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HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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KTM EXC Enduro & SX Motocross REPAIR MANUAL

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Filed Under (KTM) by admin on 06-03-2012

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Thanks to a history of competition successes, particularly in off-road racing, KTM motorcycles enjoy a large and loyal following. Established in 1953, KTM (from Kraftfahrzeuge Trunkenpolz Mattighofen where founder, Hans Trunkenpolz, had his engineering works) went through difficult times in the early 1990s. After a takeover, the Austrian company emerged as KTM Sportmotorcycle AG and has gone from strength to strength in recent years. Mainstay of their range are their Enduro and Motocross models, the EXC and SX, and these are covered in the latest new manual from Haynes. Models covered are the 250, 400, 450, 520 and 525 EXC and SX with 4-stroke sohc engines, 2000 to 2007. Information has also been included on the SMR Supermoto versions and MXC/XC derivatives. Haynes Manuals for cars and motorcycles are so popular that 150 million have been sold worldwide. Lay them end-to-end and they would circle the globe at the equator! The new manual begins with essential pre-ride checks, competition prep and routine maintenance tasks before moving on to more major repairs. There are comprehensive, fully illustrated, instructions for overhauling the engine, transmission, brakes, suspension and electrical system. Useful reference pages include colour wiring diagrams, fault-finding charts and a comprehensive section on tools and workshop tips. Because all Haynes Manuals are based on a complete stripdown and rebuild, not only are the procedures written from first-hand experience, but there is information about special tools required for each job, and its complexity, plus Haynes tips for saving time and money. The new Haynes KTM EXC Enduro & SX Motocross Manual is the only complete manual for owners of these motorcycles.

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KTM KINETO TRACKING MOUNT – MODEL K433 Installation and Removal Manual

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Filed Under (KTM) by admin on 30-01-2012

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the KTM meets the needs of a wide variety of test range and scientific applications:  On-board operator, or remote analog or digital control  Payloads up to 1200 pounds (unmanned) or 600 pounds (manned)  Mission configuration with four (manned) or six (unmanned) payload positions  Complete turnkey systems available  Detailed installation documentation FIELD-PROVEN RUGGED AND RELIABLE The KTM consistently demonstrates its performance and durability:  Weather tight seals designed to withstand harsh range environments  The KTM’s direct drive axis design delivers smooth, jitterfree tracking to ensure precise Time, Space and Position Information (TSPI)  Self-contained and trailer-mounted, the KTM is quickly and easily deployed via highway and unimproved roads to remote tracking sites  Digital Control System (DCS) that guarentees system reliability WHEN THE RANGES REQUIRED PRECISE AND RELIABLE OPTICAL TRACKING MOUNTS, THEY SELECTED THE BRASHEAR KINETO TRACKING MOUNT MORE THAN 150 TIMES. Recognized Standard for Tracking Systems Worldwide THE KTM DIGITAL CONTROL SYSTEM (DCS) INCLUDES:  High speed communication via an Ethernet interface to provide remote operation  Advanced servo loop control to optimize tracking performance  Built-in error correction to ensure precision tracking accuracy  Versatile chassis architecture that accommodates additional PC104 cards suchas an “Automatic Video Tracker” (AVT) to satisfy specific customer requirements and missions

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2004+ Victory motorcycles PGR-1000 SERIES Programmable Gear Readout Installation

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

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1. Turn the key on and make sure the transmission is in neutral and ‘n’ is displayed on the readout. (Please leave the key ‘ON’ for about 5 seconds before continuing) 2. Turn the key off (.1 seconds) and then back on (1 second) again rapidly. The display should show 1 bar. If you wait too long before continuing the readout will exit the setup routine. (If the unit has already been cleared, it will immediately jump to step 6.) 3. Repeat step #2. The display should show 2 bars. 4. Repeat step #2. The display should show 3 bars. 5. Repeat step #2. The display should show 2 bars. 6. Repeat step #2. The display should show ‘n’ with a bar over it. If the display is upside down then kick the transmission out of neutral and the display will invert and show ‘C’. Tach adapter(for open-collector tach signal from ECM w/out pull-up resistor) ( 2004+ Victory motorcycles use this option , most other bikes use application on front page) VSS Notes: The PGR-1000 is designed for motorcycles with an Electronic VSS signal. Most modern motorcycles use a 3-wire hall-effect type speed sensor in the transmission with a power, ground, and a signal wire. The SEN-1019 is available for motorcycles without a factory VSS signal, fabrication will be required for sensor mounting

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KTM ATV 525 XC specification

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Filed Under (KTM) by admin on 12-11-2010

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

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Motorcycle Safety & Licensing Start Seeing Motorcycles

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Filed Under (Tips and Review) by admin on 10-02-2012

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What All Drivers Should Know • Assume a motorcycle is closer than it looks. Motorcycles look further away than they are and seem to move slower than they really do. • Allow more following distance. Keep three to four seconds behind a motorcycle. Motorcyclists often slow down without using the brakes, thus not activating the brake light. • Make sure the turn signal is for real. Motorcycle turn signals are usually not self-canceling. • Use extra caution with passengers. A passenger complicates a motorcyclist’s task. Balance is more diffi cult. Stopping distance is increased. • Don’t crowd them. Maneuverability is one of a motorcycle’s better characteristics, but only at slower speeds with good road conditions. They can’t always dodge out of the way. Motorcycle Traffi c Laws Motorcyclists have the same rights and the same responsibilities as other drivers in Nevada. There are also some special conditions: • Motorcyclists must wear helmets in Nevada. • Motorcyclists have the right to use a complete traf- fi c lane. Two motorcycles may share a lane if the operators both agree to do so. • Motorcyclists may not pass or ride next to another vehicle in the same travel lane. • Motorcycles may not be driven between vehicles in adjacent lanes even if the vehicles are stopped. Police offi cers are an exception. (NRS Chapter 486) Gonna Ride? Take a Course – Get the License Riding a motorcycle is an enjoyable and challenging pastime. The best thing you can do for your safety and your family is to take a rider education course and get a Class M driver license

KTM OM-2 Split Body Floating Ball Valves Installation and Maintenance Instructions

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Filed Under (KTM) by admin on 26-01-2012

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Remove the valve from the shipping package (box or pallet) with care taken to avoid any damage to the valve and actuator (plus accessories where applicable). •Before installation, remove the seal discs from the flange. Clean the inside of the valve using an air line that includes an appropriate air-filter. Ensure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on the valve seat. •Confirm that the materials of construction listed on the valve nameplates are appropriate for the service intended for and are as specified. When in doubt contact KTM, or your local Tyco facility. •Define the preferred mounting orientation with respect to the system pressure. The arrow on the body helps to identify the upstream side (high pressure) and downstream side (low pressure). •Ensure that all stud bolts and nuts of the body joint are firmly fastened. Caution •Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional. •See the Actuator User Manual for the actuator preparation. 2.2. Installation Instructions •Ball valves are normally installed in horizontal pipes with the stem facing up. However, there are no limitations regarding the pipe or stem orientation. •Unless otherwise recommended by KTM, the valve should be installed with the ball in the open position, to ensure that the seat rings are not damaged during installation. •Particular care should be taken for valves equipped with “fail-close” actuators. •For operating temperatures above 200°C (392°F), thermal insulation of the valve body is recommended to protect the actuator/accessories from heat beyond the recommended temperature range. •Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in points 1.2. and 1.3

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KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork

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2000-2003 KTM MXC / EXC Dual Sport Kit Installation And Removal Manual

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Filed Under (KTM) by admin on 08-02-2012

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00-’03 KTM 400/450/520/525 EXC & MXC Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3
4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

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