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2009 Honda CRF450R Decompression Plunger PRODUCT UPDATE CAMPAIGN

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Filed Under (Honda) by admin on 21-04-2011

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JH2PE053*9K700001 thru JH2PE053*9K703372 (*) Denotes check digit UPDATE PROCEDURE DEALER VENTORY Any affected unit in your inventory must be updated with a new decompression plunger and weight before delivery to the customer. Refer tothe PARTS INFORMATION and the UPDATE PROCEDURE sections of thisb Service Bulletin. Refer to the 2009 CRF450R Service Manual for specific removal instructions. 1. Remove the seat (page 3-3). 2. Remove the shrouds (page 3-4). 3. Properly hang the fuel tank (page 4-6). 4. Remove the camshaft (page 9-10) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. 5. Replace the decompression weight and plunger with kit parts (page 9-14). 6. Reinstall all previously removed parts. IDENTIFICATION When you have completed the update, place a punch mark before the first digit of the V.I.N. located on the right side of the steering head. 0080 WARRANTY INFORMATION This Product Update Campaign ends on arch 7, 2012. Normal claim submission requirements apply. fter completing the UPDATE PROCEDURE,submit one warranty claim per unit with the following information: WARRANTY CLAIM TEMPLATE: Template: R02A* Flat Rate Time: 1.2 hours *Template reads “R-zero-2-A”.

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Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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HARLEY DAVIDSON HYBRID CAM PLATE AND HIGH FLOW OIL PUMP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the service manual and follow the instructions to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) NOTES Installing this kit requires removal and installation of the cam support plate. Refer to the service manual for instructions with the following exception pertaining to cam compartment compo- nents: The crank and primary cam sprocket flange bolts are specially hardened, and the flat washers are of a special diameter and have ground surfaces. Use ONLY the parts provided in the Drive Gear Retention Kit (H-D Part Number 25533-99A, sold separately) when installing this kit. -J04804 1 of 7
The cr ank sprocket flange bolts and pr imary cam sproc ket flange bolts ARE NOT interchangeable. 2. Refer to the service manual to remove and discard the crank sprocket flange bolts and primary cam sprocket flange bolts and washers. 3. For 1999 models only: Refer to the service manual to remove and discard the currently installed cam drive sprocket. 4. Refer to the service manual to remove and disassemble the cams from the support plate and oil pump. Discard the support plate and oil pump. 5. For 1999 – 2000 Dyna, 2000 Softail, 1999 – 2000 Touring, and 2001 EFI Touring models only: Inspect the cams, chain, sprockets and chain tensioners for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. For 2001 – 2005 Dyna, 2001 – 2006 Softail, 2002 – 2006 Touring, and 2001 carbureted Touring models only: Inspect the cams and secondary cam chain for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. The primary cam chain, primary sprockets and both tensioners will be replaced by new components from the kit. For ALL models and years: Discard the guide, as it will not be used. INSTALLATION 1. ALL models: See Figure 1. Obtain the new Rear Cam Roller Bearing Kit (H-D Part Number 8983) from inside the Cam Service Kit (H-D Part Number 17045-99C, purchased separately), and install as indicated in Step 2. NOTE See Figure 2. If not enough of the splined shaft is exposed to install the sprocket, omit the spacer (4) and proceed to Step 2e. When the bearing inner race is started onto the machined area, remove the flange bolt (5), flat washer (6) and sprocket, then assemble using the spacer (4). Repeat Step 2e to fully install bearing inner race. To center thrust washer, be sure o-ring is installed in relief groove. Damage to bearing cage and engine can occur if thrust washer is not centered. (00473b) 2. See Figure 1. Install the O-ring (5), thrust washer (4) and bearing inner race (3) onto the rear camshaft as follows: a. See Figure 2. To properly locate the thrust washer (2), install the O-ring (3) in the grinding relief groove on the splined end of the rear camshaft between the machined area and the secondary cam sprocket.

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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Yamaha YZ400/426F Camshafts REMOVAL AND INSTALLATION MANUAL

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

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Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly. And as always, replace any fiber-based gasket that was moved in any way, i.e.: cam chain tensioner. You will need basic hand tools and a torque wrench, machine towels (rags), some cleaning solvent, and a cam chain tensioner gasket. And the Hot Cams’ Degree Wheel Kit if you so desire. We will start by removing the tank and seat, top engine mount, and the cam cover. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise (CCW) direction. Position the engine on top dead center (TDC) using the mark on the flywheel or better yet a degree wheel using a positive stop. Be sure to notice that the intake valves were the last to move, this will ensure the engine of being on “true” TDC. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the Page 1
beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Note the positioning of the cam lobes (their included angle will be close to 170 degrees), this will help during the installation of your new Hot Cams camshafts Remove the cap bolt on the end of the cam chain tensioner block, be aware of the copper washer. Release the spring tension on the cam chain tensioner by turning the flat blade screw slot inside the adjuster block in a clockwise (CW) direction; it will lock in the retracted position. Remove the two 8mm headed bolts that hold the cam chain tensioner to the cylinder block. Remove and discard the gasket. Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that secure the intake cam cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust camshaft out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft

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2005 Honda CRF450R OWNER'S MANUAL AND COMPETITION HANDBOOK

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

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Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) 2 – 3 times, and then close it. 4. Depress and hold the engine stop button (2) until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting. Emergency Engine Stop To stop the engine in an emergency, press the engine stop button. Basic Operating Instructions 15 Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •piston is replaced •piston rings are replaced •cylinder is replaced •crankshaft or crank bearings are replaced Break-in Guidelines 16 Basic Operating Instructions Servicing Your Honda 17 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 156).

Harley-Davidson Twin Cam Engines Cam Chain Drive System Installation and removal MANUAL

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Filed Under (Harley Davidson) by admin on 27-03-2012

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Removing the Cam Chain Drive System. NOTES Changing camshafts and cam drives in the 2006-up Harley-Davidson® Twin Cam 88® engines is different than in pervious engines. Procedures require use • of some special tools. Installation should be done by an experienced mechanic with access to factory service manual and required tools. Tighten all fasteners to the correct specifications and in order described. Always use an accurate torque wench. • Incorrect installation can cause engine damage not covered under warranty. CAUTION Failure to install components correctly can result in sudden engine seizure. Engine seizure may result in serous injury to motorcycle operator, passenger, or others. A- Disconnect the battery ground cable to eliminate potential sparks and inadvertently engagement of the starter while working on the motorcycle. B- Remove spark plugs and pushrod cover clips. Collapse the pushrod covers to expose the pushrods. C- Safely elevate and stabilize the rear of the motorcycle. Place the transmission in high gear. Turn the rear wheel to rotate the engine until both lifters and pushrods for either cylinder are at the lowest point on the camshaft (TDC of compression stroke). Both intake and exhaust pushrods for that cylinder will be under pressure from the valve springs and will rotate with light finger pressure. NOTE: 510G camshafts may use stock style non-adjustable pushrods instead of adjustable pushrods. If installing non-adjustable pushrods, disassemble and assemble rocker boxes per H-D® instructions. All other S&S® gear driven cams require installing adjustable pushrods. As a time-saving measure, the stock pushrods can be removed with bolt cutters. Be sure to head caution and warnings of these instructions. D- Cut the pushrods for the cylinder that is at TDC with the bolt cutter and remove the pushrod covers from the engine. Rotate the engine to place the pushrods for the other cylinder at their lowest point. Cut and remove the remaining pushrods. WARNING CAUTION Cutting pushrods with a saw or cutoff wheel may result in debris entering the engine, causing engine damage not covered under warranty. WARNING Cutting pushrods without releasing spring pressure, by rotating the engine until tappets are at the lowest point of travel can result in bodily injury. E- Remove the pushrod covers and lifters form the crankcase. F- Remove engine cam cover and gasket. Secure lifers with a tool made from a large binder clip

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. 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 (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS 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: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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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

HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

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