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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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Kawasaki Exhausts – ZX-6 ZX-10 Zx-14 Exhaust – Slip-ons INSTALLATION MANUAL

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

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Our favorite exhaust options for Kawasaki ZX Ninjas – ZX-10,ZX-6r, and the new horsepower king, Zx-14.. Grab your horsepower today. We love Rob Muzzy and Muzzy Exhausts.Going back to Doug Chandler and Scott Russell, Muzzy has been synonomous with Kawasaki and performance – and for years, if you rode Kawasaki,and you were on the podium, Muzzy was on your exhaust. We also feature Arrow and Yoshimura exhausts for your ZX-6R, ZX-10 and ZX-14. We love the sound of a Yosh exhaust on any Kawasaki Ninja. Yoshimura Oval (RS-3) Race Slip-On for Kawasaki ZX14R 2006 The easiest and least expensive way to experience Yoshimura performance is with our Slip-On/Bolt-On lines. Bolt-On style bolts to the O. E. M. mid-pipe Slip-On style with its stainless steel easily attaches to the mid-pipe RS-1 is available where noted Usually, no jetting or re-programming is required and installation is a snap Hindle Stainless Exhaust High Head Pipes – Kawasaki ZX6R-RR 03-04 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo North Denver News http://northdenvernews.com Powered by Joomla! Generated: 19 October, 2010, 12:28 Hindle Stainless Exhaust Low Head Pipes – Kawasaki ZX9R 00-03 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo

1982 Kawasaki KZ550C Electric Motorcycle Conversion Notes

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Filed Under (Kawasaki) by admin on 03-12-2010

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Starting point: • 1982 Kawasaki KZ550C that I found in an alley near my house. Frame rust sanded and repainted. • Rebuilt front suspension ($25 for front fork oil seals, 1 weekend for repair) • Need-to-be-rebuilt front brake caliper • Need-to-be-replaced front master brake cylinder (expected ~$80) • Need-to-be-refurbished electrical wiring system and 12V battery • Working rear brake • Flat rear tire, patched with fix-a-flat (temporary repair), 77″ circumference. • In-tact 530 size 62″ chain with 36 tooth driven sprocket • Miscellaneous spare parts from 1978 Kawasaki KZ450, most of which fit on the 1982 frame, including an ignition switch and key. I started with a chassis I found in an alley near my house. It was in rough shape and needed some refurbishment before I could start the conversion. Most of refurbishment steps are listed above in bullets. In addition to the repainting and repair of important aspects of the bike, I also needed to remove the IC engine components and the grease caked on from years of IC use. The Clymer manual for this bike was helpful in this process, which was about $18 from [13]. Steps for removing the engine were as follows. I removed the seat and the gas tank. I removed the electrical system wiring and 12V battery holder. I then removed the carburetors (which took a lot of pushing and shoving) and air filter box. I then removed the drive socket cover and removed the drive socket from the engine drive shaft. This allowed me to slip the chain off of the drive socket after loosening the rear wheel to put slack into the chain. I slipped the chain off and let it rest on the rear wheel swing arm and drained the old motor oil. I then removed all of the engine mounting bolts and pushed the entire engine out of the right side of the bike. This took a lot of effort but it is possible to remove the engine without removing the piston heads as recommended in the Clymer manual. The engine weights about 60-70 lbs, so it was possible to handle with one person. I suggest using a flat car jack to help with engine removal. I will eventually sell the IC parts through Ebay

TOYOTA L, 2L ENGINE REPAIR MANUAL FOR 2L-T ENGINE DESTINATIONS FUEL SYSTEM

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Filed Under (Toyota Manuals) by admin on 21-05-2011

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INSUFFICIENT TURBOCHARGING PRESSURE Check turbocharging pressure (See page EM-6). If not within the  standard shown below, begin diagnosis from item 2. Standard pressure: 0.41 – 0.54 kg/cm2 (5.8 – 7.7 psi, 40 – 53 kPal RESTRICTED INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as necessary. (See page EM-6)
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as necessary. (See page EM-6)
4. RESTRICTED EXHAUST SYSTEM Check exhaust system, and repair or replace parts as necessary, (See page EM-6)
5. LEAK IN EXHAUST SYSTEM Check exhaust system, and repair or replace

KTM 250-525 SX, MXC, EXC RACING ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 07-02-2012

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TM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents. Remove page (s) Replace by page (s) Insert page (s) after page 2-1 / 2-7 2-1C 2-7C to 2-9C 3-1 3-1C 4-1 to 4-14 4-1C to 4-13C 5-1 / 5-3 5-1C / 5-3C 5-6 to 5-8 5-6C to 5-8C 5-12 to 5-26 5-12C to 5-27C 6-1 / 6-4 6-1C / 6-4C 6-7 to 6-16 6-7C to 6-17C 7-1 to 7-2 7-1C to 7-2C 7-7 to 7-11 7-7C to 7-11C 8-1 to 8-13 8-1C to 8-21C 9-1 9-1C 9-10 to 9-13 9-10C to 9-16C 10-1 10-1C 10-8C to 10-11C 11-1 11-1C 11-11C to 11-13C
Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E EXPLANATION – UPDATING Edition 01/2003 3.205.85-ERepair Manual 400/520 SX, MXC, EXC RACING Basic version Model year 2000 (Engine number with first digit “0″) 2/2000 3.210.01-EUpdating of Rep.Manual 3.205.85-E Model year 2001 (Engine number with first digit “1″) 1/2001 3.210.44-EUpdating of Rep.Manual 3.205.85-E Model year 2002 (Engine number with first digit “2″)

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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)

The New Kawasaki ZX-6R Trading in gets easier and easier

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Filed Under (Kawasaki) by admin on 18-02-2011

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didn’t go to my local Kawasaki shop expecting to trade in the 2004 636 I’d been happily riding. I honestly didn’t expect there to be anything on the floor that would motivate me to bring the bike in. Some of you reading this may be able to relate to what I am saying, the day you don’t look for something is the day that you find exactly what you didn’t know you need. That was the day I decided I needed to take home the new ZX-6R. The reworking of the new ZX-6R is more than just about looking good. According to KMC the engine has been redesigned from the crankcase up for the first time in ten years. Racing technology built into the new bike is a close-ratio cassette transmission that can be removed without the needing to split the main crankcases in case you needed to make repairs or adjustments at the track. They also tell us that the fuel injection system has shorter throttle bodies with a smaller diameter bore which claim to give this new smaller sized engine more torque in the mid-range. It also comes with a GPS – Gear Position Sensor. The new ZX-6R comes stock with a slipper clutch which is one difference between the 2004 and 2007. My 2004′s rear wheel would hop if I geared down before a corner and my engine rpms were too high. The slipper clutch allows quicker downshifts. To experience the gains of a slipper clutch you don’t have to buy a 2007 Kawasaki – it was introduced to the 636 in 2005. A quick glance at the exhaust might leave the impression that the ZX-6R comes stock with stacked twin small diameter exhaust cans but if you look closely you will see it is a single oval pipe with a shotgun styled end cap. The titanium pipe has the pre-chamber and catalyser located below the engine to keep the weight on the bike low and centered and the temperature of the under seat silencer reduced. Looking at the new Kawasaki with its fairing removed, I wonder how much more it would have cost the consumer to have an exhaust system that not only works wonders but would be worth showing off? Even if some of the systems of the new 600 look better hidden by plastic the bike does have a cohesive look and every year the fit and finish of Kawasaki’s bikes seem to get better. You can look at this bike from almost any angle and nothing jumps out at you – unless you are on the right side of the bike looking at the rear brake reservoir. It seems odd to me that they would leave the rear brake reservoir exposed. Another design feature of the smooth body of the 2007 ZX-6R is the lack of tie down points for any luggage. It can be argued that this is a bike intended for Sunday morning canyon rides or track days on weekends but if you want to take the 600 out for a weekend away then there is aftermarket solution. Ventura Racks allow you go on vacation with your bike. A Ventura Rack provides you with a frame that you attach to your bike that you can secure luggage to. There is no drilling of body work and the Ventura rack I got fit onto the bike perfectly the first try. One of the things I really like about the Ventura Rack is that you can easily attach bags that you may already have or you have the option of buying the Ventura luggage system. Just give yourself time before a motorcycle trip to pack

KAWASAKI STX-12F, STX-15F Riva/Vortech Supercharged STX-15F Engine INSTALLATION MANUAL

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

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Our race bred Supercharger System for the Kawasaki STX-15F contains all necessary engine components to produce the ultimate 80mph closed course race craft. Kit contains the same specifications that Team Kawasaki won two 2004 Pro Runabout World Titles with. System produces over 300hp using VP MS109 race fuel (Jet X). Kit includes Vortech Supercharger & Intercooler Forged Racing Pistons, Free flow Exhaust Kit, Race programmed ECU, High volume Injectors & Fuel Pump along with all necessary hardware and detailed installation instructions. Riva/Vortech Supercharged STX-15F Engine (Team Kawi Spec) PERFORMANCE DATA Stock 61 MPH @ 7,600 RPM Supercharged 80+ MPH @ 8,300 RPM RIVA STX-15F OFFSHORE RACE KIT Our Offshore Racing Kit for the Kawasaki STX-15F contains the same components and specifications that Team Kawasaki developed to dominate the international racing circuit. This modification delivers over 200hp producing awesome acceleration and a top speed of over 700mph using VP MS109 race fuel (Jet X). Kit includes high compression racing pistons, performance intake & exhaust cam shafts, Race programmed ECU along with all necessary gaskets and detailed installation instructions

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KTM 250 – 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 04-02-2012

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KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.

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