ktm my17 top case instructions

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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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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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PIAGGIO VESPA ACCESSORIES Top Case

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Filed Under (Vespa) by admin on 28-10-2010

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623698M0F2 Gray GTS Top Case 623698M0R7 Dragon Red GTS Top Case 623698M092 Black 94 GTS Top Case 623698M0DE Midnight Blue GTS Top Case 623698M0RI Vintage Red GTS Top Case 602959M GTS Full Chrome Kit 598979 GT/GTS Windscreen 602927M GT/GTS Top Case Bag 602935M0BR GTS Leather Seat 602938M0BR Matching Leather Backrest (for top case)
PIAGGIO VESPA ACCESSORIES – Vespa GTS cont. 23 605108M GT/GTS Flyscreen 602942M Vehicle Lock 602734M GT/GTS Floor Mat 602845M002 Electronic Alarm “E-Power” for GT/GTS

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BMW R1100GS, R1150GS and R1150GS Adventure Side Cases Installation Instructions

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

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1. Mounting blocks Note: On the low mount (for rear cross bar), attach the mounting block vertically with the opening (slot) pointing up and slightly rearward. See photo below. On the two upper mounts, attach the mounting block horizontally with the opening (slot) pointing towards the front. See photo below. Using the M5 x 16 button head screws, with M-5 split washers, attach the backing plate to the mounting block. With the backing plate inside the case and the case mounting blocks outside the case, assemble loosely, using a 3 mm Allen key. These screws will all need to be tightened after final fit up. See photo below. After each block is mounted, insert the black securing knob through the locking tab and into the center hole of the case mounting blocks, from inside the case. Use anti seize on the thread of the thumbscrews to prevent corrosion. See photo below. During riding, these screws will secure the cases to your bike. The locking tabs must be backed off (counter-clockwise), allowing the screws to firmly engage the bullet notches on the bike; then the locking tabs will be rotated clockwise to lock the screws in place and prevent them from loosening. 2. Foot peg stainless Steel “U” Brackets Mount the foot peg bracket to the front of each case with the flat side up, angle side down, using the M-5 Nylock nuts and rubber backed washers, from the inside. Put the rubber side of the washer next to the case. See photo below and photo on page 2 for the correct orientation. These nuts will be tightened, using an 8 mm wrench, after final fit up.

KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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KTM 250F Timing Chain Tensioner Installation Instructions

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Filed Under (KTM) by admin on 19-10-2010

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1) Remove OEM Tensioner: On some models including the 250F motors, it may be necessary to put the engine at TDC before proceeding. Check your manual. This is not the case on the 450 and 530 single cam motors. • Remove the outer cover plug. • Remove the large cover with copper washer. • Using needle nose pliers grab the end of the OEM tensioner and pull it outward. Be careful not to damage the aluminum port or face. • If the O-ring did not come out with the tensioner, carefully reach into the port and remove it without pushing it further into the engine. 2) Install new Tensioner: • To prepare the new tensioner, set the spring aside. Put the new tensioner in the collapsed position. (They are packaged and shipped in the collapsed position.) If you have extended it, rotate the assembly until the “top” on the piston is facing up. Then a light tap from the bottom will release the ratchet. This will now allow the plunger to be retracted to about 1- 13/16″ (46mm). • Install the O-ring over the tensioner body, keeping it outboard of the ridge as shown. • Slide the tensioner assembly with O-ring (without the spring), into the engine port. The end (with the hex-head spring hole) should only protrude from the engine about 1/32″ (.75mm). • Install the cover and tighten. The copper washer should be tight. • Insert the spring through the cover port. As it is slowly inserted, you may hear clicks as it pushes the plunger inward while ratcheting. • Install and tighten the plug against the spring. Note: some 250F engines have a one piece cap. Slide the spring into the tensioner far enough to hold it, then capture it with the cap and tighten. • Start the engine and carefully check for oil leaks. Adjustment will occur internally as it is needed. No further maintenance of the tensioner is required

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Pulsar XR 650R ELECTRIC-START KIT INSTALLATION INSTRUCTIONS

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Remove the seat, fuel tank, side panels, muffler, and headers. 2. Disconnect the stator wires from their corresponding mates underneath the seat (trace the wires up from the left side case.) Un-route the stator wiring so it hangs free from the left side case. 3. Remove the stock shift lever and the left side engine case cover. You do not need to drain the oil from the engine. 4. Unbolt and remove the stator and wiring from the stock cover. Do not cut any wires. 5. The stock pulsar coil (small black box hanging from the stator) will have to be modified slightly to clear the ring gear before installation into the new cover. Remove (file or grind) about .030 inches of material from the base of the pulsar coil so that the base is flush with the face of the rest of the coil as shown in Photos 1 and 2. File Here Photo 2 Make flush with this surface Remove material here Photo 1 6. Install the stator and modified pulsar coil into the new engine case cover as shown in Photo 3. Use the three provided Phillips head bolts, split lock-washers, and plastic cable clamps to secure the wiring as shown. You will need to pull about ½” of extra wire through the grommet (Photo 4) to give you enough wire length for the grommet to sit in its case cutout. To do this, remove the electrical tape from the end of the stator wires and pull each wire individually through the grommet. Neither of the stock metal wire guides will be used when reinstalling the stator into the new case (Photo 5). 5/16″ cable clamps 1/8″ cable clamp Photo 3 Photo 5 Not Used Pull extra wire through grommet Photo 4 7. Remove the stock flywheel nut (An air impact tool works best to remove this nut without turning the motor). Remove the flywheel using the flywheel puller provided. 8. Locate the T and F marks on the stock flywheel (Photo 6). The T mark is used to adjust valve clearances and its location needs to be transferred to the ring gear. Scribe a line in the edge of the flywheel in line with the T mark as shown in Photo 7

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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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2007 KTM SX-F 250- 450 Kickstand Installation and Removal Manual Instructions

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

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Remove the lower d bolt making sure you keep track of the order of the small parts for re-assembly. 2) Remove the lower in-frame bolt. 3) Install the supplied lower kickstand mounting bracket onto the frame at the lower chain roller boss. The counter bore should slide over and onto the frame boss. The chain roller should go back into place just how it came e supplied lower kickstand mounting bracket between it and the frame. Do not is bracket needs to pivot to align with the lower hole in the main . 4) Install the kickstand onto the bike using one of the provided M8x30mm flat head sub-frame to main-frame bolt location. Do not tighten yet. 5) Line up and install the other provided ad bolt thru the lower kickstand mounting hole into the supplied lower kickstand mounting bracket. 6) Now tighten all three bolts, two mounting bolts (front) and one lower kickstand mounting bracket 7) Periodically check the kickstand and all mounting bolts for tightness. Maintenance: Clean and lubricate the kickstand pivot area after each ride! We recommend using a heavy-duty chain lube. If necessary, you can remove the back cover plate for additional cleaning. Never remove the kickstand leg pivot bolt!

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2004-2005 KTM 250/ 400/ 450/ 525 Side Panel Fuel Tank removal and Installation Instructions

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Filed Under (KTM) by admin on 22-01-2012

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1. Remove airbox cover. Drill stock rivet nut in frame tube through with a ¼” drill as shown in Photo 1. Drill completely through frame tube. We suggest you make a small guide hole in the top of the frame tube first so that you drill straight through the frame member and not come out the side of the frame tube. Photo 1 .Install Lower mounting bracket as shown in Photo 3 noting its orientation. Install the aluminum cone into the recess at the bottom of the stock airbox , then bolt the bracket on with the 6 x 70 mm bolt. Nylock nut threads to top of bolt on top of frame tube as shown in photo 2. Photo 3 2 3. Install the upper mounting bracket shown in Photo 4. Note that in either the MXC or the EXC installation four to six of the 6 x 18 mm fender washers should be installed between the bracket and the subframe. The counter-sunk hole should be positioned toward the rear wheel. Leave the bracket slightly loose until step 6. Photo 4 The best routing for the fuel line (Photo 5 & 6 ) requires drilling holes in the airbox. See Step 4 for hole locations. 4. Drill a 3/8″ hole at the front left corner of the airbox as shown in Photo 6. Make sure the location you choose will not result in the hole coming out behind the frame tube or into the rubber airbox boot. Be very careful drilling this hole.

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