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Honda Motorcycle Digital Audio System Owner's Manual

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Filed Under (Honda) by admin on 22-11-2010

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Applicable portable audio unit A commercially available portable audio player with a stereo mini jack terminal can be connected to this accessory. (An attachment kit designed for the model is necessary to connect the portable audio player to this accessory.) American Honda Motor Co., Inc. recommends you use a shock-resistant portable audio player such as a flash-memory player (e.g. MP3, etc.) or an MD player equipped with sound skip prevention function. American Honda Motor Co., Inc. also recommends you always ride your motorcycle safely on paved roads, because sound skip can occur during riding on rough roads. Refer to the following instructions on storage and handling of the portable audio unit. This accessory is not designed to operate the portable audio unit connected to the accessory. Refer to the portable audio unit manufacturer’s Owner’s Manual for how to operate the portable audio unit and operate it accordingly. Note that the warranty of this accessory does not cover function and failure of the portable audio unit connected to the accessory 5 Storage of portable audio unit connected to this accessory After connecting the digital audio system, put the portable audio unit in a stable place where it does not interfere with riding the motorcycle (e.g. in the sold separately front pouch, tank belt pocket, etc.) in a place free from vibration as much as possible. Do not place the portable audio unit in your pockets or clothes while connected to this accessory. The portable audio unit can vibrate and contact other materials while riding, causing a sound skip. To prevent such skips, store the portable audio unit in a suitable place while protecting it from vibration and shock by covering it with cushioning material. (Protect the remote control and peripheral devices as well as the portable audio unit.) Any system failure and damage to the portable audio unit and its peripheral devices are not covered by the warranty of this accessory.

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Aermacchi IHRO1 Machine Specifications

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

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1. IHRO 1 caters for single cylinder thoroughbred Grand Prix racing motorcycles constructed during the period 1945-1972 inclusive, for the specific purpose of participation in Grand Prix competition during that era. Maximum capacity for any machine is 500cc, and wherever possible it is intended to run three classes, for machines up to 250cc, 350cc and 500cc. 2. Motorcycles must be presented in original, period condition, with no external updating. Period appearance seats, fuel tanks and fairings (if fitted) must be used. No external changes may be made to the appearance of any machine unless it can be proved that such a change was made in the period. Modern safety fixtures required by some federations and modifications mentioned in this document are not covered by this ruling. 3. No disc brakes are allowed. Drum brakes only may be used. 4. No alloy/magnesium wheels are allowed. Wire wheels only may be used. 5. All machines must have twin shock rear suspension: No monoshocks except Vincent Grey Flash. Suspension units must resemble period components, i.e. no external gas reservoirs etc. 6. All frames and swinging arms must conform exactly to period appearance; no box section swinging arms allowed unless fitted by the manufacturer to that machine in the period. 7. The maximum permitted rim width on either wheel is WM3. 8. No slick tyres, hand cut slicks or modern racing tyres designated by the manufacturer as being exclusively for wet weather use are permitted. Only the following rear tyres may be fitted. Any 19″ tyre. The following 18″ tyres, Dunlop 3.50×18, 3.50/3.25×18 KR124 and KR124A, Avon AM22 110/80×18 Rear Fitment and Avon AM18 120×18 9. Choice of carburettor is free, provided that this is of a period type cylindrical slide model, albeit of a later manufacture. Flat slide instruments are not permitted with the exception of Gardner carburettors. Fuel injection is not permitted except if it can be proved that particular motorcycle ran between 1945-72 with the same type of injection system fitted. A Wal Philips injector is classified under this heading. 10. The type of fuel used must conform to the ACU and FIM’s current fuel regulations for 100LL Avgas at 102 MON. See full specifications below. All machines must finish a race with a minimum of 2 litres of fuel in the tank to allow a sample to be taken for analysis. 11. The use of belt primary drives is encouraged.

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8950 and 8960 Series High Performance Tire Changer Operation Manual

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Filed Under (Tips and Review) by admin on 23-11-2010

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GENERAL CAUTIONS A. DURING THE USE AND MAINTENANCE OF THE MACHINE IT IS MANDATORY TO COMPLY WITH ALL LAWS AND REGULATIONS FOR ACCIDENT PREVEN- TION. B. THE ELECTRICAL POWER SOURCE MUST HAVE A GROUND CABLE AND THE GROUND CABLE OF THE MACHINE MUST BE CONNECTED TO THE GROUND CABLE OF THE POWER SOURCE. C. BEFORE ANY MAINTENANCE OR REPAIRS ARE ACCOMPLISHED THE MACHINE MUST BE DISCONNECTED FROM THE AIR AND ELECTRICAL SUPPLY. D. NEVER WEAR TIES, CHAINS OR OTHER LOOSE ARTICLES WHEN USING, MAINTAINING OR REPAIRING THE MACHINE. LONG HAIR IS ALSO DANGEROUS AND SHOULD BE KEPT UNDER A HAT. THE USER MUST WEAR PROPER SAFETY ATTIRE – GLOVES, SAFETY SHOES AND GLASSES. 2.0 INSTALLATION Your new JBC 8950 or 8960 Series Tire Changer requires a simple installation procedure requiring only a few moments. Follow these instructions carefully to insure proper and safe operation. The Tire Changer is delivered mounted to a wooden skid. Remove tire changer from its mounts carefully, taking care to avoid any back strain. Place Changer where proper operation will be unobstructed to all sides. Install the machine in a covered and dry place. 2.0.1 Models with SRA attached (8955IN, 8965IN) Once placed in the desired location the tire changer must be bolted to the floor using only the rear two mounting holes. Mounting anchors are provided with those machines with a Safety Restraint Arm. Tire Changer must be anchored to concrete floor if equipped with a “Safety Restraint Arm” BUILDING ELECTRICAL INSTALLATION MUST BE MADE BY A LICENSED ELECTRICIAN. Check that the electrical specifications of the power source are the same of the machine. The machine uses 110v, 60 hz, single phase 20 amp source. Electric specifications are clearly marked on a label at the rear of the machine. FAILURE TO PROVIDE PROPER ELECTRICAL SUPPLY AND GROUNDING WILL CREATE A SHOCK HAZARD TO THE OPERATOR

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YAMAHA FZS 600 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-11-2010

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CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. If the pin 2 on the terminal is flattened, bend in up. 4. Connect: lead coupler connector Make sure that all connections are tight. 5. Check: continuity (with a pocket tester) Pocket tester 90590-03112 If there is no continuity, clean the termi- nals. When checking the wire harness, perform steps 1 to 3. As a quick remedy, use a contact revitaliz- er available at most part stores.
1-5 GEN INFO SPECIAL TOOLS 1 2 1 2 1 2 1 EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Usage Illustration 90890-01268 Ring nut wrench This tool is used to loosen and tighten the steering ringnut. 90890-01304 Piston pin puller This tool is used to remove the piston pin. 90890-01460 -01326 Damper rod holder T-handle These tool ar used for holding the damper rod when removing or installing the damper rod. 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. 90890-01325 -01352 Radiator cap tester Adaptor These tools are used for checking the cooling system. 90890-01362 -01382 Flywheel puller Crank shaft protector These tools are used for removing the rotor and starter clutch. 90890-01367 -01381 Fork seal driver weight Fork seal driver attachment (ø41 mm) These tools are used when installing the forkseal.

SUSPENSION SERVICE TOOLS/ FORK DAMPER ROD BLEED TOOL

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Filed Under (Tips and Review) by admin on 30-11-2010

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33 SHOP EQUIPMENT & TOOLS SUSPENSION SERVICE TOOLS K&L FORK TUBE U-BLOCKS Precision machined from billet aluminum, these quality three piece sets are a handy, accurate and safe way to straighten and check fork tubes. 35-9411 36mm (for 33 thru 36mm tubes) 35-9412 40mm (for 37 thru 40mm tubes) 35-9413 43mm (for 41 thru 43mm tubes) 35-9414 46mm (for 44 thru 46mm tubes) 35-1964 35-8579 35-7995 DAMPER ROD HOLDERS Holds damper rod when disassembling forks. 35-8578 Yamaha front forks, 43mm Kayaba YZ125/250 (1988) YZ490 (88-90) 35-8579 Yamaha YZ125/250 with UD(upside down) forks FORK DAMPER ROD TOOLS Sold each. 35-7995 Combination Fork Damper Tool Designed to hold the damper rod during assembly & disassembly of Honda XR400′s or Suzuki DR-Z400S. One end features spanner type prongs for the XR400 and the other a 27mm hex for Suzuki. 35-1964 Combination Damper Rod Fork Tool Designed for assembly and disassembly of most inverted Kayaba and Showa 41mm, 43mm, 46, and 47mm forks. Use one end for Kayaba forks and the other for Showa forks. (not required for 91-92 Honda CR models) ROD HOLDER Double sided damper rod holder. Works on Kayaba U.D (upside down) 41mm forks. 35-8580 Yamaha YZ125/250Amodels (89-90) FRONT FORK CAP SOCKET Designed to remove and install Yamaha front fork caps with female hex head. Sold each. 35-8571 14mm female socket 35-8573 19mm female socket FORK DAMPER ROD HOLDERS Holds damper rod when disassembling and assembling front forks. 35-8576 Use for Yamaha 43mm Kayaba forks, 30mm hex YZ125 (84-87), YZ250 (81-87) IT250 (1983) YZ490 (82-87) 35-8577 Use for Yamaha 38mm Kayaba forks, 24mm hex YZ125 (81-83), IT175 (82-83), IT250 (81-82) YZ250 (77-80), YZ400 (77-79), IT465 (81-82) FORK CAP WRENCH Designed to remove the front fork caps on late model Honda CR’s and Suzuki RM’s. Can also be used for adjusting compression. One end of wrench is 49mm, the other is 50mm. Sold each. 35-7803 Fork Cap Wrench 35-8576 35-8577 35-8571 35-8573 6 Point Hex 35-8578

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1945-1957 AJS Pitmans Installaiton Manual

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Filed Under (AJS) by admin on 31-10-2010

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AN A.J.S. O.H.V. single is easy to handle, and even the absolute novice quickly acquires confidence in the saddle. Beware, however, that you do not indulge in big throttle openings until you have had ample road experience. Also do not forget to digest the Highway Code. FIG. 1. A FLEXIBLE AND FAST TOURER WITH CLEAN LINES AND MECHANICAL QUIETNESS – THE 1957 MODEL 18S The 500 c.c. A.J.S. model shown is similar to the 350 c.c. model 16MS. Both models have snappy push rod O.H.V. engines with light-alloy cylinder heads, “Monobloc” carburettors, hairpin valve-springs, and automatic-ignition control. Their specification includes: “Teledraulic” front forks, Girling rear-suspension units, a quickly detachable rear wheel, die-cast light-alloy hubs, a deep secondary-chain guard, a new A.M.C. four- speed gearbox, Lucas headlamp, twin pilot-lights, and other attractive features. * The A.J.S. engine and frame numbers required on Form R.F. 1/2 will be found on the near-side of the crankcase and the off-side of the saddle lug, or on the off-side of the front down-tube (later models). THE BOOK OF THE A.J.S. 1 Essential Preliminaries. Before you can legally ride on the road – (1) Insure against all third-party risks and obtain the vital “certificate of insurance.” With a new machine you cannot get this until the machine is licensed, and an insurance “cover note” must be obtained. If you have a valuable machine, you are advised to take out full comprehensive insurance. (2) Obtain the registration licence and registration book (Form R.F.I/2)* or renew the licence (Form R.F. I/A). (3) Obtain a three-monthly “provisional” or an annual driving licence (Form D.L.I).* (4) Fit a reliable speedometer if one is not fitted (not essential if machine registered prior to 1st Oct., 1937). (5) If you carry a pillion-passenger, see that he or she sits astride a proper pillion seat securely fixed to the machine (all “springers” have dualseats), and that the passenger holds a current annual or substantive driving licence for Group G if you are a “learner.” (6) If you are ineligible for an annual or substantive driving licence, attach “L” plates to the front and back of the machine. (7) If not already provided, fit a red reflector (1½ in. minimum diameter) vertically at the rear of the motor-cycle and, on a sidecar outfit, an additional red reflector and rear lamp at the rear of the sidecar and at the same height as those on the motor-cycle. (8) Use an ignition-suppression type sparking plug or terminal cover if the machine was registered for the first time after 1. st July, 1953. All the official forms referred to above may be obtained from any money-order post office. See also footnote **, with reference to Forms R.F, 1/A or R.F. 112. You are not eligible for a substantive driving licence for Group G unless you are 16 and have complied with one of these conditions- (a) You have held a licence (other than a provisional or Visitor’s licence authorizing the driving of vehicles of the class or description applied for within a period of ten years ending on the date of coming into force of the licence applied for. (b) You have passed the prescribed driving test (this includes a test passed while serving in H.M. Forces) during the said period of ten years

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1994 TOYOTA SPECIAL SERVICE TOOLS

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Filed Under (Toyota Manuals) by admin on 07-06-2011

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The following TSB contains information regarding the 1994 Special Service Tools (SST’s). Both the Essential and Available SST’s are listed by part number, tool name, model application, illustration / usage (for Essential SST’s only) and appropriate reference in repair manual. All Special Service Tools (SST’s) may be ordered by contacting OTC at 1-800-933-8335.

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YAMAHA CRANKSHAFT LOWER END REMOVAL AND INSTALLATION TOOLS

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Filed Under (Yamaha) by admin on 08-01-2012

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90 LOWER END REMOVAL & INSTALLATION TOOLS SHOP EQUIPMENT & TOOLS 35-8399 35-8513 35-8516 35-8508 35-8504 35-8507 YAMAHA CRANKSHAFT PROTECTORS Sold each. 35-8504 YM-4063-A, XV750/920 Virago, XT550, YFP350, YFM660R Raptor 35-8399 YM-1382, XT250/XT350, RZ350, YFP350, YFZ350 35-8507 YM-33282, XV500 Virago, XZ550 Vision, XVZ12/13 Venture & Venture Royale, VMX12 V-Max 35-8508 YM-38145, XV750/XV1000 Virago YAMAHA CRANKSHAFT INSTALLATION SET Sold as a set. Consists of the following: Qt1-Installing Pot, Qt1-Pot Spacer, Qt1-Bolt. 35-8509 YU-90050 Crankshaft Installation Set OPTIONAL POT SPACERS 35-8513 YU-90070-A, XV750/920 Virago, XT550, TT600 35-8515 YU-91044, YFM350, SRX600, XT550/600 35-8516 YU-1202, SR500, TT/XT500 CRANKCASE PRESSURE TESTER An accurate method for checking possible air leaks on two-stroke engines. Complete with air pressure gauge, pump-up bulb and all fittings and adapters for single and multi-cylinder two-cycle engines. 35-5962 Crankcase Pressure Tester CRANKSHAFT INSTALLING JIG TOOL Supports and centers crankshaft webs while assembling two-stroke engine cases and rebuilding crankshafts. Prevents rod misalignment. Adjustable tang ends. 35-9804 Crankshaft Installing Jig Tool CRANKCASE SEPARATOR TOOL This tool will work on most two and four stroke engines that have a vertically split crankcase. Moveable fingers allow a multitude of bolt patterns to be used so it will work on a variety of models. Includes 6mm and 8mm mounting bolts, center pulling bolt and a three leg frame that is appropriate for many applications. 35-9642 Crankcase Separator Tool 35-9637 Replacement 6mm and 8mm mounting bolts. Each

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Yamaha 2005 R1 Bike Tech Sheet

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Filed Under (Yamaha) by admin on 18-01-2012

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Engine: Type: Liquid cooled, four stroke, transverse four cylinder, DOHC, 5 valves per cylinder. Displacement: 1000cc Year: 2005 Horsepower: 180hp Clutch: PM Exhaust: Vance & Hines Race Exhaust Mufflers: Vance & Hines Frame: Type: Stock Year: 2005 Swing Arm: Performance Machine Chromoly +4 Extended Shocks: Race Tech Modifications: Race Tech Tuned and Lowered. Forks: Stock lowered 2.5″ Rim: Performance Machine Contrast Cut Torque Size: 19″ X 3.0″ Finish: Contrast Cut Fender: None Tire: Dunlop Sportmax D208ZR 120/70ZR19 Brake: Dual Performance Machine 4 piston Radial Calipers Wheels Rear: Rim: Performance Machine Contrast Cut Torque Size: 18″ X 8.5″ Brake: Performance Machine 4 piston Radial Caliper Finish: Contrast Cut Tire: Dunlop Elite3 250/40/R18 Other Parts: Handlebars: Stock Foot Controls: Over Racing Seat: Stock Turn Signals F/R: Anything Extra? Mirrors: Performance Machine Torque chrome Mirrors 19″ FRONT WHEEL! Paint, Chrome, and other F/X’s: Colors: yellow/Black Type: Special Paint: AirTrix Industries The Painter: Chris Wood Powder Coating: A to Z Coatings

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HARLEY DAVIDSON CHROME ON/OFF SWITCH CAP KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION Models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. Models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. 1 2 is0771a 1. Auxiliary accessory housing cover 2. Cover screw (2) Figure 1. Auxiliary Accessory Housing 2. ALL models: If the Auxiliary Accessory Housing Kit and the Rocker Switch(es) ARE NOT already installed on the motorcycle handlebar: a. Proceed to Step 3 of these instructions. Install a chrome switch cap onto each switch before installing the Auxiliary Accessory Housing Kit onto the vehicle. If the Auxiliary Accessory Housing IS already installed on the motorcycle handlebar: a. See Figure 1. Using a T-25 TORX® driver, remove the two screws (2) retaining the Auxiliary Accessory Housing cover (1), and remove the cover. b. See Figure 2. Remove the switch mounting bracket, along with any attached switch(es) and accessories, from the switch housing. Note: it is not necessary to remove the switch from the mounting bracket, or to disconnect the switch wiring to replace the switch caps

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