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KTM Starter Gear Maintenance Instructions

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Filed Under (KTM) by admin on 26-11-2010

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Checking the electric starter motor for wear -Check Bendix 1 for smooth operation and signs of wear. -Check the sprocket of the electric starter for wear and radial clearance. -Replace O-ring 2 of the electric starter. -Replace gasket 3 . -Check starter idler gear 4 for smooth operation and wear, check that the bearing bushings are seated firmly. Electric starter motor – checking for and adjusting play -Mount the electric starter and the starter idler gear. -Mount the tighten cover 5 . -Move starter idler gear 4 back and forth in the direction of rotation, the maximum play may not exceed half the width of a tooth. -If play is larger, cover 5 must be removed and as many shims 6 with a thickness of 0.10 mm as necessary must be added to eliminate all play. Then remove one shim again. -Check the play again; the maximum play may not exceed more than half of the width of a tooth. 1 2 3 4 5 4 5 6

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How to Replace your starter : 99 Corolla VE

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Filed Under (Toyota Manuals) by admin on 17-06-2011

Use a 10mm ratchet attachment to remove the battery from the vehicle. Negative terminal first, then positive. Be careful not to cause an arc between the two terminals as intense pain will result.
Remove the plastic plate that the battery sits in. 2. Using the 10mm attachment again, remove the 6 bolts that hold the passenger side front splash guard from underneath the front bumper. 3. From underneath the vehicle, locate the oil filter. Look above oil filter and you will see the starter. Locate the bottom 14 mm bolt that attaches the lower portion of the starter to the engine. The bolt drives from left to right. The starter is mounted toward the front of the vehicle and underneath the intake manifold. Still cant find it?
Follow the cable that leads from the positive battery terminal. It ends at the starter. Not sure you have the right bolt? Stick your 14mm attachment on it with your fingers and see if it fits on properly

REMOTE ENGINE STARTER OWNER’S GUIDE

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Filed Under (Toyota Manuals) by admin on 16-06-2011

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The REMOTE ENGINE STARTER allows you to start your engine from outside the vehicle. It uti-
lizes your vehicle’s keyless entry remote, so there is no need to carry around an extra remote.
The REMOTE ENGINE STARTER is operated the same way for vehicles equipped with or without
the Smart Entry / Push Start system; simply push the remote’s LOCK button in a quick, two-
step sequence. In addition, the REMOTE ENGINE STARTER can activate the heater or air condi-
tioner according to your preset temperature controls, providing you with a comfortable cabin
upon entry. As an added convenience, the REMOTE ENGINE STARTER can also activate the
defroster (when preset) to clear up the windshield during cold weather

HARLEY DAVIDSON XL STARTER MOTOR COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation 1. Remove exhaust system according to Service Manual instructions. 2. See Figure 1. Remove the outer primary screw shown and retain it for reinstallation. 3. See Service Parts Illustration. Insert the thread cleaning screw (9), through the primary cover and the crankcase until the full screw diameter protrudes through the crankcase. Remove any debris from from the tip of the thread cleaning screw. Remove thread forming screw and discard. NOTE If thread cleaning screw binds in crankcase hole, remove thread cleaning screw and chase threads with 1/4 – 20 tap. 4. Install set screw (8) from outer primary side using the wrench provided. Set screw should extend past the crankcase approximately .375″. 5. With wrench in set screw to prevent rotation, install the backplate over the set screw and fasten with the 1/4-20 nylock nut (5). 6. Reinstall the primary cover screw saved in Step 1. Torque to 80-110 in-lbs (9-12 Nm). 7. Remove the the oil hose clamp from the starter stud. Do not remove the clamp from the hoses. 8. Replace the original equipment starter stud with stud (7) provided. Torque to 39-65 in-lbs (4-7 Nm). 9. Install bracket (2) over stud (7) and fasten with #10-24 nylock nut (6). Rotate bracket until the tab on the bracket rests on starter motor. 10. Install oil hose clamp onto bracket (2) using one of the #10-24 screws (4). Tuck the hoses down as far as possible without contacting the drive belt or kinking the hose. Contacting the drive belt or kinking the hose may cause damage to the hoses or powertrain. 11. Install the cover (1) to the backplate (3) and bracket (2) using four of the #10-24 screws (4) with the wrench provided. The cover should fit inboard of the gear cover and partially on top of the sprocket cover. Start the bracket screw first, then follow with the (3) backplate screws. 12. Reinstall exhaust system according to Service Manual Instructions

2006 KTM 250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING, REPAIR MANUAL

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Filed Under (KTM) by admin on 05-05-2012

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Hot start lever (250 SX-F) If you pull the red hot start lever [1] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean” fuel-air mixture of the type needed for hot starts.
ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXCUSA) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button (EXC) Pushing the black starter button [2] will actuate the E-starter. Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 2 3 4 5 6 Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on

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2007 KTM 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING INSTALLATION MANUAL

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Filed Under (KTM) by admin on 05-02-2012

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Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button Pushing the black starter button [2] will actuate the E-starter. Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on. ENGLISH 7 2 Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 3 4 5 6 1 OPERATION INSTRUMENTS » ENGLISH 8 TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21″ with production tires). Afterwards the display will return to the previous display mode

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2008 KTM 250 SX-F 250 XC-F, XCF-W 250 EXC-F, EXC-F SIX DAYS INSTALLATION MANUAL

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Filed Under (KTM) by admin on 22-10-2010

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Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see “Maintenance”). 1 A Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 2 Headlamp switch (XCF-W) In this model the headlamp is switched on with the pull switch [5] . 5 Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right
OPERATION INSTRUMENTS » ENGLISH 7 1 2 3 4 5 Starter button Pushing the red starter button [1] will actuate the E-starter. Emergency OFF switch (EXC-F Australia) The red emergency-OFF switch [2] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [3] will actuate the E-starter. Indicator lamps The green control lamp [4] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [5] lights up when the high beam is on. TEST All of the display segments briefly light up for the display function test. Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The button is used to change between display modes. The + and – buttons are used to control various functions

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2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

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Honda GL1000/1100 starter motor Removal/ Over haul Manual

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Filed Under (Honda) by admin on 08-04-2011

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1. Remove the three long bolts that hold the sections together and separate them. Be careful as there are a series of flat thrust washers on each end of the armature (located in the middle section). 2. The end cap basically performs no function other than to cover the brush plate and commutator area as well as center the armature shaft in a pressed in bushing located in the end of the cap. 3. The drive end contains the reduction gearing and if need be, can be disassembled to replace the bearing. This is extremely unlikely. The shaft should turn freely and normally only requires a cleaning and grease application. If the bearing in fact needs replacing, simply remove the “C” clips on either end, drive out the bearing and reinstall with an appropriate size replacement. Any decent auto parts / industrial supply should be able to supply the correct bearing. 4. Remove the brush plate from the end of the center section by removing the screw at the one brush connection. Before removing the brushes, note that one of them has an insulating sleeve over the braided wire. The replacement must go in the same brush holder. Remove the brushes and replace if necessary and clean the brush plate. ** Brake Cleaner is a good general cleaner for this entire job. 5. Remove the thrust washers from brush plate end of the armature. Count them and ensure they go back on the correct way. 6. The end of the center section that had the drive end on it has a circular plate covering it with a short splined shaft protruding through the plate. Drive the plate out by tapping the opposite end of the section on the shaft – just lightly with a rubber hammer or piece of wood to protect the shaft. Once the plate is out, remove the armature from the section. You will find more thrust washers at this end. Make sure they go back on correctly. 7. In the center of the center section there are four large Philips screws. These hold in the field coils found within the housing. Using an “impact driver”, loosen the four screws that go around the circumference of the center section and remove them. Remove the 10mm nut for the battery connection and the accompanying fiber insulating washers. With the screws and nut removed, the entire field coil assembly should withdraw entirely from the housing. There will be four (4) metal plates that the screws mounted into come falling out. They are easily replaced into the field coils when you slide it back into the housing. Do not be alarmed that you suddenly have four loose metal parts. 8. With everything out of the housing, thoroughly clean everything using the Brake Cleaner. Although the cleaner will dry without leaving a film, it is suggested that the components be dried with compressed air. 9. Get some extremely fine steel wool (“000″ of even “0000″ is better) and gently clean the metal surfaces or bars of the armature and the commutator. Blow with compressed air. 10. Using a volt/ohmeter, test for continuity between pairs of armature bars (the long ones). There should be continuity between the pairs around the entire circumference.

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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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