how to check the coil on a 2007 mule 610

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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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HARLEY DAVIDSON DYNA CHROME COIL COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Installation 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Note the position of each spark plug wire in the ignition coil, then disconnect the two wires. 3. If there is an existing coil cover: Remove and discard the coil-cover mounting screws and spacers. Remove and discard the coil cover. If there is not an existing coil cover: Remove and discard the two coil mounting screws. 4. See the Service Parts illustration. Obtain the coil cover bracket (3), two long screws (4) and two spacers (2) from the kit. 5. Insert the screw into one of the holes in the bracket as shown, through a spacer, and into a coil mounting hole. Repeat with the second screw and spacer. 6. Assemble the coil to the electrical caddy with the two screws. Tighten the screws to 50 in-lbs (5.6 Nm). 7. Obtain the new chrome coil cover (1) from the kit. Position the cover over the coil, and fasten to the coil cover bracket with the three chrome screws (6) and washers (7) from the kit. Do not fully tighten the screws at this time. 8. Connect the spark plug wires through the holes in the side of the coil cover onto the correct coil terminals. 9. Adjust the cover to center the spark-plug wire boots in the coil cover holes for best appearance. Tighten the three chrome screws securely 10. Refer to the Service Manual and follow the instructions given to install the maxi-fuse

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Kawasaki Mule 610 Without coil springs Installation

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

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1.)Begin by loosening the lug nuts on both front tires. Raise the unit, using a suitable lifting device or procedure, until the front tires are off the ground. If using a floor jack with stands, chock the rear wheels to prevent the unit from rolling. If using jack stands, make sure the stands are placed under the frame and not the body. Make sure the unit is stable and secure . 2.)Remove the tires / wheels. NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure. 3.) The first thing to do is remove the front cowl and trunk on the bike. You can accomplish this by removing all the bolts (screws) around the perimeter of the cowl and removing some plastic “snap rivets”. To remove the rivets simply pull the center section up and then the rest will follow. 4.)Place a floor jack, or other suitable device, beneath the left side lower control arm. This is to prevent damage to the tie rod or slip yoke boot while disassembling the lower control arm and strut. Using a 14mm socket, remove the two retaining nuts and lock washers on the top of the struts. 5.)Leaning the strut forward toward the headlamp buckets will put the strut in position to allow you to reach over the top and place the strut spacer in place. Install the strut spacer on top of the coil retainer and tightening the nuts. Install the supplied gasket on top of the strut spacer, and re-install the strut assembly

HARLEY DAVIDSON CHROME SEAT POST REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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REMOVE 2 1 is00000 1. Seat Post 2. Screw Figure 2. Lower Seat Post 1. Refer to Owners Manual to remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery negative cable. 3. On motorcycles equipped with oxygen sensors, disconnect the rear sensor connector. 4. See Figure 2. Remove screw (2) and washer from the lower seat post (1) and discard. -J04294 1 of 2 5. Disconnect spark plug wires and primary wire from ignition coil. 6. See Figure 3. Loosen the bracket screws (1). Remove seat post screw (2) and seat post with ignition coil and cover. 7. See Figure 4. Remove coil cover screw (5) and cover (4) from stock seat post (1). 8. Remove ignition coil screws (3) and coil (2) from seat post. 2 1 is04241 1. Bracket Screws 2. Upper Seat Post Screw Figure 3. Upper Seat Post Fasteners 2 5 1 3 4 is04337 1. Seat Post 2. Ignition Coil 3. Coil Screw 4. Coil Cover 5. Coil Cover Screw Figure 4. Install Ignition Coil to Seat Post INSTALL 1. See Figure 4. Install ignition coil (2) to new seat post using screws (3). Tighten ignition coil screws to 10-15 ft-lbs (13.6-20.3 Nm) . 2. Install coil cover (4) to seat post with screw (5) and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 3. See Figure 1. Place seat post (1) in position and attach lower post with screw (2), washers (3) and dome nut (4). Tighten screw (2) to 10-15 ft-lbs (13.6-20.3 Nm) . 4. See Figure 3. Attach upper seat post with screw (2). Tighten screw (2) to 12-15 ft-lbs (16.2-20.3 Nm) . Tighten bracket screws (1) to 12-15 (16.2-20.3 Nm) . 5. Connect primary wire to ignition coil. 6. Connect spark plug wires to ignition coil. The rear cylinder plug wire attaches to the top coil post. Ensure that spark plug wire boots are fastened securely. 7. Connect rear oxygen sensor connector, if equipped. 8. Reconnect battery negative cable

2005-2007 Kawasaki 610 Mule Winch Mount Installation Instructions

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

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1. Remove the plastic lower front cover. 2. Remove the two bolts on the left side mud shield that connect to the frame for easier access. 3. Install the winch to the winch mount using the hardware supplied with the winch. 4. Install the winch and mount per the illustration using the provided U-Bolts, flat washers and nuts around the frame tubes and through the mount. Tighten all nuts and bolts securely. 5. Install the roller fairlead to the winch mount using (2) 5/16″ x 3/4″ bolts and 5/16″ nylock nuts provided. (Rollers should turn freely. NOTE: Bottom roller may need to be removed to run wire rope through. 6. Using the instructions provided with the winch, wire accordingly. 7. Reinstall the two bolts from the mud shield. 8. Reinstall the plastic lower front cover. NOTE: For some winches, this cover may need to be trimmed so it does not rub

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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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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

Kawasaki Mule Roof 600, 610 and 4010 Trans Crew, Roof Installation Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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INSTALLTION INSTRUCTIONS – Mule 600/610 (4010 Trans skip to pg 4) 1. Place Roof Panel on top of UTV Roll cage and center front to back, and left to right. 2. Using Figure 1 Below – place UTV Roof Mounting Brackets around roll cage bar and using a marker, mark the position of the holes needed in the roof for each Roof Mounting bracket . Figure 1 Copyright 2007 DiamondBack Automotive Accessories, Inc. Page 3 3. Next, remove the roof from the roll cage and using a drill with 1/4″ bit, drill holes using the marks as a guide. 4. Cut (4) 3″ strips of adhesive foam and apply to roof in where mounting brackets are positioned to prevent roof rattling once mounted. Foam should run in the direction of the roll cage as shown in Figure 1 above. 5. Next, reposition the roof on the roll cage according to step 1. 6. Prior to attaching the roof mount brackets, cut the remaining adhesive foam in half and apply one section to the roof in the center of the roof where roof and each roll cage bar meet as shown in Figures 1 above. If additional tape is required to prevent rattling it can be purchased from any hardware store as window sealant foam tape. 7. Next, attach the roof mount brackets according to Figure 2. Use channel locks or pliers to hold top of carriage bolt and turn nut with 7/16″ socket.

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HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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