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1995 Camry WIPER MOTOR CIRCUIT BREAKER INSPECTION PROCEDURE

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Filed Under (Toyota Manuals) by admin on 15-10-2011

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INSPECTION PROCEDURE: Inspect the Wiper Fuse. Verify there is power and ground to the Wiper Motor on all speeds (including “Intermittent” or “Mist” if applicable). After verifying power and ground to the Wiper Motor, follow the procedure below to prevent unnecessary Wiper Motor replacement because of a temporary open in the Wiper Motor Circuit Breaker. 1) Disconnect the Wiper Motor Harness Connector. 2) Wait (10) minutes before checking continuity. 3) Check the continuity of the motor with an ohmmeter. REPRESENTATIVE CHECKING PROCEDURE: NOTE: Continuity check can be performed between either the low speed or high speed terminal and the ground terminal of the wiper motor. The standard resistance of a good wiper motor is approximately 1.5 to 4.5 ohm

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Commonwealth of Massachusetts Registry of Motor Vehicles Motorcycle Manual

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

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DEFINITIONS MOTORCYCLE Any motor vehicle having a seat or saddle for the rider that is designed to travel with no more than three wheels contacting the ground, including any bicycle with a motor or driving wheels attached. MOTORIZED BICYCLE A pedal bicycle which has a helper motor, or a non-pedal bicycle which has a motor, with a cylinder capacity not exceeding fifty (50) cubic centimeters, an automatic transmission, and which is capable of a maximum speed of no more than thirty (30) miles per hour (mph) . OPERATION OF MOTORIZED BICYCLES Under Massachusetts law, mopeds fall into the category of “motorized bicycles”(with or without pedals) and are therefore regulated by the Registrar of Motor Vehicles. Individuals must have a valid learner’s permit or driver’s license to operate a motorized bicycle or moped. Mopeds must have automatic transmissions and cylinder capacities of no more than 50 cubic centimeters. In addition, mopeds must meet all federal motor vehicle safety standards and have maximum speeds of no more than 30 mph. The following limitations apply:  Individuals may not operate at speeds greater than 25 mph;  Individuals may not operate on state highways or limited- access roads with signs prohibiting bicycles;  Individuals may not operate on off-street recreational paths;  Individuals may use bicycle lanes along roadways;  Individuals must use the proper hand signals before stopping or turning;  Individuals and their passengers must wear United States Department of Transportation (US DOT) approved helmets when operating;  Individuals may not carry passengers while operating on a permit.

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TRIUMPH ROCKET III TIP OVER BARS INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-12-2010

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1. Starting on the right side (towards the front of the motor) locate the three mounting bolts that secure the brake assembly bracket (a chrome tube) to the bottom of the motor. Remove the bottom and front bolts. Repeat for left side. 2. Locate the front motor mount bolt. This is the black bolt located at the very front of the engine about halfway down behind the radiator. Remove the nut from this bolt on the left side. Properly secure the bike and use a jack to lift up on the motor to release the pressure from the motor mount bolt. Remove the bolt. 3. On the right side place the motor mount bolt thru the upper mounting hole of the right tip over bar. Install the tip over bar by feeding the motor mount bolt thru the original hole and inserting the two bolts (supplied) into the bottom mounting holes. (Do not tighten yet.) 4. On the left side install the top of the left tip over bar by inserting it into the right side tip over bar. Align the tip over bar so that the motor mount bolt extends thru the upper mounting hole. Thread the original locking nut onto the motor mount bolt a couple of turns. Now align the bottom of the tip over bar and install the remaining two bolts (supplied). Tighten the motor mount bolt (torque to 28-32 ft/lbs) and the lower four bolts (torque to 14-18 ft/lbs) securely. 5. Re-check all hardware for tightness

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New Automatic Transmission for Motorcycles Human-Friendly Transmission

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Filed Under (Honda) by admin on 18-12-2011

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High-pressure fluid flow The engine rotates the pump swash plate, which has a gear mechanism. The rotating swash plate pushes the pump pistons to increase the pressure on the hydraulic fluid and feed it to the high-pressure annular chamber. The high- pressure fluid is then fed to the oil motor piston chamber where it pushes the pistons forward, which then push the motor swash plate. Power Fluid flow from pump to motor Fluid flow from motor to pump Low-pressure fluid flow The lower-pressure hydraulic fluid returns to the pump through the low-pressure annular chamber. In this way, the fluid circulates between the pump and the motor. Movement of distributor valves and pistons The distributor valves play an important role in fluid circulation. The valves are placed both in the oil pump and motor. When the pump pistons move to the compression side, the valves connect the piston chamber and the high- pressure chamber. When the pump pistons move to the expansion side, the valves allow a connection between the piston chamber and the low-pressure chamber. The valve in the oil motor moves opposite to its counterpart in the pump, ensuring the circulation of fluid within the system

BMW R1100RT, BMW R1150RT Signal Mirror Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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1. These instructions start with the right side mirror. Grab the mirror housing as shown and slowly push down to disengage housing from motorcycle. 2. Once you have the mirror housing removed partially, twist and remove the light bulb from mirror housing. Remove mirror housing and set it on a cloth covered surface. 3. Remove the factory mirror by inserting a slotted screwdriver against each mirror mount snaps. Slowly twist and pry each snap until it releases from motor actuator. Repeat process until factory mirror disengages. NOTE: Insert the slotted screwdriver as close to each of the snaps as possible before prying out the OE mirror. Not doing so may cause the crossbar on the motor actuator to break. Connect the two mating connectors from the adapter Signal® mirror wire harness and the new Signal® mirror wire harness. Cut a slot in the foam disc to accommodate the anti-vibration prongs on the motor adapter. Place the foam disc onto the center of the Signal® mirror motor interface. Connect the Signal® mirror mating connector to the Signal® mirror wire harness. 5. Remove Cap Sheet from two-sided adhesive disc on back of Signal ® mirror. Align the anti-rotation prongs found on the top and bottom or left and right with the corresponding slots on the motor mount. Use the palm of your hand, push down on the Signal® mirror and the mirror housing until the Signal® mirror motor mount is fully engaged. Note: Push firmly on all sides of the Signal® mirror to ensure proper engagement and travel. Not doing so could result in mirror falling off. 6. Locate the light bulb and carefully disconnect the original light blue with black stripe wire [hot wire]. Connect the red wire from the Signal® mirror wire harness to the spade terminal on the light bulb. Connect the original light blue with black stripe wire to the other spade terminal located on the red wire of the Signal® mirror wire harness. Repeat the process for the original brown wire and the black wire from the Signal® mirror wire harness [ground wires]. Insert the light bulb back into the mirror housing. 7. Align the 3-pins with their corresponding snap holes and snap the mirror housing into place. 8. Insert key into the ignition and turn to the “ON” position. Activate the right hand turn indicator to verify that the new Signal® mirror is working correctly. Replace any other accessories necess

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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

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YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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Lambretta UNO50 Owners Manual

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

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brakes: Inspect brake cables/hoses/linkage for correct mounting, chafing, leaks and damage. Check and adjust both front and rear brakes. If hydraulic, check fluid level and correct if necessary (DOT 4 fluid only). Engine: Check and correct the engine oil level. Fuel system: Check fuel tank, carburetor, fuel valve and all hoses for leaks. Throttle system: Check for correct throttle cable routing. Throttle operates smoothly and self-returns to idle from all handlebar positions. Wheels/tires: Check wheels, tires and valve stem for damage, etc. Check and adjust tire pressures. 11 Suspension: Check for smooth suspension operation. Lubricate all grease points using correct specification grease. Check for correct suspension adjustments. Inspect fork and shock seals for leaks. Steering: Check for smooth steering operation and handlebar bearings for proper adjustments. Electrical Systems: Check for correct function of all side, headlight (high/low beam) and taillights, turn indicators, brake lights, warning lights and instrument illumination. Check for correct horn operation. Check harnesses for correct routing. Check for correct function of starter lockout system. Check for correct engine stop switch operation. Check for correct function of the low oil warning light. (2 stroke only) Emission Systems: Check connections and hoses for routing and kinks.
12 Fastening hardware: Check front and rear axle nut and bolt torque. Check torque of drain plug and oil filter bolt. Check torque of all brake system nuts and bolts. Check torque of all steering system mounting hardware. Check torque of exhaust mounting hardware. Check torque of all remaining nuts, bolts & screws. Road test Front and rear brake operation. (approx. 10km): Check cold engine start performance. Evaluate performance, handling and braking. After road testing: Check hot engine starting. Check and adjust idle speed. Check for oil and fuel leaks. Make necessary adjustments and repair any defects seen or observed before, during and after test drive. Retest as necessary. Clean the vehicle prior to deliver

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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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HARLEY DAVIDSON SPORTSTER FORWARD FOOT CONTROLS

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

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LEFT (SHIFTER) SIDE 1. Remove stock footrest assembly and save footrest for reinstallation. Replace existing sockethead capscrews that attached footrest bracket to primary cover with washers (5) and shorter screws (21) from kit. 2. Remove stock shift lever and save shifter peg and mounting screw. 3. See Figure 1. Remove left side stock motor mount and save nuts, washers, and P-clamp for clutch cable. The bolts will be replaced. 4. Put Loctite 243 on threads of left side foot control support (15) and thread support into left side machine motor mount (11). Install C-clip (8) onto support where it exits the backside of machine motor mount to hold support in place. 5. Install left side motor mount assembly in place of stock motor mount using washers and nuts saved from step 3, and bolts (22 and 23) from kit. Tighten bolts to 25-30 ft-lbs (41-47 Nm). Make sure to reinstall the P-clamp and clutch cable in the same hole location they were removed from in step 3. 6. Install shift lever (14) from kit using stock fastener. 7. Put Loctite 243 on threads of clevis mounting screw (4) and install shift lever pedal (13), clevis (17), and footrest (stock), as shown. To install footrest, place a spring washer (19), along with the mount end of the footpeg, inside the slots of the clevis. Make sure the spring washer is positioned inside the clevis with the square edge towards the inside as shown in Figure 3. Secure footpeg and spring washer with bolt (2) and locknut (7). Tighten locknuts to 19 ft-lbs (26 Nm)

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