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ACE -325X/ 395 X-XX CLOCK, UNIT, WHEEL, ODOMETER, TEMPERATURE & FUEL METER SETTING

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Filed Under (Honda) by admin on 24-12-2011

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Setup operations include 12/24hour clock, bar tachometer scale, shift warning RPM, numbers of engine rotation per signal, wheel circumference, units, odometer adjustment, units of temperature, temperature warning and fuel meter input resistance selection. These must be set up step by step. The computer will automatic reversion to main screen if no button operation for 75 seconds at any setting screen. 2. Press both MODE & RESET buttons to go into setting screen. In setting screens, press RESET button to add the flashing digit by 1 or convert units, press MODE button to confirm the digit setting and jump to next digit or next setting screen to be set. Press MODE button for 2 seconds at any setting screen to finish the setting and go to main screen. 3. It displays “12 or 24H and XX:XX-XX” symbols and AM/PM in case you select 12H. Operates buttons as descriptions of item 2 to finish clock and jump to 8,000/16,000rpm scale setting. 4. It displays 8,000rpm scale, presess RESET button to convert 8,000 or 16,000rpm. Press MODE button to confirm the setting and jump to shift RPM warning setting. 5. It displays ” RPM rXXX00 “. Follow the item 2 of button operation to finish the shift RPM warning setting and jump to engine specification setting. 6. It displays “SPC-X.X RPM”, the default value is 1.0; there are 4 options: 1.0, 2.0, 3.0 and 0.5. It means the numbers of engine rotation per signal. For example the value 2.0 means the engine rotate 2 turns to output a signal. 7. Press RESET button to move in loop sequence from one to another value of the 4 values. Press MODE button to confirm the setting and go to wheel circumference setting screen. 8. In “cXXXX” display, “c” means “Circumference”, following 4 default digits; flashing digit is digit to be set. Follow the item 2 of button operation to finish the wheel circumference setting and jump to unit setting. 9. It displays KM/h or MPH, each press of RESET button converts unit; press MODE button to confirm unit setting and jump to odometer setting. 10. It displays “ODO & 00000Xkm”, the “X” is tested odometer in factory, follow item 2 to setting a desired odometer and jump to thermometer unit setting. The setting screen will disappear when the odometer is over 30km or your setting is over 30km and returned to main screen. 11. It displaysm ” , or oFF”, each press of RESET button converts , or oFF; press MODE button to confirm temperature setting and jump to temperature warning setting. 12. It displays ” XXX” and the selected unit. Follow the item 2 of button operation to finish the temperature warning setting and go to fuel sensor input resistance setting. 13. It displays “100r and fuel tank symbol”, follow the item 2 to select 100, 250, 510 Ohm or oFF and return to the main screen. The fuel meter bar will disappear if you select oFF mode.

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Daytona 675 Motorcycle Race Kit Installation Manual

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Filed Under (Triumph) by admin on 29-10-2010

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Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Fit the chosen race kit cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Caution The use of the following race kit cylinder head gaskets will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. Item Description Qty 1 Head gasket (t = 0.65mm) 1 1 Head gasket (t = 0.60mm) 1 1 * Page 7 of 29 © Triumph Designs Ltd 2007. Cams, Valve Spring & Sprocket Kits Parts Supplied Camshaft Inlet Kit – A9618055 Camshaft Exhaust Kit – A9618056 Valve Spring Kit – A9618058 Camshaft Sprocket Kit – A9618057 Warning The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of the Camshaft, Valve spring & Sprocket race kits detailed below will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. 5 5 4 1 3 2 4 3 Item Description Qty 1 Cam assy, inlet, race 1 Item Description Qty 2 Cam assy, exhaust, race 1 Item Description Qty 3 Valve spring, 14.4id, race12 Item Description Qty 4 Sprocket, camshaft, 34T 2 5 Socket head cap screw, Encapsulated, M6x10 4
Page 8 of 29 © Triumph Designs Ltd 2007. NOTE •The standard inlet cam is 9.25mm max lift and 258.50o duration. The race kit inlet cam is 9.25mm max lift and 268.74o duration. •The standard exhaust cam is 8.5mm max lift and 246o duration. The race kit exhaust cam is 8.5mm max lift and 262.21o duration. •The race kit valve spring must be used in conjunction with the standard spring platforms and retainers. The fitted length of the race springs is the same as the standard spring. 1. The race kit valve springs should be assembled in the same manner as the standard valve springs. Follow the procedure detailed in section 3 of the Daytona 675 service manual. Ensure the springs are installed with the close wound, colour coded end of the springs facing downwards, towards the piston. 2. The race kit camshafts should be assembled in the same manner as the standard camshafts. Follow the procedure detailed in section 3 of the Daytona 675 service manual. 3. The race kit cam sprockets should be mounted and secured to the camshafts using the slotted holes in the sprocket. The slotted holes allow adjustment of the valve timing. The circular holes in the sprockets are for Triumph service tool T3880102 and should not be used to mount the sprockets to the camshafts. NOTE •No timing marks are included on the race sprockets. Race engines will typically have different depths skimmed off the cylinder head and, therefore require specific individual timing. 4. The camshafts should be timed using cam degreeing equipment which typically consists of a degree wheel, pointer, dial indicator and piston stop. Optimum cam timing will depend on the exact specification of the engine, but a recommended starting point is 104o IMOP (Inlet Maximum Opening Point) and 104o EMOP (Exhaust Maximum Opening Point). 5. Always check the inlet and exhaust piston to valve clearance for the timing selected to use, before running the engine. You must ensure both clearances are adequate. As a guide, the standard nominal piston to valve clearance is 1.3mm inlet & 1.5mm exhaust

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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SUZUKI M109 1800 cc FRONT/REAR EXHAUST / HEATSHIELD INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set collar and grommet aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve actuator solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System

Harley Davidson Sportster 2 into 1 SS2 R Race Exhaust System Instalation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove the nut that mounts the front muffler to the engine, located below the rear brake pedal. 4. Remove the bolt that mounts the rear muffler to the mounting bar. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note : If circlips look bent or twisted replace them with new circlips. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Remove the acorn nut that mounts the top of the right rear shock to the frame. 2. Install the large angle cut end of the new mounting bar to the shock bolt (with the shock in place). Replace the acorn nut but leave it loose at this time. Note : Check the clearance between the mounting bar and the shock. Space the mounting bar out with a washer (not supplied) if needed. 3. Install the circlips and flanges from the stock system onto both of the new head pipes. 4. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 5. Install new header using the stock nuts and tighten them evenly. 6. Slide the tailpipe of the new exhaust system over the collector of the front header. 7. Install two of the exhaust springs (supplied) between the collector and the tailpipe using the spring puller tool (supplied). 8. Slip the silencer over the tailpipe while aligning the hole in the mounting bar with the hole on the top of the muffler, with the muffler positioned to the outside of the mounting bar. 9. Install the bolt, washers and lock nut (all supplied) through the muffler and mounting bar. 10. Install the two exhaust springs over the tabs on the muffler and tailpipe using the spring puller tool. 11. Tighten the acorn nut on the top of the right rear shock. 12. Be sure to tighten all hardware before starting your motorcycle. 13. Important: Check to be sure that there is adequate clearance between the head pipe and the rear

2007 Yamaha V-Star 1300 Classic Straights Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Stock Exhaust System Removal 1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install Nut strip into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 8. Install Nut strip into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks. NOTE: To achieve optimum performance from your Hard-Krome exhaust system we suggest installing the Dynojet jet kit for carbureted models

BMW K1200 RS/ GT Full Exhaust System Full Exhaust System Installation Manual

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

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the side- stand or ideally a rear service stand. 2. Remove the lower fairing. 3. Unscrew the O 2 sensor. Remove the stock exhaust system at the rear canister support bracket and where it bolts to the engine. CAUTION -the stock exhaust is very heavy, be careful not to drop it! Also, be careful not to damage the engine sensor located near the front header pipe. 4. Pry out the old exhaust port gaskets and replace with new BMW OE (x4) exhaust port gaskets. Adab of grease will help hold the gaskets in place while you work. 5. Coat the exhaust studs and O 2 sensor threads with high temperature anti-seize compound. 6. Install the TBR headers into the exhaust ports making sure to get a good seat onto the exhaust port gaskets. Next, install the header nuts starting at the rear/outside stud and working your way forward on the outside set of studs. Once that is finished repeat along the inside set of studs. Tighten header nuts only finger tight at this point. 7. Be sure to coat the threads of the sensor with the included packet of hi-temp anti-seize. Install the O 2 sensor into the TBR headers. Turning the sensor in the counterclockwise direction a few times then screwing it clockwise to install will help make it easier to install and prevent the wire from binding. 8. Place a bead of the hi-temp sealant on the outside edge of the headers that goes into the canister. Slide the TBR canister onto the end of the S-bend pipe. Wipe off the excess sealant that will squeeze out. 9. Carefully slide the muffler clamp over the muffler. ( Note: The stainless steel canister clamp and the name badge on the canister come from the factory with a clear plastic protective film. Please remove this film before operation.) Attach it to the canister support bracket using the stock BMWhardware. Both tabs of the canister clamp should be located on the inside of the canister support bracket. Leave loose for the moment. 10. Make sure everything is lined up and start to evenly tighten up the header nuts to BMWfactory torque specification. Tighten the canister support hardware and install the springs as well. 11. Start the bike and check for leaks around the exhaust ports and the header/canister junction. 12. Reinstall the lower fairing

2009 TRIUMPH DAYTONA 675 Triumph/ Arrow Race Rearsets

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

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race harness kit, air funnel kit, racing oil pump gearing kit, adjustable camshaft sprocket kit, manual camshaft tensioner and blade kit, a reusable engine cover gasket set and racing cylinder head gaskets. Here’s a closer look at the new racing parts and their associated performance improvements: TRACS – Triumph Race Calibration Software TRACS ( T riumph Ra ce C alibration S oftware) is a new computer program that allows racers to tune Triumph’s programmable race ECU from a laptop PC. Developed by one of Triumph’s most experienced EFI calibration engineers, the programmable ECU and software was created for the growing number of competitors that are riding Triumph motorcycles at the track. The new software provides racers with quick access to a wide range of adjustments that can be downloaded to the race ECU in about 35 seconds for tuning during testing, practice and qualifying sessions. Features include: Fully programmable fuel mapping (500rpm increments, for individual cylinders). Fully programmable ignition mapping. Switchable wet and dry maps. Adjustable pit lane speed limiter and speedo calibration. Adjustable quickshifter cut duration (adjustable at low, mid and high RPM) Adjustable rev limiter up to 15,000rpm. New software strategies to improve throttle progression. Optimized software to run faster to cater for the higher RPMs involved in a race environment. Ability to save multiple maps within the memory of the PC. Ability to update an existing 2007/2008 Race ECU to 2009 specification and functionality.* (*Not all features will be available if using the 2007/08 Race harness.) Exhaust – Triumph/Arrow Titanium “Stage 3″ System Triumph has continued to collaborate with Italian race exhaust specialists Arrow Special Parts to develop a new, full titanium racing exhaust system. This system complies with current FIM regulations, works as part of the factory race kit, and offers a significant weight reduction and considerable power gains.

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VESPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT

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Filed Under (Vespa) by admin on 11-11-2010

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VE SPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT To replace the exhaust manifold, order part number 872659 as spare part following standard proceedings. OPERATION PROCEDURE The above picture references the old exhaust flange and the replacement exhaust flange kit part number 872659. Replacement Old Page 5 of 16 With the complete exhaust system removed from the vehicle remove the lambda sensors. Refer to page 88 and 89 of your Vespa GTS workshop manual for exhaust removal. Loosen the 13 mm bolt to loosen the clamp. Bolt Remove lambda sensor Page 6 of 16 Remove the header pipe from the exhaust box. Remove the exhaust packing and clamp. Remove exhaust manifold Gasket Clamp Page 7 of 16 Once all packing is removed check and make sure all surfaces are clean. This will help the installation of the exhaust gasket. Install the new clamp supplied with the kit, but do not tighten down at this point. Fit the exhaust gasket onto the new manifold. Push the new exhaust gasket in with the manifold until fitted all the way down to the flange. Check surfaces. Manifold Gasket Clamp Flange Page 8 of 16 Replace the lambda sensor and tighten down to 40- 50 Nm (29.5 -36.8 ft lbs. ) .

BMW R1200GS Exhaust System Installation instructions

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

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The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury or any other damages caused by improper installation or operation of the Akrapovič exhaust system. When installing the Akrapovič exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature. 2. Akrapovič makes no representation or warranties with regard to damage caused by the improper installation, use and maintenance of the Akrapovič exhaust system. The warranty is limited to defects recognized by our technical department and due to normal use, and excludes items subject to normal wear (gaskets and damping wool). The guarantee is void in case of accident, modification, improper or competition use. 3. Do not attempt to install the Akrapovič exhaust system on a vehicle model for which it was not made or tested by Akrapovič. 4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust system or parts which are in direct contact with it, even when the engine is not running. Also protect other people, especially children, from the injuries mentioned above. 5. In some cases Akrapovič exhaust system kits contain chemical products (ceramic anti-seizing grease; bolt sealant). Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous membranes. Keep out of reach of children. 6. Technical specifications of Akrapovič exhaust systems and related products are subject to change without notice. 7. Before removing the original exhaust system from your vehicle, please compare the parts you received with the list of materials provided in the installation manual in order to assure that you have all the parts necessary for the installation of your new Akrapovič exhaust system. 8. Although this manual consists of instructions for installation in written form, as well as photographs and pictures representing individual steps of the installation, please note that the photographs and pictures are symbolic and are intended for representation of general overview only. The photographs and pictures contained herein should serve as a guideline only and actual installation of the exhaust system may not correspond with the photographs and pictures entirely.

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