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KTM KINETO TRACKING MOUNT – MODEL K433 Installation and Removal Manual

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

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

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KTM EXC Enduro & SX Motocross REPAIR MANUAL

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

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

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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

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

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KTM ATV 525 XC specification

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

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

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Kawasaki Prairie 360,650,700 ATV PLOW Plow Mounting Kit INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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Mount Installation Note: There are different hole locations on the plow mount depending on the bike model. For Prairie 360 use the middle hole locations (B), for Prairie 650 and Twin Peaks 700 use hole locations (A) on mounting plate, as shown in Figure 1. Figure 1 Hole Locations WARN INDUSTRIES PAGE 3 67954 Rev A3 To install the plow mount to the underside of the vehicle install the front two U-bolts PN 60869, and loosely tighten the 5/16″ nuts. Pull the plow mount back in the furthest position and then fully tighten, as shown in Figure 2. For the Kawasaki Prairie 360 use the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (B) . For Kawasaki Prairie 650 and Suzuki Twin Peaks 700 drill a 3/8″ hole through the aluminum skid plate, using the plow mount as a template, as shown in Figure 3. Repeat the same process on the other side. After both holes are drilled attach the mounting plate with the second set of U-bolts PN 61262 and securely tighten around the frame in hole location (A) . Tighten all fasteners securely. Torque 5/16″ Bolts: 20ft. lb.

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

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

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

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

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

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

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KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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

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

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HARLEY DAVIDSON 360 DEGREE HIGHWAY FOOTPEG MOUNTING KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a) Mount the footpegs so they will not strike the ground during cornering. Foopegs striking the ground during cornering can cause loss of control, resulting in death or serious injury. (00458b) NOTE See Figure 2 for steps 2 through 6. 1. Determine what height on the engine guard you prefer for the final mounting of the footpeg mounts. Mark location, if desired. 2. See Figure 2. Obtain clamp assembly (1) from kit. Wrap the clamp halves around the engine guard and install with hinge pin head facing upward. Place the flatwasher between the ears of the clamp halves. Hold parts in posi- tion. 3. Obtain the lockwasher (13), screw (7) and one of the footpeg extensions (14) (long or short depending on kit number) from kit. 4. Position the clamp adapter (10) over the clamp assembly (1) with the “cogged” face of the adapter facing the extension arm (14). Hold clamp adapter in place. 5. Install screw (7) with internal tooth lockwasher (13) through the clamps, the clamp adapter (10) and into the extension arm (14). Position extension arm as desired. Do not tighten completely at this time. 6. Obtain the clevis/extension assembly (6) from kit. Position assembly such that footpeg pivots upward and toward the rear of the bike. NOTE: It may be necessary to loosen the screw slightly and rotate the extension to obtain this position. Tighten item 9 securely. 7 5 1 3 4 2 6 8 is02511 1. Clamp assembly 2. Arm extension 3. Clevis 4. D-washer 5. Footpeg 6. Screw 7. Clamp adapter 8. Clamp halves Figure 1. 360 Degree Footpeg Mounting Installed (Shown with Footpeg Installed) NOTE The footpeg will be a tight fit if the D-spring washer is installed correctly. 7. Refer to Figure 1. Obtain the footpeg (5), sold separately, D-spring washer (4) and screw (6) from kit. Install the D- spring washer so it is positioned inside the clevis (3) with the square “D” edge towards the inside of the mount. Hold the washer in place and slide the footpeg into position. Install the screw (6) and tighten to 19 ft-lbs (26 Nm). 8. Repeat Steps 1 through 7 for the opposite side. Position the footpeg assemblies so they are at equal heights and symmetrical. Securely tighten each assembly until it cannot be rotated on the guard with reasonable foot pressure, but do not exceed 55 ft-lbs (81 Nm) on item 7

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Ktm 690 SM/ SMC/ SMR/ Duke Removal and Installation weld slag

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Filed Under (KTM) by admin on 04-03-2012

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1. Each bike varies with regard to welds and gussets. Review the photos first to get the idea of what needs to be done. 2. These photos may not be your exact model but depict the concept of what must be done. 3. Block the front tire securely before removing the top triple clamp so the tire cannot move at all. See photos. 4. Support the rear tire also, just enough to keep tension on the front tire so the forks stay tight. 5. Warning: Once the triple clamp is loose, the forks can roll away from the bike AND it happens very quickly . 6. The main triple clamp nut adjusts the tension on the steering head bearings. Make note of its tension before removing and do not over tighten the nut. It should be seated just enough to take the play out of the bearing.. 7. The top of the gauge/light cluster is mounted to the top triple clamp. You have to take out 4 self tapping Phillips head screws to remove the gauge pod. There is one connector on the back side of that and then it comes off. Then there are two bolts that need to come out with an 8mm wrench to free the top triple clamp. 8. Loosen the triple clamp pinch bolt under the main nut and forks pinch bolts and remove the top triple clamp, taking note of how tight the main nut is, so you can re-tighten it to the exact amount. Remove the tin bearing shroud (cover) and rubber seal making note of how the seal goes on, (lips face downward). 9. Grease your bearings while you have them exposed. (Keep the grease off the area where our frame bracket mounts!). 10. The goal is to allow the frame bracket to clamp cleanly and squarely around the upper half of the head tube. 11. Review your individual bike’s welding characteristics at the head tube. You’ll notice on the head tube there is a “groove” machined 360 degrees around the head tube. Everything in or above this groove must be clean of welds or slag. If this groove is visible all the way around and no welding slag has extended upward into or past this groove, then you’re installation should be easy. Any welds extending into or above this groove must be filed away, but without changing the clamping area diameter. DO NOT file away the paint on the clamping area if possible. Spend a little more time filing carefully and your bracket will stay tight. 12. Each bike seems to have not only different welds, but slightly different gussets. Evaluate your individual bike to determine the best fit. The bracket must clamp squarely and cleanly to the area just above that groove and yet SIT FLUSH all the way around the diameter of the head tube as per the photo in the lower right corner. Do not allow the bracket to protrude above the seal seating surface. Use a flashlight to see up under the bracket where it’s hitting if it’s not Flush. This bracket has clearance cut into it to clear the backbone of the frame

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