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HONDA ATV Carburetor Repair Kits Installation

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Filed Under (Honda) by admin on 21-12-2011

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ATV Carburetor Repair Kits Complete kits to rebuild one OEM carburetor. Each kit contains necessary gaskets/o-rings, needle valve or needle valve set, and jets. Made in Japan. Note: Check all parts before installation. Honda Model Year Order No AT C70 78-85 025-001 AT C90 70-71 025-003 ATC90K1/K2/K3 72-75 025-003 AT C90 76-78 025-003 TRX90 Fourtrax 90 93-98 025-084 ATC110 79-83 025-005 ATC110 84-85 025-061 ATC125M 84-85 025-062 TRX125 Fourtrax 85-86 025-050 TRX125 Fourtrax 87-88 025-063 ATC185 1980 025-009 ATC185S 81-83 025-009 AT C200 81-82 025-008 AT C200 1983 025-009 ATC200E Big Red 82-83 025-064 ATC200ES Big Red 1984 025-064 AT C200M 84-85 025-064 AT C200S 84-86 025-065 AT C200X 83-85 025-012 AT C200X 86-87 025-014 TRX200 Fourtrax 200 90-91 025-066 TRX200D Fourtrax 200 Type II 1991 025-066 TRX200D Fourtrax 200 Type II 92-93 025-067 TRX200D Fourtrax 200 Type II 94-97 025-068 TRX200SX Fourtrax 87-88 025-069 ATC250R 81-82 025-017 ATC250R 83-84 025-018 AT C250R 1985 025-019 ATC250ES Big Red 85-87 025-029 AT C250SX 1985 025-070 TRX250 Fourtrax 250 1985 025-071 TRX250 Fourtrax 250 86-87 025-072 TRX250EX Sportrax 250EX 01-04 025-085 TRX250R Fourtrax 250R 86-87 025-060 TRX250R Fourtrax 250R 1988 025-073 TRX250X 91-92 025-074 TRX300 Fourtrax 300 1988 025-075 TRX300 Fourtrax 300 91-92 025-076 TRX300 Fourtrax 300 93-95 025-078 Honda Model Year Order No TRX300EX Fourtrax 300EX 93-98 025-081 TRX300FW Fourtrax 300 4×4 1988 025-075 TRX300FW Fourtrax 300 4×4 91-92 025-076 TRX300FW Fourtrax 300 4×4 93-95 025-078 AT C350X 1985 025-035 TRX350 Fourtrax 4×4 86-87 025-079 TRX350FE Fourtrax Rancher 4×4 ES 00-03 025-082 TRX350FM Fourtrax Rancher 4×4 00-03 025-082 TRX350TE Fourtrax Rancher ES 00-03 025-082 TRX350TM Fourtrax Rancher 00-03 025-082 TRX350D Fourtrax Foreman 4×4 87-89 025-079 TRX400FW Fourtrax Foreman 95-00 025-080 TRX450ES Fourtrax Foreman ES 98-01 025-083 TRX450FE Fourtrax Foreman ES 02-03 025-083 TRX450FM Fourtrax Foreman S 02-03 025-083 TRX450S Fourtrax Foreman S 98-01 025-083 TRX500FAFourtrax Rubicon 01-04 025-086

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1998 YAMAHA YZF-R6 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max. camshaft runout Chain drive (right) 23.000 23.021 mm 22.967 22.980 mm 0.020 0.054 mm 33.05 33.15 mm 25.14 25.24 mm 7.81 8.01 mm 32.55 32.65 mm 25.07 25.17 mm 7.38 7.58 mm 0.08 mm 33.0 mm 25.09 mm 32.50 mm 25.02 mm 0.06 mm
2-5 ENGINE SPECIFICATIONS SPEC Head Diameter Face Width Seat Width Margin Thickness Item Standard Limit Timing chain Model/number of links Tensioning system RH2015/120 Automatic Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions 0.11 0.20 mm 0.21 0.30 mm Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 24.9 25.1 mm 21.9 22.1 mm 1.14 1.98 mm 1.14 1.98 mm 0.9 1.1 mm 0.9 1.1 mm 0.6 0.8 mm 0.6 0.8 mm 3.975 3.990 mm 3.960 3.975 mm 4.000 4.012 mm 4.000 4.012 mm 0.010 0.037 mm 0.025 0.052 mm 0.9 1.1 mm 0.9 1.1 mm 1.6 mm 1.6 mm 0.5 mm 0.5 mm 3.950 mm 3.935 mm 4.042 mm 4.042 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm
2-6 ENGINE SPECIFICATIONS SPEC Item Standard Limit Valve springs Free length Intake (inner) (outer) Exhaust Installed length (valve closed) Intake (inner) (outer) Exhaust Compressed spring force (installed) Intake (inner) (outer) Exhaust Spring tilt Intake (inner) (outer) Exhaust Winding direction (top view) Intake Exhaust 37.0 mm 38.4 mm 41.7 mm 30.0 mm 32.5 mm 36.1 mm 69 79 N (7.0 8.0 kgf) 114 132 N (11.6 13.4 kgf) 160 184 N (16.3 18.7 kgf) Clockwise Clockwise 35 mm 36.5 mm 39.5 mm 2.5/1.6 mm 2.5/1.7 mm 2.5/1.8 mm Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max. taper Max. out-of-round Forward-inclined, parallel 4-cylinder 65.5 45.5 mm 12.4 : 1 65.50 65.51 mm 0.05 mm 0.05 mm

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Ural Motorcycle Repair Manual

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

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FLUID CAPACITIES TOURIST & -10 Models Sportsman Solo Gasoline tank 19 L / 5 Gal 19L / 5 Gal 18.5 L / 4.9 Gal Reserve 2L / 0.5 gal 2L / 0.5 gal 2L- / 0.5 Gal Engine crankcase 2 L / 2 qt. + 3.6 oz. 2.0L / 2.11 qt 2 L / 2 qt. + 3.6 oz. Gearbox 0.9L / 1 qt 0.9L / 1 qt 0.9L / 1 qt Final drive 110 ml / 3.85 oz. 150 ml / 5.25 oz. 110 ml / 3.85 oz. Telescopic Forks (-10 & solo models) N/A on Tourist N/A on Sportsman 135 ml / 4.56 oz. Shock Absorbers 105 ml / 3.55 105 ml / 3.55 oz 105 ml / 3.55 oz
RUNNING GEAR TOURIST / SPORTSMAN SOLO Frame Tubular welded Rear wheel suspension Swing arm with hydraulic spring shock absorbers Sidecar: same as -40 Solo: Lower spring rate Front fork Leading link Telescopic spring Sidecar Cushioned body (on rubber cushions) and wheel on long-lever suspension with hydraulic spring shock absorber N/A Brakes Shoe-type with mechanical drive on front, rear and sidecar wheels, front wheel has dual cams. Tires 4″ x 19″ Front & Side: 22 psi cold Rear: 36 psi cold 3.5″ x 18″ Solo: Front 25 psi cold Rear: 32 psi cold -10′s: Front & side: 25 psi cold Rear: 36 psi cold CLEARANCES mm in Valves with engine cold 0.05 0.002 Between spark plug electrodes 0.50 – 0.65 0.020 – 0.026 Between brake shoes and drum 0.3 – 0.70 0.012 – 0.028 Backlash between tooth faces of bevel gears in final drive 0.1 – 0.3 0.004 Between rotor and ignition pickup 0.3 – 0.4 .012 – .016 FREE TRAVEL / ADJUSTMENTS mm in Hand brake control lever 5 – 8 0.2 – 0.3 Clutch control lever 5 – 8 0.2 – 0.3 Foot brake drive pedal ¼ of full stroke of pedal, 25 – 30 1.0 – 1.2 Toe-in throughout motorcycle center distance (exception: Sportsman 0 ° toe-in) 10 N/A Angle of motorcycle inclination to vertical plane (camber angle of rear wheel) 1° away from sidecar N/A Headlight installation (with motorcycle laden) horizontal (high beam) TORQUE SPECIFICATIONS Metric (in repair manual) US Equivalent Location on Bike 29 to 33 Nm 22 ft/lb. to 30 ft/lb. cylinder heads 22 to 25 kgf-m 175 ft/lb. to 185 ft/lb. fly wheel tightening screws 3.8 to 4.2 kgf-m 30 ft/lb. to 40 ft/lb. cylinder 2.1 to 3.0 kgf-m top 14 ft/lb. to 22 ft/lb. shock absorber 3.6 to 5.0 kgf-m bottom 28 ft/lb. to 36 ft/lb. shock absorber 3.0 to 3.4 kgf-m 22 ft/lb. to 26 ft/lb. bearing nut 3.0 to 3-4 kgf-m 22 ft/lb. to 26 ft/lb. final drive to swing arm bolts 1.6 to 1.8 kgf-m 12 ft/lb. to 14 ft/lb. oil pump bolt .8 to 1.0 kgf-m 5 ft/lb. to 8 ft/lb. engine sump 1.4 to 1.8 kgf-m 10 ft/lb. to 14 ft/lb. final drive case nuts 7 to 9 kgf-m 50 ft/lb. to 66 ft/lb. nut fastening the pinion bearing 2.2 to 2.8 kgf-m 16 ft/lb. to 20 ft/lb. reverse gear brake lever 1.8 to 2.0 kgf-m 14 ft/lb. to 16 ft/lb. generator gear nut 14.0 to 16.8 kgf-m 100 ft/lb to 120 ft/lb steering stem nut CONVERSIONS To convert from mm to in, divide by 25.4 (there are 25.4 mm per inch). To convert from liters to gallons, divide by 3.785 (there are 3.78 liters per gallon). To convert from liters to quarts, multiply by 1.056 (there are 1.056 quarts per liter). To convert from liters to pints, multiply by 2.112 (there are 2.112 pints per liter). To convert from km to miles, multiply by .62 (there is .62 mile per km). To convert from km/hr to mph, multiply by .62. To convert from Newton-meter (Nm) to inch-pound, multiply by 8.86. To convert from cm 3 (cc) to pints, divide by 473 (there are 473 cc per pint). To convert Celsius to Fahrenheit, F° = C° x 1.8 = 32°. To convert Fahrenheit to Celsius,C ° = (F° – 32° ) divided by 1.8

Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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HONDA CR 500R/ 500AF Hi Power Digital Ignition AND Light Coil Installation Instructions

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Filed Under (Honda) by admin on 16-12-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI. 6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator.
10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 kg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012″. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012″. Use a good/no good technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap. 15. If the pulser gap needs to be adjusted loosen the pulser mounting bolts adjust the pulser up or down as needed

CR500R/ 500 AF Hi Power Digital Ignition & Light Coil Installation Instructions

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Filed Under (Honda) by admin on 19-11-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI.b6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator. 10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on
the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 bkg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012”. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012”. Use a good/no good
technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap

Yamaha XVS 650AN Supplementary Service Manual

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Filed Under (Yamaha) by admin on 15-12-2010

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MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in) -4- MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer 182 222 Ω at 20C (68F)/Gray – Black J4T088/MITSUBISHI (U.S.A) J4T128/MITSUBISHI (CAL) Ignition coil: Model /manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance F6T541/MITSUBISHI 6 mm (0.24 in) 3.6 4.8 Ω at 20C (68F) 10.7 14.5 kΩ at 20C (68F) Voltage regulator: Type Model /manufacturer No load regulated voltage Semi-conductor, short-circuit type SH650C-11/SHINDENGEN 14.1 14.9 V Rectifier: Model /manufacturer Capacity Withstand voltage SH650C-11/SHINDENGEN 18 A 200 V Electric starter system: Type Starter motor: Model /manufacturer I.D. number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model /manufacturer Amperage rating Constant mesh type SM-13/MITSUBA SM-13 0.7 kW 10 mm (0.39 in) 28 mm (1.10 in) 0.7 mm (0.08 in) MS-5F-441/JIDECO 180 A 4 mm (0.16 in) 27 mm (1.06 in) Flasher relay: Type Model /manufacturer Self cancelling device Flasher frequency Wattage Semi transistor type FB257H/DENSO Yes 75 95 cycle/min 27 W 2 + 3.4 W Fuel pump relay: Model /manufacturer G8R-30Y-Q/OMRON

Bridgestone 350 SPECIFICATION AND SERVICE MANUAL

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Filed Under (Bridgestone) by admin on 03-12-2010

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Engine ( 1 ) Type : ( 2 ) Piston Displacement : ( 3 ) Bore & Stroke : ( 4 ) Compression Ratio : ( 5 ) Max. Brake Horse Power ( 6 ) Max. Torque : ( 7 ) Air Intake System : ( 8 ) Starting System : ( 9 ) Charging System : (10) Ignition System: (11) Ignition Timing: (12) Spark Plug: (13) Carburetor: (14) Engine Lubrication: (15) Fuel: (16) Transmission Oil: Performance ( 1 ) Max. Speed : ( 2 ) Climbing Ability : ( 3 ) Fuel Consumption : ( 4 ) Min. Turning Radius : ( 5 ) Acceleration : (Standing Start 1/4 mile) (Zero to 60 mph) : ( 6 ) Braking Distance : Frame and Suspension (1) Frame: (2) Front Suspension: (3) Rear Suspension: 2-stroke, Dual Cylinders 344.9cc (21.5 cu-inches) 61 mm × 59 mm (2.40 × 2.32 inches) 9.31:1 40 HP/7500 rpm 4.0 kg-m/7000 rpm Rotary disc valve Kick Starter A. C. Generator Contact breaker gap : 0.3 – 0.4 mm (0.012 – 0.016 inches) Battery (25+1-2) degrees before T.D.C. N.G.K. B-8H, Electrode gap : 0.6 mm (0.024 inches) Type AMAL VM 26 SC Venturi: 26 mm Main Jet No.: 130 Throttle Valve Cut Away: 2.0 Air Jet : 2.0 Adjustment of Needle Jet : 0.6 Pilot Jet: 22.5Pilot Air Screw Position: 2 turns out Needle Position: 3 2 cycle oil Regular Gasoline 1.5 liter (2/5 US gal.) in transmission case SAE No. 10W/30 in all seasons or SAE No. 30 in summer and SAE No. 20 in winter 100-110 mph 1 in 2 94 mpg/25 mph (40 km/litre at 40 km/h) 2.25 m (7.38 feet) 13.7 sec 5.2 sec (Less than 12m at 50 km/h) 39 feet, at 30 mph Pipe Frame, Cradle Type Telescopic Fork with Hydraulic Damper Swinging Arm with Hydraulic Damper
Technical Data 2 Transmission ( 1 ) Clutch : ( 2 ) Transmission : ( 3 ) Gear Ratio : Dimensions and Weight ( 1 ) Overall Length : ( 2 ) Overall Width : ( 3 ) Overall Height: ( 4 ) Saddle Height : ( 5 ) Wheelbase: ( 6 ) Road Clearance : ( 7 ) Tire Size (Front) : (Rear): ( 8 ) Tire Pressure (Front) : (Rear): ( 9 ) Caster : (10) Trail: (11) Banking Angle: (12) Net Weight: (13) Fuel Tank Capacity: (14) Oil Tank Capacity : Electrical Equipment ( 1 ) Head Light : ( 2 ) Tail Light : ( 3 ) Stop Light : ( 4 ) Speedometer Lamp : ( 5 ) Tachometer Lamp : ( 6 ) Neutral Indicator Lamp : ( 7 ) 5th Gear Indicator Lamp : ( 8 ) Headlight High Beam Lamp : ( 9 ) Battery : Manual, Multiple discs, Dry type Constant mesh 6-speeds Primary (Helical Gear) 1:3.095 Gear Box: 1st 1:2.46 2nd 1:1.647 3rd 1:1.25 4th 1:1.00 5th 1:0.852 6th 1:0.759 Secondary (Chain) : 1:2.40 Total Gear Ratio : 1st 1:18.27 2nd 1:12.23 3rd 1:9.29 4th 1:7.43 5th 1:6.33 6th 1:5.64 2,110 mm (83.1 inches) 825mm (32.5 inches) 1,115 mm (43.9 inches) 810mm (31.9 inches) 1,375 mm (54.1 inches) 145 mm (5.7 inches) 3.25-19 4 ply 3.25-19 4 ply 2.0kg/cm2 (28-30 lbs/in2) 2.2 kg/cm2 (30-32 lbs/in2 ) 63° 105 mm (4.15 inches) 46° 165 kg (363 lbs) 15 litre (3-4/5 US gal.) Including 3.2 litre (4/5 US gal.) reserve 2.5 litre (3/5 US gal.) 12V-35/30W 12V-7W 12V-23W 12V-3W 12V-3W 12V-3W

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2003 COBRA PW3 Owners And Service Manual

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Filed Under (Cobra) by admin on 14-11-2010

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Specifications – General Items PW3 Dimensions Wheelbase 35.75″ (908mm) Wheel size 10″ (254mm) Seat height 22″ (559 mm) Stock #TCHO0001 23.9″ (607 mm) Optional #TCHJ0001 Engine Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm Ignition system Digital Electronic Spark plug Champion C53, NGK B11EGV Gap 0.023″ – 0.025″ (0.58 – 0.64 mm) Fuel type Sunoco MO2 X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Injector oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios Fill oil reservoir as required Ignition timing Fixed Carburetion 12 mm Dell’Orto PHVA – PS Main jet 82 Slow (Pilot) jet 42 Float height 5 mm + 0.3mm (0.2″ + 0.012″) Transmission Speed Single Clutch 3 shoe centrifugal Final drive ratio 10/46 T Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 250 ml (8.5oz) 5 Chassis Front tire 2.50 – 10 Pressure 15 psi minimum Rear tire 2.75 – 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Marzocchi 32mm Fork oil type SAE 20 weight Fork oil amount 200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild Fork oil height 70 mm (2.75″) collapsed from top with spring (no spacer) Specifications – Torque Values

KAWASAKI KLX 140 160cc BORE KIT INSTALLATION INSTRUCTIONS

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

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Engine assembly requires special attention to detail. Your cylinder must be bored to fit this new piston. For long engine life it is very important that the cylinder bore is professionally machined to be very round and without taper. Piston-to-Cylinder Clearance: .002″ Ring End Gap: .007″ – .012″ Once the cylinder is bored to size, installation of this piston kit is identical to OEM installation. Please refer to the Kawasaki shop manual or a qualified mechanic for assistance.The side of the piston marked EX should go toward the exhaust port. Coat both sides of copper gasket with a quality gasket sealer. (Gasgacinch or comparable product) Every effort has been made to insure the quality of this product. Because BBR cannot control the installation or use there is NO warranty or guarantee with this product. Using quality motorcycle oil will help prolong engine life. Be sure to change it often. Recommended main jet: 100 Main (at sea level, 65 degrees) Recommended Fuel: 91-93 octane pump fuel

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