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Lambretta UNO50 Owners Manual

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Filed Under (Lambretta) by admin on 25-11-2010

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brakes: Inspect brake cables/hoses/linkage for correct mounting, chafing, leaks and damage. Check and adjust both front and rear brakes. If hydraulic, check fluid level and correct if necessary (DOT 4 fluid only). Engine: Check and correct the engine oil level. Fuel system: Check fuel tank, carburetor, fuel valve and all hoses for leaks. Throttle system: Check for correct throttle cable routing. Throttle operates smoothly and self-returns to idle from all handlebar positions. Wheels/tires: Check wheels, tires and valve stem for damage, etc. Check and adjust tire pressures. 11 Suspension: Check for smooth suspension operation. Lubricate all grease points using correct specification grease. Check for correct suspension adjustments. Inspect fork and shock seals for leaks. Steering: Check for smooth steering operation and handlebar bearings for proper adjustments. Electrical Systems: Check for correct function of all side, headlight (high/low beam) and taillights, turn indicators, brake lights, warning lights and instrument illumination. Check for correct horn operation. Check harnesses for correct routing. Check for correct function of starter lockout system. Check for correct engine stop switch operation. Check for correct function of the low oil warning light. (2 stroke only) Emission Systems: Check connections and hoses for routing and kinks.
12 Fastening hardware: Check front and rear axle nut and bolt torque. Check torque of drain plug and oil filter bolt. Check torque of all brake system nuts and bolts. Check torque of all steering system mounting hardware. Check torque of exhaust mounting hardware. Check torque of all remaining nuts, bolts & screws. Road test Front and rear brake operation. (approx. 10km): Check cold engine start performance. Evaluate performance, handling and braking. After road testing: Check hot engine starting. Check and adjust idle speed. Check for oil and fuel leaks. Make necessary adjustments and repair any defects seen or observed before, during and after test drive. Retest as necessary. Clean the vehicle prior to deliver

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POLINI X1 GENERAL INFORMATION AND SPECIFICATIONS

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

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Air cleaner – Clean and reoil daily or after each moto to prevent motor failure and reduced performance. Transmission oil – change after every race, or at end of riding day. Chain – check tension and lubricate before every ride, adjust or replace as needed. Reoil after riding in damp conditions. Clutch – disassemble and clean clutch assembly frequently, every 2-3 races at least. Inspect kickstarter gears at this time. Ignition cover – remove cover and wipe dry after each ride or after washing bike to remove condensation. Piston rings – replace as often as every 3-5 races with expert rider, less often with less aggressive riders. Piston, pin, rod bearing & circlips – replace as often as every 8-10 races with expert rider, less often with less aggressive riders. Coolant – change yearly, make sure there is at least a 50/50 mixture of antifreeze if freezing temperatures are possible. Steering bearings – Check daily for looseness or play. Adjust and regrease as needed. Swingarm – Check often for looseness. Regrease several times a year. Replace bushings if any play is evident. Sprockets – check for worn or curved teeth each time chain is adjusted. Chain roller& wear pads – check roller for free rotation when checking chain. Make sure roller is not bent or damaged. Check chain wear strips on swingarm and chain guide frequently. Replace as needed to prevent chain from damaging motorcycle. Spokes – Check after each race or after each day of riding for looseness or damage. Wheels & tires – check wheels after each race for dents, cracks or other damage. Check tires for cuts, damage or wear. Check tire pressure daily and adjust for riding conditions. Shock – Check shaft area daily for signs of oil leakage or damage. Check swingarm and shock bushings for looseness. Forks – Check forks daily for leaking oil or damage to tubes. Make sure forks are not twisted check for smooth operation. Spark plug – check sparkplug color and condition after each race or end of riding day. Adjust jetting to keep plug from fouling or overheating. Silencer – If bike seems to be getting louder, replace packing and decarbonize inner tube. Expansion pipe – check daily for large dents, damage or leakage. Remove carbon from headpipe when pipe is removed. Have large dents fixed, or any dents within 8″ of the cylinder. Replace o-rings on pipe as needed to maintain a good seal. Footpegs – check daily for proper operation, pegs should spring back into place. Make sure pegs are not bent or overly dull. Handlebars – check bars after any crash for bending. Look for cracks near bar clamps. Replace bars that have been straightened more than 2 or three times, or if bar is badly bent. Aweakened bar can snap suddenly causing injury to rider. Throttle – check throttle for proper operation each time before bike is started. Remove and clean inside of grip and bar as needed. Grips – check grips daily for wear or looseness. Replace as needed. Use grip glue & safety wire to help hold grips in position. Calipers & pads – check pad wear and caliper function daily or after each race. Replace pads and clean calipers as needed. Brake lever – check lever daily for damage or wear. Make sure lever is at proper angle for both seated and standing positions. Leave lever clamp loose enough to allow clamp to rotate during crash rather than breaking lever. Check and adjust freeplay as needed. Brake pedal – Check pedal daily for damage and proper freeplay. Adjust rear caliper as needed. Reeds – Remove and inspect reed block during every ring change. Check reeds for signs of wear, fraying and cracking. Make sure reeds sit flat and seal well. Replace at any sign of wear or damage or at least once a year, more often for expert riders. Nuts & bolts – Check all nuts and bolts regularly. Make sure to check engine mounting bolts and swingarm bolt frequently

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BMW F 650 GS Repair Manual And Maintenance schedule

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Filed Under (BMW) by admin on 19-11-2010

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Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) every 2years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS ) 40,000 km Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check

HONDA CT110 OWNERS MANUAL

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

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ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be maintained between the upper (2) and lower (3) marks on the dipstick (1). 1. Start the engine and let it idle for a few minutes. 2. Stop the engine and hold the motorcycle in an upright position on firm, level ground. 3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the dipstick without screwing it in. The oil level should be between the upper and lower marks on the dipstick. 4. If required, add the specified oil up to the upper level mark. Do not overfill. 5. Reinstall the oil filler cap/dipstick, check for oil leaks. CAUTION Running the engine with insufficient oil can cause serious engine damage. TYRES Proper air pressure will provide maximum stability, riding comfort and tire life. Check tire pressure frequently and adjust if necessary. NOTE Tire pressure should be checked before you ride while the tyres are cold. Select the right replacement tire in accordance with the following specifications: Cold tire pressures kPa ( kg/cm2, psi ) Front: 175 ( 1.75, 25 ) Rear : 225 ( 2.25, 33 ) Tire size Front: 2.75 – 17 41P Rear : 2.75 – 17 41P Check the tires for cuts, embedded nails, ore other sharp objects. See your authorized Honda Dealer for replacement of damaged tires or punctured inner tubes OPERATION PRE-RIDE INSPECTION WARNING If the Pre-ride Inspection is not performed, serious damage or an accident may result. Inspect your motorcycle very day before you ride it. The items listed here will only take a few minutes to check, and in the long run they can save time, expense and possibly you life. 1. Engine oil level – add engine oil if required. Check for leaks. 2. Fuel level – fill the fuel tank when necessary. Check for leaks. 3. Brakes – check operation. Adjust free play if necessary. 4. Tyres – check condition and pressure. 5. Drive chain – check condition and slack. Adjust and lubricate if necessary. 6. Throttle – check for smooth opening and full closing in all steering positions. 7. Lights – check that headlight, tail/brake light, turn signals, indicators. 8. Engine stop switch – check for proper function. 9. Battery electrolyte – check the level and add if necessary Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance if you cannot correct the proble

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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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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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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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POLINI MINICROSS AND MlNlMOTARD OWNER'S AND MAINTENANCE MANUAL

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Filed Under (Polini) by admin on 22-11-2010

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Fit the stand using the M8x18 screw to fasten it and the spring provided (photo 1 6). A DANGER! We suggest you to remove the stand during competitions as it could be dangerous and bruising. 18- Fit the gear lever l~hoto 171. 19- Fill the fuel tank (See section 4.13). 20- Check the engine oil level (See section 4.3). INTRODUCTION Always ensure that the motorcycle has been efficiently serviced and check it over before riding it. Take your motorcycle to an authorised POIJNI MOTOR1 dealer for all maior servicing and repair. Because of the manufacturer’s policy OF continuous development, and because of constant innovations in technology, your motorcycle may differ in some details from that described in the illustrations and text in this manual. Original POLlNl MOTOR1 spare parts are always made from the same materials and in the same way as the parts originally fitted to your minicross motorcycle. Always insist on original POIJNI MOTOR1 spore parts. Their use ensures a longer life and improved efficiency for your motorcycle. 2. STARTING THE ENGINE FOR THE FIRST TIME Always check over your motorcycle thoroughly before starting the engine. To start the engine for the first time, as instructed below. 1 – Turn the fuel tap located under the fuel tank to #ON” position (photo 18) Run your new motorcycle in as instructed How to ensure that the engine and transmission bed in correctly and to ensure continuous reliability in Future. A CAUTION! The first time yw ride your new motorcycle, ride for about two hours at low engine speeds to ensure that it runs in correctly. Also respect the following precautions. 2- Once the engine starts, leave it idle until it warms up to normal temperature. If you switch the engine off for a short time, wait for it to cool down completely before you re-start it. – 3- During the running in period, always ride at constant 2- Before starting the engine put the gear in neutral position speeds. AVOID RAPID ACCELERATION. (photo 19, gear N). 4- Even when riding at low engine speeds, avoid extended A WARNING! IF the gear position is not neutral the bike could move when started. 3- If the engine is cold, lift the choke lever on the carburettor (photo 20). A WARNING! Lower the starter lever again as won as the engine starts to warm up. 4- Leove the throttle closed. Pivot the kick-start lever out wards and push energetically downwards with your foot to start the engine. 5- Return the kick-start lever to its rest position. Leave the engine idle for a few minutes to warm it up. A WARNING! Check that the engine stop button stops the engine effectively before yw begin riding the motorcycle. difficult sections of road or Lck that could cause the engine to become very hot. 5- Once you have run in your motorcycle following all these instructions, take it to a Polini Motori dealer for its post- running-in service. Apart from a change of spark plug and engine oil, this service also includes the disassembly

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BMW Motorcycles R1100R Maintenance Schedule

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Filed Under (BMW) by admin on 12-11-2010

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spect crate on receipt for signs of damage, start vehicle historyfile Uncrating the motorcycle – Remove document package from crate wrap – Unpack and check for missing items; complete QEWfax if needed formissing parts – Clean brake rotors priorto moving from crate – Complete assemblyusing BMWuncrating and assemblyinstructions – Equalize pressure in front forks – Clean entire motorcycle of transport preservatives Battery: – Remove battery – Add battery acid – Allowbatteryto cool priorto charging – Charge batteryat 10% AH rating until fullycharged – Grease the terminal posts – mark in service date Check complete specification delivery: – Tools – Handbooks and documents (including warrantyinformation) – Keys – Retailer directory/retailerbusiness cards – Documentation forinstalled options Check function of side stand safetyfunction Check headlamp (basic setting), adjust if necessary Check and adjust front and rearbrake fluid levels Check tire pressures – set at ______PSI front, ______PSI rear Check torque setting of the rearwheel retaining bolts _______lb/ft Check engine oil level, top up if necessary Fuel the motorcycle (full tank of fuel forcustomerdelivery) Check basic clutch setting. adjust if necessary Safety/ operating check as final inspection: – Cold start / idle speed – Clutch, gear shifting – Steering – Front / rearbrakes and ABS – Indicator and warning lights, instruments, lighting, horn and signalling equipment – Function of optional equipment (radio, alarm, etc.) – Test ride, check forfluid leaks – Visual qualitycheck

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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