how to replace harley road king primary chain tensioner

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARlEY DAVIDSON AUTOMATIC PRIMARY CHAIN TENSIONER INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Refer to the appropriate Service Manual and remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect negative (-) battery cable. 3. Refer to the appropriate Service Manual and remove primary cover. 3 1 2 5 4 is00561 1. Screw (2) 2. Anchor plate 3. Nut and washer 4. Manual tensioner 5. Screw (2) Figure 1. Manual Tensioner: 1985-2000 Models 4. For 1985-2000 model motorcycles, remove manual tensioner and replace the carriage bolt as follows: a. See Figure 1. Remove two screws (5) and nut and washer (3), and remove chain tensioner (4). b. Remove two screws (1) and anchor plate (2). c. Replace the carriage bolt in the anchor plate with the carriage bolt from the kit. d. Apply 2-3 drops of Loctite 262 (red) to the threads of the anchor plate mounting screws (1), then install anchor plate and two screws. Tighten screws to 12- 14 ft-lbs (16-19 Nm) . For 2001 and later model motorcycles, remove manual tensioner as follows: a. See Figure 2. Remove nut and washer (1) and remove chain tensioner (2) Removing the Autotensioner for Service 1. Use a tie wrap and secure the shoe to the base of the autotensioner, without securing it to the autotensioner bracket. This will retain the autotensioner adjustment for reinstallation during service. 2. Remove two autotensioner hex screws, and autotensioner. Resetting the Autotensioner 1. See Figure 5. Compress autotensioner wedge (1) and spring back to the base. 2. Hold wedge in position by inserting a hex wrench or pick tool through the hole in the base of the autotensioner. 3. See Figure 6. Move plastic autotensioner shoe (1) into place as shown. 4. If available, install shipping plate (2) to secure the shoe to the base. If it is not available, secure the shoe to the base with a tie wrap

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Harley-Davidson CHAIN DRIVE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 15-04-2012

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1) Assemble & install the chain tensioner assembly over the primary chain as shown in figure 1. 2) Install the compensator sprocket with extender & spacer (numbers 5, 6, & 7, FIG 2)(#7 is not included in this kit), primary chain, chain tensioner, and clutch basket simultaneously onto the motor drive shaft & transmission main shaft. Rotate the chain drive slightly as needed to allow the splines to line-up. 3) Install the chain tensioner nut loosely on the chain tensioner bolt. 4) Install the sliding cam onto the compensator sprocket, & slide the compensating sprocket cover-assembly (#3) over the cam. 5) Apply 2 drops of Rivera “Red” thread-lock on the threads of the motor drive shaft, & install the motor nut loosely with the fingers at this time. The hex spacer (#7) and spacer (#2) as seen in fig.2 are not provided in Rivera Engineering’s chain drive kit. These components are required with some applications, and can be purchased from your local Harley-Davidson dealer. FIG 2 6) Apply 2 drops of Rivera “red” thread-lock on the threads of the transmission main-shaft and loosely install the clutch hub nut (left hand threads). 7) Place the HD “Primary Drive Locking Tool” HD-41214 on the primary chain as shown in figure XXX and tighten the motor sprocket nut to 150-165 foot-pounds. 8)Turn the locking tool 180 degrees and move it to the clutch sprocket. Tighten the clutch hub nut to 70-80 foot pounds (left- hand thread). Adjust chain tension so that the top strand has 5/8″- to-7/8″ of up and down play (cold drive train). Tighten the center bolt nut to 21-29 foot pounds of torque.

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Lilac LS-18 Motorcycle Maintenance Standards

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

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

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Harley-Davidson BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-04-2012

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1) Remove the primary chain case cover. Refer to your Factory Service Manual for this procedure. 2) Remove the compensating sprocket nut with a 1-1/2″ socket. A ½” impact gun is best for this task. *) Remove the 1-3/16″ clutch nut. This is a left handed nut so loosen it by turning it in the clockwise direction (as viewed from the left side of the motorcycle). 4) With one hand on the compensating sprocket and one on the clutch assembly, remove the primary drive assembly (compensating sprocket, primary chain, tensioner assembly, and clutch as shown in figure a and set it on a clean surface. 5) Flip the adjuster shoe bracket on the chain tensioner assembly. figure b shows the stock orientation of the adjuster show and bracket. Figure C shows the adjuster show bracket flipped 180°. To flip the shoe bracket, remove the two ¼-28×2 bolts that hold the bracket assembly together. This will allow you to separate the chain tensioner assembly components from the primary chain. Flip the bracket around as shown in figure c . PAGE 4 Figure B Figure A BAKER COMPENSATING SPROCKET INSTALLATION INSTRUCTIONS 6) install the new compensating sprocket, chain, and clutch onto the motor sprocket shaft and the transmission input shaft. The flipped chain tensioner assembly (as shown in figure c ) is not ‘captured’ on the primary chain like the stock configuration. Loosely install the chain tensioner assembly onto the anchor plate bolt. Tighten the compensating sprocket nut to 157+ 7 ft-lbs and the clutch hub nut to 75+ 5 ft-lbs using red Loctite on the threads.

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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

2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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MOTORCYCLE ROLLER CHAIN Maintenance and Lubrication

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Filed Under (Tips and Review) by admin on 27-11-2010

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Cleaning and Relubrication Perhaps the largest contributor to shortened chain life is inadequate lubrica- tion. All working parts of a chain should be lubricated uniformly. The use of the highest viscosity oil that allows for flow between the link plates and coats pin-bushing areas will normally provide the greatest wear resistance. Apply oil to the upper edges of link plates. This allows for the greatest access of oil to pin-bushing joints. For open drives, excess lubrication on outer chain surfaces should be removed, since it will either be thrown off during operation or serve to collect foreign materials. If foreign objects or surplus lubrication accumulates on chain surfaces to the extent of making re-lubrication of the joints impossible, the chain must be cleaned. Standard roller chains may be cleaned by washing in kerosene or any other good petroleum-based solvent. WARNING: These solvents are flammable. Agitate the chain to assure penetration of the solvent and a thorough flushing of the pin-bushing areas. Drain off excess solvent and inspect bushings and pins for wear. Replace the chain if wear is excessive or parts are fractured or missing. O-ring chains may be cleaned externallyby washing in kerosene. Do not use any other cleaning agent or the O-rings may be damaged. When cleaning O- ring chain, clean only the external areas of the chain. Do not attempt to force kerosene into the pin-bush cavity. Do not try to repair a worn-out chain by replacing individual links. The pitch of the new links will be shorter and will most likely result in chain fatigue failure and/or severe sprocket damage. For chains which are still usable, soak them in SAE 40 or 50 automotive engine oil (without additives). Flexing the chain in oil will assure greater penetration of lubricant. Inspect and clean sprockets. If sprockets are worn or damaged, they should be replaced.Installing new chain on worn out sprockets will significantly shorten the chain’s service life. WARNING: always wear eye protection when assembling or disassembling chain

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KTM 250F Timing Chain Tensioner Installation Instructions

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Filed Under (KTM) by admin on 19-10-2010

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1) Remove OEM Tensioner: On some models including the 250F motors, it may be necessary to put the engine at TDC before proceeding. Check your manual. This is not the case on the 450 and 530 single cam motors. • Remove the outer cover plug. • Remove the large cover with copper washer. • Using needle nose pliers grab the end of the OEM tensioner and pull it outward. Be careful not to damage the aluminum port or face. • If the O-ring did not come out with the tensioner, carefully reach into the port and remove it without pushing it further into the engine. 2) Install new Tensioner: • To prepare the new tensioner, set the spring aside. Put the new tensioner in the collapsed position. (They are packaged and shipped in the collapsed position.) If you have extended it, rotate the assembly until the “top” on the piston is facing up. Then a light tap from the bottom will release the ratchet. This will now allow the plunger to be retracted to about 1- 13/16″ (46mm). • Install the O-ring over the tensioner body, keeping it outboard of the ridge as shown. • Slide the tensioner assembly with O-ring (without the spring), into the engine port. The end (with the hex-head spring hole) should only protrude from the engine about 1/32″ (.75mm). • Install the cover and tighten. The copper washer should be tight. • Insert the spring through the cover port. As it is slowly inserted, you may hear clicks as it pushes the plunger inward while ratcheting. • Install and tighten the plug against the spring. Note: some 250F engines have a one piece cap. Slide the spring into the tensioner far enough to hold it, then capture it with the cap and tighten. • Start the engine and carefully check for oil leaks. Adjustment will occur internally as it is needed. No further maintenance of the tensioner is required

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