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POLINI X1 GENERAL INFORMATION AND SPECIFICATIONS

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Filed Under (Polini) by admin on 02-12-2010

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Air cleaner – Clean and reoil daily or after each moto to prevent motor failure and reduced performance. Transmission oil – change after every race, or at end of riding day. Chain – check tension and lubricate before every ride, adjust or replace as needed. Reoil after riding in damp conditions. Clutch – disassemble and clean clutch assembly frequently, every 2-3 races at least. Inspect kickstarter gears at this time. Ignition cover – remove cover and wipe dry after each ride or after washing bike to remove condensation. Piston rings – replace as often as every 3-5 races with expert rider, less often with less aggressive riders. Piston, pin, rod bearing & circlips – replace as often as every 8-10 races with expert rider, less often with less aggressive riders. Coolant – change yearly, make sure there is at least a 50/50 mixture of antifreeze if freezing temperatures are possible. Steering bearings – Check daily for looseness or play. Adjust and regrease as needed. Swingarm – Check often for looseness. Regrease several times a year. Replace bushings if any play is evident. Sprockets – check for worn or curved teeth each time chain is adjusted. Chain roller& wear pads – check roller for free rotation when checking chain. Make sure roller is not bent or damaged. Check chain wear strips on swingarm and chain guide frequently. Replace as needed to prevent chain from damaging motorcycle. Spokes – Check after each race or after each day of riding for looseness or damage. Wheels & tires – check wheels after each race for dents, cracks or other damage. Check tires for cuts, damage or wear. Check tire pressure daily and adjust for riding conditions. Shock – Check shaft area daily for signs of oil leakage or damage. Check swingarm and shock bushings for looseness. Forks – Check forks daily for leaking oil or damage to tubes. Make sure forks are not twisted check for smooth operation. Spark plug – check sparkplug color and condition after each race or end of riding day. Adjust jetting to keep plug from fouling or overheating. Silencer – If bike seems to be getting louder, replace packing and decarbonize inner tube. Expansion pipe – check daily for large dents, damage or leakage. Remove carbon from headpipe when pipe is removed. Have large dents fixed, or any dents within 8″ of the cylinder. Replace o-rings on pipe as needed to maintain a good seal. Footpegs – check daily for proper operation, pegs should spring back into place. Make sure pegs are not bent or overly dull. Handlebars – check bars after any crash for bending. Look for cracks near bar clamps. Replace bars that have been straightened more than 2 or three times, or if bar is badly bent. Aweakened bar can snap suddenly causing injury to rider. Throttle – check throttle for proper operation each time before bike is started. Remove and clean inside of grip and bar as needed. Grips – check grips daily for wear or looseness. Replace as needed. Use grip glue & safety wire to help hold grips in position. Calipers & pads – check pad wear and caliper function daily or after each race. Replace pads and clean calipers as needed. Brake lever – check lever daily for damage or wear. Make sure lever is at proper angle for both seated and standing positions. Leave lever clamp loose enough to allow clamp to rotate during crash rather than breaking lever. Check and adjust freeplay as needed. Brake pedal – Check pedal daily for damage and proper freeplay. Adjust rear caliper as needed. Reeds – Remove and inspect reed block during every ring change. Check reeds for signs of wear, fraying and cracking. Make sure reeds sit flat and seal well. Replace at any sign of wear or damage or at least once a year, more often for expert riders. Nuts & bolts – Check all nuts and bolts regularly. Make sure to check engine mounting bolts and swingarm bolt frequently

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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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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

KAWASAKI VULCAN 800 STRAIGHT SHOT EXHAUST SYSTEM INSTALATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install a chrome header flange onto the front and rear head pipes. 3. Install the heat shield to the front head pipe using the two hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 5. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 6. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. 8. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Do this to each muffler but leave the clamp loose at this time. 9. Install one muffler to the four hole bracket welded to the V&H mounting bar using the two 5/16″ flange bolts (supplied) and leave them loose. (See figure 1) 10. Slip the muffler and mounting bar assembly onto the front head pipe while aligning the grommet holes in the mounting bar with the holes in the frame.

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KAWASAKI VULCAN 800 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install the heat shield to the front head pipe using the three hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 3. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 4. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bracket and into the frame. Leave them loose at this time. 5. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time.

Kawasaki Vulcan 400/ 800 Preload Improvement Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 01-12-2010

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1. Begin by removing both side compartment covers. The RH compartment cover requires the use of the ignition key for removal; the LH compartment cover is secured by a large Phillips screw. Once you’ve removed the LH cover, place the Phillips screw back into the hole in the frame (so you don’t misplace it) and set both covers aside. In many applications, you must remove the upper exhaust pipe (from the rear cylinder), and loosen the other pipe, to remove the inner parts of the RH side compartment cover (see below). Before attempting step #2 below, try step #3 first… depending on the brand of exhaust pipes you have, you may be able to avoid removal in step #2, if you are successful with step #3 first. Some brands of exhaust pipes provide access to the fasteners securing the RH side covers, eliminating the requirement to remove pipes for rear suspension access. 2. Remove the rear cylinder’s exhaust pipe. To do so, remove the two Allen nuts on the exhaust header, where it attaches to the engine, using an 8mm Allen wrench. Most often, this goes much more smoothly if you first spray the inside of the allen nut with a penetrating lubricant like WD-40. Remove the black acorn nut from the discharge end of the exhaust pipe (under the upper exhaust pipe, near the discharge end of the pipe) using a 12mm open-end wrench or socket. You’ll find a black metal spacer, through which the bolt goes, that is pressed through the rubber grommet. To avoid the potential of having it fall out unnoticed, remove it and place it aside with the nut. Remove the black bolt from the pipe just aft (to the rear) of where the pipe enlarges and above the pipe. This is actually a bracket that holds the two pipes together at a joint. Loosen the bolt using a 12mm socket, then slide it back onto the pipe you’re removing. Once you have the pipe off of the bike, the clamp will be loose. Be sure to keep it with the pipe, along with the rest of the removed parts. Loosen the pipe from the front cylinder BEFORE trying to remove the pipe from the rear cylinder. By loosening the header nuts on the pipe from the front cylinder, and removing the two black Allen bolts (6mm Allen wrench) under the forward pipe that attach it to the frame, you will be able to remove the rear pipe. There are more spacers in grommets where the 6mm Allen bolts secure the lower pipe to the frame (like those used in the rearmost connection o

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HONDA CT110 OWNERS MANUAL

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Filed Under (Honda) by admin on 22-04-2011

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ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be maintained between the upper (2) and lower (3) marks on the dipstick (1). 1. Start the engine and let it idle for a few minutes. 2. Stop the engine and hold the motorcycle in an upright position on firm, level ground. 3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the dipstick without screwing it in. The oil level should be between the upper and lower marks on the dipstick. 4. If required, add the specified oil up to the upper level mark. Do not overfill. 5. Reinstall the oil filler cap/dipstick, check for oil leaks. CAUTION Running the engine with insufficient oil can cause serious engine damage. TYRES Proper air pressure will provide maximum stability, riding comfort and tire life. Check tire pressure frequently and adjust if necessary. NOTE Tire pressure should be checked before you ride while the tyres are cold. Select the right replacement tire in accordance with the following specifications: Cold tire pressures kPa ( kg/cm2, psi ) Front: 175 ( 1.75, 25 ) Rear : 225 ( 2.25, 33 ) Tire size Front: 2.75 – 17 41P Rear : 2.75 – 17 41P Check the tires for cuts, embedded nails, ore other sharp objects. See your authorized Honda Dealer for replacement of damaged tires or punctured inner tubes OPERATION PRE-RIDE INSPECTION WARNING If the Pre-ride Inspection is not performed, serious damage or an accident may result. Inspect your motorcycle very day before you ride it. The items listed here will only take a few minutes to check, and in the long run they can save time, expense and possibly you life. 1. Engine oil level – add engine oil if required. Check for leaks. 2. Fuel level – fill the fuel tank when necessary. Check for leaks. 3. Brakes – check operation. Adjust free play if necessary. 4. Tyres – check condition and pressure. 5. Drive chain – check condition and slack. Adjust and lubricate if necessary. 6. Throttle – check for smooth opening and full closing in all steering positions. 7. Lights – check that headlight, tail/brake light, turn signals, indicators. 8. Engine stop switch – check for proper function. 9. Battery electrolyte – check the level and add if necessary Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance if you cannot correct the proble

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KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 23-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove right side frame cover. 2. If motorcycle is oxygen sensor equipped, remove passenger seat. Remove two bolts securing operator seat and set seat aside. Locate and unplug oxygen sensor connector from wiring harness (Figure 1).(Note wire routing for reassembly). 3. Remove right side floorboard assembly held in place by two bolts (Figure 2). 4. Remove exhaust port flange nuts. 5. Remove flange bolts securing rear muffler to exhaust system mounting bracket. 6. Remove complete exhaust system. Start by removing front head pipe from exhaust port (assistance may be required). Page 1of 4 K400IN Rev. 1.1 KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM Part #18311 Tools required for installations 6mm Allen wrench 8mm 12mm 14mm sockets 3/8″ Ratchet & Extensions 19mm Wrench 9/16 Wrench Brake bleeder & fluid
7. Check condition of stock exhaust gaskets. Replace if damaged or worn. 8. Remove plastic hose clamp securing rear brake hose to swingarm.Save for re-use. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loops in swingarm. 11. Remove three bolts holding stock exhaust mounting bracket and slide bracket off end of brake hose. 12. Slide brake hose through loop on new bracket (stamped 357-P) and install to the original mounting bracket location, using three 8mm x 16mm Allen bolts (supplied) (Figure 3). 13. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 14. Slide brake hose through loops on swingarm and reconnect brake hose to caliper. 15. Reinstall plastic clip onto swingarm. 16. Brake system must be bled or brake will not operate correctly.

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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N

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Filed Under (Kawasaki) by admin on 30-11-2010

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Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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BMW R1100 – R850R Maintenance Guide

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Filed Under (BMW) by admin on 27-11-2010

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R1100 Checklist – Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check battery acid level • Fuel filter (replace 24K) • Throttle body sync • Oil and filter (replace 6K) • Check transmission fluid level (replace 12K) • Check rear wheel drive fluid level (replace 12K) • Check tires and pressure • Check all nuts and bolts • Check all air and oil hose clamps • Check all lights PARTS – TOOLS Tools Parts Misc. sockets spark plugs compressed air wrenches oil filter anti seize torque wrench air filter carb cleaner hex sockets brake pads rag hex wrenches oil – 4 qt. BMW #10 grease feeler gauges gear oil – 1 1/4 qt. flexible tubing oil filter tool alternator belt (tygon) flashlight fuel filter, o-ring, clamps measuring cylinder crush washers Mityvac -3 small = trans.drain, rear drive fill and drain digital volt meter -1 medium = oil drain heat gun -1 large = trans.fill tire change tools 5 R1100 Maintenance Steps – Carl Kulow Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet” except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Check Alternator Belt remove four bolts holding black plastic cover(4mm hex), remove cover, check belt for cracks etc., check belt tension, replace belt every 36K miles, leave cover off for valve adjustment (see Jon Diaz “Alternator Belt Adjustment”)

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