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TOYOTA ALL MODELS IRON PARTICLE CONTAMINATION REPAIR

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Filed Under (Toyota Manuals) by admin on 28-10-2011

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During rail transportation or extended storage near industrial areas, vehicles may occasionally be subjected to contamination by airborne iron particles shed from either railroad tracks, train wheels, etc., or exposure to heavy machinery facilities. These particles can adhere to horizontal painted surfaces of vehicles and quickly corrode when combined with moisture. If not immediately recognized and removed from painted surfaces, they become embedded and cause further paint damage. INSPECTION: This type of contamination can be identified by the presence of small red or brown particles on the paint surfaces. These particles are often difficult to see on dark color paints, but still can be readily felt when brushing a hand or fingernail across horizontal body surfaces such as hood, roof, or decklid. CAUTION: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be attempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. CORRECTIVE ACTION: Washing the affected paint surfaces with an oxalic acid solution is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. ZEP X-20472 “INDUSTRIAL FALLOUT REMOVER” is one of several commercially pre-mixed oxalic acid wash solutions and is very effective in removing iron particle contamination. The correct usage of oxalic acid solutions is described in this bulletin

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2003-2007 Kawasaki Ninja ZX6R/ RR HID Installation Removal Manual

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Filed Under (Kawasaki) by admin on 02-05-2012

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take out the original bulb and install the HID bulb. Be careful, do not touch the HID bulb at any time. Plug in the power wires into the original power plug. They go in easy and slide right in. Black wire connects into the black wire on the plug. On the right side, pink goes to red. On the left side, blue goes to red as these are positive wires. Pull the wires toward you slowly and carefully as you near the cover toward the headlight. Spin the rubber grommet if you need to line up the dust cover to the head light. Now lock it in. The arrow should point up if it is locked in properly. Left side installed the same way as the right. Mount the ballasts on the under side of the cowling covers with two nuts and bolts. Position the ballast in the proper place. Then, hold in one spot while drilling two holes for the bolts. An alternate mounting may be with industrial double sided tape or industrial Velcro. Do not use those cheap double sided tape of Velcro mounts as they will not hold the weight of the ballasts. Close up of underside of the cowling cover with ballast installed.
Top side of the cowling cover. Repeat installation on the second cowling. Then reinstall on the bike, connecting all the plug wires.

Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

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Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

2010 Toyota Motorsports/ TRD USA Contingency Award Program

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Filed Under (Toyota Manuals) by admin on 29-09-2011

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To enroll in the program, complete the registration form included in the enclosed material and mail, fax or e-mail it to TRD per the instructions at the bottom of the form. Contact personnel are listed on the attached 2010 Contingency Award Guidelines sheets. These people are available to assist you throughout the year. Parts Ordering: If you are planning to order Toyota parts during 2010 you must supply us with your Visa or Master Card credit card number at the time you register in the program. There is a line on the registration form for this number. See the attached Parts Ordering Guidelines for detailed information on how to order parts. TRD is looking forward to working with each of you, and we wish you a very successful year with your racing program

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Yamaha YZ400F Engine specification

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Filed Under (Yamaha) by admin on 13-11-2010

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During more than 25 years as one of the world’s leading manufacturers of advanced motocross machinery Yamaha has consistently developed and produced exciting and innovative new engine technology. Now Yamaha are about to amaze the off-road world once again with what is surely the most important new powerplant to be produced since our liquid cooled YZ 2-strokes of the early 1980s. Extremely compact and remarkably light, the YZ400F’s 4-stroke powerplant incorporates some of the most sophisticated technology ever seen on a production motocross engine. Displacing 399cc, this 55hp high performance liquid cooled motor features bore and stroke dimensions of 92 x 60.1mm – a free-revving short stroke configuration which allows this ground-breaking motorcycle to produce a wider powerband than today’s 250cc 2-strokes. Short skirt piston runs in a ceramic composite plated cylinder which reduces frictional losses, thereby enhancing throttle response throughout the rpm range. To ensure overall dimensions are kept to a minimum this revolutionary new engine is fitted with an extremely light and compact 5-valve cylinder head. Running a 12.5:1 compression ratio and with a combustion chamber volume of 20.8 cc, this high efficiency 5-valve design runs with lightweight valves, springs and lifters for immediate throttle response and smooth high rpm operation. Feeding the three lightweight inlet valves is a 39mm Keihin flat-slide carburettor which breathes through a large capacity airbox. Special feature on the YZ400F’s intake side is an innovative air valve which is designed to ensure easy starting when the engine is warm. A tube connects the machine’s inlet manifold directly to the airbox, bypassing the FCR39 carburettor. By pulling the air valve’s choke-type knob, air is fed straight from the airbox into the engine for easier warm starting.

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1500 XLT MOTORCYCLE / ATV LIFT INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

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Filed Under (Tips and Review) by admin on 29-11-2010

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1. Load should not exceed rated capacity for this lift – 1500lbs 2. 70-160PSI shop air needed. 3. Make sure the handle is in the down position and the safety plate is set in the safety lock while the lift is in the raised position. 4. Move the lift only when it is lowered. 5. Do not ride vehicle onto lift. 6. Only trained people should operate the lift. 7. Air/Hydraulic pump should be at least 3 feet away when operating. Remain clear of the lift when raising or lowering. 8. Indoor use recommended. 9. Do not move lift while loaded. 10. Keep hands, tools and other extremities from under carriage and moving parts.. 11. Maintain a safe working environment. The work area should be clean, dry, clutter free, and sufficiently lit. 12. Wear proper ANSI-approved safety attire. Do not wear loose fitting clothing while operating lift, long hair and sleeves should be secured. 13. Keep children and bystanders away from work area. Do not let children operate or play on lift. 14. Do not use if under the influence of drugs or alcohol. Operator must be alert at all times when using heavy lift equipment. 15. Never operate the lift with someone on it. 16. Do not adjust safety valve. 17. Use this lift only for the work it is intended. Do not use this product for an application for which it was not designed. Misuse can lead to personal injury and/or property damage. 18. Industrial applications must follow OSHA requirements. 19. Do not use for aircraft purposes. 20. Have your lift serviced by a qualified repair person using only identical Titan Lifts® replacement parts and attachments. This will ensure that the safety of the lift is maintained.

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Honda GL1000/1100 starter motor Removal/ Over haul Manual

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Filed Under (Honda) by admin on 08-04-2011

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1. Remove the three long bolts that hold the sections together and separate them. Be careful as there are a series of flat thrust washers on each end of the armature (located in the middle section). 2. The end cap basically performs no function other than to cover the brush plate and commutator area as well as center the armature shaft in a pressed in bushing located in the end of the cap. 3. The drive end contains the reduction gearing and if need be, can be disassembled to replace the bearing. This is extremely unlikely. The shaft should turn freely and normally only requires a cleaning and grease application. If the bearing in fact needs replacing, simply remove the “C” clips on either end, drive out the bearing and reinstall with an appropriate size replacement. Any decent auto parts / industrial supply should be able to supply the correct bearing. 4. Remove the brush plate from the end of the center section by removing the screw at the one brush connection. Before removing the brushes, note that one of them has an insulating sleeve over the braided wire. The replacement must go in the same brush holder. Remove the brushes and replace if necessary and clean the brush plate. ** Brake Cleaner is a good general cleaner for this entire job. 5. Remove the thrust washers from brush plate end of the armature. Count them and ensure they go back on the correct way. 6. The end of the center section that had the drive end on it has a circular plate covering it with a short splined shaft protruding through the plate. Drive the plate out by tapping the opposite end of the section on the shaft – just lightly with a rubber hammer or piece of wood to protect the shaft. Once the plate is out, remove the armature from the section. You will find more thrust washers at this end. Make sure they go back on correctly. 7. In the center of the center section there are four large Philips screws. These hold in the field coils found within the housing. Using an “impact driver”, loosen the four screws that go around the circumference of the center section and remove them. Remove the 10mm nut for the battery connection and the accompanying fiber insulating washers. With the screws and nut removed, the entire field coil assembly should withdraw entirely from the housing. There will be four (4) metal plates that the screws mounted into come falling out. They are easily replaced into the field coils when you slide it back into the housing. Do not be alarmed that you suddenly have four loose metal parts. 8. With everything out of the housing, thoroughly clean everything using the Brake Cleaner. Although the cleaner will dry without leaving a film, it is suggested that the components be dried with compressed air. 9. Get some extremely fine steel wool (“000″ of even “0000″ is better) and gently clean the metal surfaces or bars of the armature and the commutator. Blow with compressed air. 10. Using a volt/ohmeter, test for continuity between pairs of armature bars (the long ones). There should be continuity between the pairs around the entire circumference.

TOYOTA HILUX VEHICLES INSTALLATION, SERVICE MANUAL

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Filed Under (Toyota Manuals) by admin on 02-06-2011

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A SIBSо is simple to install, simple to operate and increases reliability significantly. It utilizes conventional ctuation and can be applied to any rotary equipment, large or small, industrial or automotive, on and off road. A SIBSо incorporates a service brake, a park brake and an emergency brake into a single brake. It is an Australian nvention that is patented worldwide. It is the only brake in the world that is able to perform consistently every time,
regardless of its environment, while requiring minimal maintenance throughout its life under the most demanding braking applications. A SIBSо set comprises four individual brakes. Each fully sealed brake consists of a sliding rotor, brake pads and a small quantity of specially formulated SIBSо fluid. Because it is fully sealed, there is no ngress of foreign substances, and brake debris is not released into the atmosphere.

TOYOTA PREVENTION AND REPAIR OF ACID RAIN DAMAGE ( REVISED)

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Filed Under (Toyota Manuals) by admin on 12-10-2011

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it is the responsibility of the dealer to protect and maintain the quality of the vehicle’s finish after receipt at the dealership. Frequent vehicle washing, up to 4 times weekly during high heat and humidity periods, should be performed to minimize the potential for paint damage due to acid rain exposure. This is especially important in areas known for high frequency and concentration of acid rain and industrial fallout. INSPECTION AND REPAIR: Acid rain damage can frequently be identified on vehicles by the presence of visible spots on the paint surface which resemble hard water stains. Unlike water spots, however, acid rain damage cannot be removed by polishing or buffing only. Because acid rain can etch and soften the paint, normal polishing or buffing repair procedures should not be attempted, as this will result in visible depressions in the paint surface. CORRECTIVE ACTION: The repair of acid rain damaged paint surfaces varies depending on how deep the acid has penetrated. Superficial damage can usually be removed by color-sanding and polishing. If the damage extends to a depth greater than 1/2 mil of the clearcoat on a pearl or metallic color, or more than 1 mil of a solid color, sanding and repainting may be necessary. Unfortunately, there is no simple method of determining the actual extent of the acid penetration other than color sanding a representative affected area until there is no visible etching or depressions and then measuring the amount of paint removed with a magnetic type paint film thickness gauge

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