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KTM 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO REPAIR MANUAL

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

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Adjusting the position of the compression and rebound damping Rebound damping: -Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: -Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, high speed: -Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Adjusting the spring preload NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. -Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. -Tighten the lock screw on the adjusting nut Disassembling the shock absorber -Write down the spring preload. -Write down the rebound and compression damping settings, counting the clicks or number of turns while turning in a clockwise direction. -Unscrew all of the adjusting screws in a counterclockwise direction. -Clamp the upper part of the shock absorber in a vise as shown in the photo, using protective jaws. -Loosen the lock screw 1 (AH 4 mm), loosen the adjusting nut 2 using the special tool T106 3 and relieve the spring. NOTE: mark the position of the lock screw. -Press the spring down with the special tool T101S and pull out the spring retainer 4 . -Remove the washers 5 and spring 6 . 4-2 Repair manual WP Shock absorber 990 Super Duke, 950 Supermoto, 950

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Harley-Davidson S&S Super E and G Series Shorty Carburetors Installation and Jetting Instructions

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Filed Under (Harley Davidson) by admin on 24-10-2010

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throttle linkage with no cable modification. S&S Super E and G carb kits for 1936 to 1989 Big Twins contain a throttle cable guide (11-2339) designed for butterfly type throttle cables, and kits for 1990 and later Big Twins contain a taller throttle cable guide (11-2338) designed for CV type throttle cables. See Picture 2. The two throttle cable guides are interchangeable on the carburetor body, and can be changed very easily to update older carburetors or to accommodate custom throttle cables which are not stock for a particular year chassis. 1981 to Present Sportster Models Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors. Sportsters from 1988 to present have a two cable throttle system designed for use with the stock constant velocity (CV) type carburetor. Since the taller #11-2338 cable guide bracket can not be used on a Sportster chassis due to insufficient frame clearance, throttle cables on Sportsters originally equipped with a CV type carburetor must be changed to butterfly style cables. S&S can supply the correct style throttle cables. See S&S Throttle Cable Application Chart. Picture 2 S&S THROTTLE CABLE APPLICATION CHART Length Total Housing Length Vinyl Housing Part Number Open Side Part Number Close Side Fitment 36″ 32″ #19-0430 #19-0431 For Buell with 7/8″ handlebars 36″ 32″ #19-0432 #19-0433 To ’95 ’81-’85 FX and FL; All ’81-’85 XL (Also pre-’81 w/2-cable throttle housing replaced.) For Buell with 1″ diameter handlebar 36″ 32″ #19-0436 #19-0437 ’96-Up 883-1200 XL 39″ 35″ #19-0434 #19-0435 To ’95 Softail (FXSTC, FXST, FLSTC, FLSTF) ’86-’94 FXR, ’93-’95 Dyna 39″ 35″ #19-0438 #19-0439 ’96-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF) ’96-Up Dyna 42″ 38″ #19-0446 #19-0447 To ’95 custom application 42″ 38″ #19-0440 #19-0441 ’96-Up custom application 48″ 44″ #19-0462 #19-0463 To ’95 All FLT Models 48″ 44″ #19-0464 #19-0465 ’96-Up All FLT Models ” 1996 to Present Buells 1996 and 1997 Buells require special S&S butterfly style throttle cables for Buells, which are compatible with the stock 1996-1997 throttle assembly. 1998 and later carburated Buells require installation of stock 1996 – 97 throttle grip and the special S&S Buell style throttle cables when installing Super E or G carburetors. S&S Throttle Kits S&S throttle kits fit 1″ handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7 ⁄ 8 ” OEM handlebars originally equipped with internal throttle cable.) Barrel fittings on S&S cables readily “plug in” to S&S Super E, G, and stock H-D 1981-’90 butterfly type carb throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36″, 39″, 42″, or 48″ length cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4″ shorter than overall length

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Vespa GTS Super Specification

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Filed Under (Vespa) by admin on 11-11-2010

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Gts super 300 ie Gts super 125 ie s 125cc s 50cc Gts 250 ie Gts 125cc LX 125cc LX 50cc 2 stroke Engine Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder LEADER 4 stroke with electronic injection Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder, catalised, LEADER 4 stroke, 4 valve Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Capacity 278cc 124cc 124cc 50cc 249cc 124cc 124cc 49cc Power 16.4 kW / 7500 rpm 10.5 Kw / 9500 rpm 7.65 Kw / 8250 rpm 3.2 Kw / 7500 rpm 15.7 Kw / 8500 rpm 7.65 Kw / 8250 rpm 7.65 Kw / 8250 rpm 2.5 Kw / 8500 rpm Max Torque 22Nm / 6500 rpm 12 Nm / 8000rpm 9.6 Nm / 7250 rpm 4.4 Nm / 6500 rpm 20.1 Nm / 6500 rpm 9.6 Nm / 7250 rpm 9.6 Nm / 7250 rpm 3.3 Nm / 6500 rpm Cooling Liquid Liquid Forced Air Forced Air Liquid Liquid Forced Air Forced Air Starter Electric Electric Electric and kick starter Electric and kick starter Electric Electric Electric and kick starter Electric and kick starter Transmission Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Front Suspension Single arm, dual chamber hydraulic shock absorber with coaxial spring Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Rear Suspension Two dual effect shock absorbers with adjustable preload Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Twin hydraulic shock absorbers with preload adjuster Twin hydraulic shock absorbers with preload adjuster Hydraulic shock absorbers with preload adjuster Hydraulic shock absorber Front Brake ø 220mm disc brake 220mm disc brake ø 200mm disc brake ø 200mm disc brake ø 220mm disc brake ø 220mm disc brake ø 200mm disc brake ø 200mm disc brake Rear Brake ø 220mm disc brake 220mm disc brake ø 110mm drum brake ø 110mm drum brake ø 220mm disc brake ø 220mm disc brake ø 110mm drum brake ø 110mm drum brake Front Tyre Tubeless 120/70-12″ Tubeless 120/70 – 12″ Tubeless 110/70 – 11″ Tubeless 110/70 – 11″ Tubeless 120/70-12″ Tubeless 120/70-12″ Tubeless 110/70 – 11″ Tubeless 110/70-11″ Rear Tyre Tubeless 130/70-12″ Tubeless 130/70 – 12″ Tubeless 120/70 – 10″ Tubeless 120/70 – 10″ Tubeless 130/70-12″ Tubeless 130/70-12″ Tubeless 120/70 – 10″ Tubeless 120/70-10″ Running weight 158kg 158kg 114kg 96kg 151kg 145kg 114kg 96kg Length/Width/Height 2230mm / 755mm / 1170mm 1930mm / 755mm / 1930mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm 1930mm / 755mm / 1170 mm 1940mm / 755mm / 1180 mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm Fuel Tank Capacity 9 litres 9 litres 8.5 litres 8.5 litres 9.2 litres 10 litres 8.5 litres 8.5 litres Emmissions Euro 3 Euro 3 Euro 3 Euro 2 Euro 3 Euro 3 Euro 3 Euro 2 Colours Rosso Dragon Nero Lucido Montebianco Rosso Dragon Nero Lucido Montebianco Taormina Nero Lucido Montebianco Taormina Nero Lucido Montebianco Marrone Terra Di Toscana Bronzo Perseo Nero Vulcano Blu Midnight

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2008 KTM Model Engine Oil Recommendation Chart

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Filed Under (KTM) by admin on 24-11-2010

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2008 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 SX MINI Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SX Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.5L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 144 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX-F Motorex Power Synt 4T 10W50 1.35 L 505 SX-F Motorex Power Synt 4T 10W50 1.35 L CROSS COUNTRY 2 STROKE 65 XC Motorex Top Speed 4T 15W50 0.5L 85 XC Motorex Top Speed 4T 15W50 0.5L 105 XC Motorex Top Speed 4T 15W50 0.5 L 200 XC Motorex Top Speed 4T 15W50 0.7 L
200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 250 XC-F Motorex Power Synt 4T 10W50 1.1 L 250 XC-F-W Motorex Power Synt 4T 10W50 1.1 L 450 XC-F Motorex Power Synt 4T 10W50 1.35 L 450 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 505 XC-F Motorex Power Synt 4T 10W50 1.35 L 530 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L ENDURO RACING 450 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 530 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L SUPERMOTO LC4 690 Supermoto Motorex Power Synt 4T 10W60 Approx. 2.0 L SPORT ATV 450 XC Motorex Power Synt 4T 10W50 2.0 L 525 XC Motorex Power Synt 4T 10W50 2.0 L LC8 950 Super Enduro (R) Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke R Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

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2007 YAMAHA ZX6RR GALFER Super Bike BRAKE LINES INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 29-01-2011

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Step 1: Identify the key components that complete our Super bike KIT, you should have 1 complete 3 line kit (front Kit), 1 single banjo bolt and 2 lower male adapters. There are also a total of 6 washers, 4 will be used, and 2 are spares. The Left hose has a locating clip and there is a new bolt to bolt that on. We ALWAYS strongly suggest having a professional mechanic install these brake lines, all other installations VOID warranty. Inspect your brake system after every race. A: Right Caliper B: Please re-use stock routing clip for right line Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install onto the calipers the Galfer male adapters, the course thread area threads to the caliper with one washer. Torque level is 12 to 13 ft pounds. See Picture C

2004 Ford Harley Davidson F-250 Super Duty Installation Manual

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Filed Under (Harley Davidson) by admin on 13-03-2012

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1. Using a 13MM socket, remove the bolt from just forward the front tire holding the bumper support. Do this to both sides of the vehicle. Set bolts and bumper support aside to be reinstalled later. 1 1 ‘ ‘ ‘ ‘ 2004 Ford Harley-Davidson F-250 Super Duty Installation Instructions BX2608 Installlation Instructions: ‘ ‘ Page 4 of 5 405-0061 Rev. A 5/18/09 4. Set the baseplate inside the opening. Underneath start three 1/2″-13 x 1 3/4″ hex bolts with 1/2″ lock washers. Be sure and use loctite on all bolts before tightening. 3. If the vehicle has tow hooks, underneath the frame end are three metric bolts to remove using a 15MM socket. Pull tow hooks forward and set aside. Do this to both sides of the vehicle. The tow hooks will Using an 18MM socket, remove two bolts from the end of the frame. Disconnect the fog lights. Do this to both sides of the vehicle. Pull the bumper forward to remove. Set bolts and the bumper aside to be reinstalled later

Bajaj Removing And refitting Automatic Cam Chain Tensioner

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Filed Under (Bajaj) by admin on 31-10-2010

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1. Remove the 2 Flanged Bolts securing the Tensioner Assembly. 2. Remove Tensioner Assembly from the engine block. 3. Unscrew and remove Lock Bolt. 4. Remove Pushrod, Ball & Retainer, Spring and “O” ring. Clean parts thoroughly and apply grease to the Balls & Retainer. Re-assembly procedure : 1. Place Spring on Pushrod and compress the spring beyond the hole in the Pushrod. 2. Insert a pin or wire into the hole in the Pushrod to hold the Spring in its’ compressed position. 3. Place Balls & Retainer onto Pushrod. 4. Insert Pushrod into the Tensioner body with the small flat on the Pushrod facing, and aligned with, the Locking Bolt hole. 5. Insert the Locking Bolt and tighten it against the small flat on the Pushrod to lock the Pushrod in the compressed position. Remove the pin that’s holding the Spring compressed. 6. Install the Tensioner assembly onto the cylinder block and install and tighten both Flanged Bolts. Be sure that the “O” ring has been installed at the base of the flange. 7.Looosen the Lock Bolt to release the Pushrod, then re-tighten the lock bolt

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S&S Super Stock Cylinder Head Kit Installation Instructions for 1984 And Later Evolution Big Twin and Sportster Engines

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Filed Under (Harley Davidson) by admin on 28-11-2010

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check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result is that the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as “blue printing”, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore. NOTE – All engines should be checked upon disassembly. This applies to any engine receiving new pistons which includes those being completely overhauled. CAUTION – Pistons which do not run true in cylinder bores may cause excessive connecting rod side thrusting. This may lead to premature ring, piston, connecting rod and rod bearing wear and eventual failure of these parts. Visual Procedure A. Reinstall cylinders on old pistons without rings. Hold cylinders securely in place. B. Move piston tight toward camside of engine. C. Turn engine over in normal direction of travel 2 or 3 revolutions and observe piston during process. D. Move piston toward driveside of engine and repeat Step C. If misalignment exists, piston will appear closer to cylinder wall at one point around circumference. Condition can be corrected by bending rod in opposite direction. Figure 1 shows an exaggerated side view. E. Repeat Steps B to D for other cylinder. F. Remove pistons and cylinders. Observe pistons for wear spots on sides above top compression ring. If either side near wristpin is worn clean while side opposite is carboned up, then piston was not running straight and true in cylinder bore. Piston will also generally show diagonal wear pattern on thrust faces of skirts and possibly signs of connecting rod to wristpin boss contact inside piston.

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2004-2007 HONDA CBR 1000RR Super bike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Make sure to save the nut and bolt that are currently holding the stock lower section of the hoses. (See picture A) Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 40-degree banjo from right line, washer, 40-degree banjo from left line, washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. (For positioning see picture B) . Make sure that the 90-degree fittings on each caliper are pointing straight up (see picture C) . Thread each banjo end onto the adapter, and torque to 6 ½ Ft pounds. Please tighten the “C” clips on the fender using the OEM bolts we asked you to save above. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, using the galfer 2line clip to bring the lines together and mounting it to the triple tree will insure proper clearness and routing. (See picture D) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with Galfer DOT 4- brake fluid is recommended.

HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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

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1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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