instructions to remove stock clutch cable. 2. Refer to the service manual and follow instructions to connect the new clutch cable to clutch hand lever. 3. For FLHT/C/CU: Follow the instructions in the service manual to route new clutch cable through fairing. 4. For FLHR/C Models: Capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. 5. See Figure 1. Route clutch cable down along left frame downtube (1). 6. Continue to route cable down between left front engine isolator and crankcase. Clutch cable will cross to the right side of motorcycle beneath the crankcase, to the clutch release cover on the right side of the transmission. 7. Install clutch cable fitting into clutch release cover. Refer to the service manual. NOTES The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. Verify that the clutch cable and the rear brake line do not make contact. Damage could result. 1 2 3 is05785 1. Downtube 2. Clutch cable 3. Route clutch cable behind left front engine iso- lator Figure 1. Route Clutch Cable Relocating Oil Pressure Sending Unit NOTES Perform this procedure on all models equipped with an oil pressure gauge or Police models. All other models proceed to “Master Cylinder Assembly/Rear Brake Pedal Modification.” 1. Remove cable strap securing oil pressure wire harness to frame. 2. Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and disconnect connector from oil pressure sender. 3. Remove the oil pressure sender using a 1-1/16 inch open- end crowfoot wrench. 4. See Figure 16. Coat threads of elbow (44) with Loctite 565 and install into crankcase oil pressure sender threads. 5. See Figure 2. Install elbow (1) until snug so open end is in the five-o’clock position (2). Do not over-tighten or crankcase may be damaged. 6. Coat threads of oil pressure sender with Loctite 565 and install into 90 degree brass elbow. Use a 1-1/16 inch open- end crowfoot and tighten to 96-120 in-lbs (11-14 Nm) . 7. Install connector on oil pressure sender unit. Verify that slight clearance to the right engine isolators is present. Adjust position of elbow as required to provide clearance

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