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Motorcycle Derived Steering / Suspension Systems

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

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1. Examine the handlebars and fork yokes. 2. Turn the steering from lock to lock with the steered wheel both on a turning plate and clear of the ground. Cont’d Reason for Rejection 1. A handlebar or fork yoke a. deformed b. fractured c. cracked d. excessively corroded e. clamps not tight, or any bolt loose or missing f. handgrips missing or not secure to handlebars g. handlebar flexible mounting excessively deteriorated. 2. a. any fouling or restriction of the free movement of the steering from lock to lock b. handlebar grip/s or handlebar mounted control/s have no clearance with any other part of the machine when the steering is placed on either full lock c. steering movement excessively stiff or rough Reason for Rejection 5 does not apply to fork gaiters or shrouds. . Cont’d Method of Inspection 3. Examine the steering damper. 4. Examine the steering head bearings. 5. Examine the front fork assembly. Cont’d Reason for Rejection 3. A steering damper a. insecure b. ineffective c. impairing the steering action. 4. Excessive free play in the steering head bearings. 5. A fork assembly component which is a. missing b. loose c. cracked d. excessively bent, misaligned, corroded, worn, or has excessive free play between the sliding members of the forks, the pivot bearings or bushes e. restricted in operation f. fouling

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STEERING GEAR/ STEERING WHEEL REMOVAL AND INSTALLATION

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Filed Under (Uncategorized) by admin on 05-10-2011

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TEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION Page 3 of 4 STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES (Cont’d) 2. Center spiral cable. a. Turn the cable counterclockwise by hand until it becomes harder to turn. b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4) 3. Install the steering wheel. a. Align the matchmarks on the wheel and steering main shaft. b. Temporarily tighten the wheel set nut. c. Connect the spiral cable connector. 4. Bleed Power Steering System (when applicable). 5. Check steering wheel center point. 6. Torque steering wheel set nut. See the applicable vehicle’s repair manual for the torque specification. 7. Install and center steering wheel pad. NOTICE: Make sure the pad is centered and installed to the specified torque. If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts. a) Connect the airbag wiring connector. b) Install the pad after confirming that torx screws are in the screw case. c) Using a torx socket, torque the screws to the specification in the vehicle’s Repair Manual. (See Fig. 5) d) Install the steering wheel lower cover

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Tacoma Power Steering Pump Improving Power Steering Reservoir modification

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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For my SAS I decided to add hydraulic steering assist as it comes in real handy for rock crawling. I got the Redneck Ram setup from the folks at West Texas Off-road that includes rebuilding an earlier IFS steering box along with drilling and tapping the box for the included ram. One of the down sides of adding a ram is that it slows the steering down because the stock steering pump has to supply the added volume for the hydraulic ram. Another is that it creates a fluid volume change in the system reservoir that needs to be compensated for in some way. After doing some reading on the West Texas site about how to go about modifying a Saginaw pump and reading up on earlier Toyota pump mods for steering assist setups on the Pirate board, I decided to give it whirl and see what I could do about the Tacoma pump. Chuck Gardella was kind enough to supply me with a blown pump that I could rebuild and submit to my endless fiddling and tinkering. I plan to give him my pump in return when I get this one done and installed. You need to do something to allow for more room in the reservoir for the standard hydraulic ram assist setup so I decided to tackle the reservoir first. The reason you need the extra space is because the ram is unbalanced. That is there is a rod on one side of the cylinder and not on the other side so the volume of the fluid has to change in the system to account for the volume of the rod as it travels back and forth. I calculated the volume of the rod that I have at full stroke to be about 2 oz or so. This would equate to plus or minus up to 2 oz. in the pump reservoir. Well first off, it’s no wonder why so many folks boil their steering pumps over with heavy wheeling and have so many other steering problems. The stock power steering reservoir doesn’t even rate pint sized

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Vengeance Motorcycle Specification And Owner's Manual

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Filed Under (Vengeance) by admin on 20-11-2010

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Vengeance Maxis • Vengeance Raven • Vengeance Banshee • Vengeance Whiplash • Hotrod Drifter • Hotrod CalChop • Hotrod Teacher • Hotrod Bone Shifting Gears Starting off and changing gears requires coordination of the clutch and throttle and gearshift lever. If you don’t do things right, the amount of control you have over the bike is lessened. To start off, pull in the clutch, shift into first gear, roll on the throttle a little, and ease out the clutch. You will become familiar with the friction zone (that’s where the clutch begins to take hold and move the bike), and you add a bit more throttle. You don’t want to stall the engine, nor do you want to over-rev it. There’s a sweet spot in there; find it. Shift while traveling in a straight line. Shifting in a curve is not good practice, and something to be avoided. Become familiar with the sound of your engine, so you can tell when you should shift without looking at your instruments. When you downshift to a lower gear, you should (in one swift, smooth movement) be able to squeeze the clutch, rev the engine a little to let it catch the lower gear smoothly, and shift down. When you come to a stop in traffic, leave the bike in first gear with the clutch disengaged (just in case you want to accelerate out of there in a hurry). Who knows what may be coming up behind you. Braking Don’t ever forget: The front brake on your motorcycle can supply as much as 70 percent or more of your stopping power. The single most important thing you can learn about braking is to use that front brake every single time you want to slow down. Turning When you are riding along the road, you lean a motorcycle into a turn. Learning to lean is an essential part of riding a motorcycle. It is a normal function of the bike when you are changing its path of travel – and quite different from turning the steering wheel of your car. To get the motorcycle to lean in a normal turn, press the handlebar in the direction of the turn and maintain slight pressure on that handlebar to take you smoothly through that particular turn. In other words: press right to go right; press left to go left. Your instincts to keep the motorcycle on a smooth path while keeping it from falling over usually take care of this without you even noticing it. (Demonstrate to yourself how a motorcycle moves by pressing a handlebar slightly while traveling in a straight line. The motorcycle will move in the direction of the handlebar you pushed.) • Slow down before you enter the turn; look as far ahead as possible through the turn. • Keep your feet on the pegs, and grip the gas tank with your knees. • Lean with the motorcycle; don’t try to sit perpendicular to the road while the motorcycle is leaning over. • Keep an even throttle through the turn, or even accelerate a little bit. Checking the Bike before the Ride It’s not fun to have things go wrong on a motorcycle, but if you spend a minute before you go off on a ride, you can increase the chances that nothing will.

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YAMAHA XVS650/ XVS650A OWNER’S MANUAL

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Filed Under (Yamaha) by admin on 27-04-2011

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INSTRUMENT AND CONTROL FUNCTIONS Main switch/Steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00038 OFF All electrical circuits are switched off. The key can be removed in this position. EAU00040 LOCK The steering is locked in this position and all electrical circuits are switched off. The key can be removed in this posi- tion. To lock the steering, turn the handlebars all the way to the left. While pushing the key into the main switch, turn it from “OFF” to “LOCK” and remove it. To release the lock, turn the key to “OFF” while pushing. EW000016 WARNING Never turn the key to “OFF” or “LOCK” when the motorcycle is moving. The electrical circuits will be switched off which may result in loss of control or an accident. Be sure the motorcycle is stopped before turning the key to “OFF” or “LOCK”. 1. Push 2. Turn EAU00044 (Parking) The steering is locked in this position and the taillight comes on, but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to “ ”. Do not use this position for an extended length of time as the battery may discharge

HARLEY DAVIDSON FRONT BRAKE DISC LOCK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION Do not operate vehicle with brake disc lock in place. Operation with lock on disc will restrict movement of the wheel, which could result in death or serious injury. (00457b) NOTE Insert key all the way to the bottom of the cylinder. Turn key clockwise 180 degrees to the open position. DO NOT FORCE KEY! Key should turn freely. If key does not freely rotate, try turning key slightly left and right while inserting to align disks inside cylinder. Failure to insert key all the way to the bottom of cylinder could cause key to jam. For Models with Hydraulic Fork Front Ends 1. See Figure 1. Insert reminder cord (3) into slot on disc lock (1). 2 1 3 is 01599 1. Lock 2. Caliper 3. Reminder cord Figure 1. Installing Disc Lock 2. Slide lock (1) over front brake disc as close to rearward edge of brake caliper (2) as possible. Push button completely down to lock. 3. Roll motorcycle forward slowly until lock gently contacts caliper. 4. See Figure 3. After installing disc lock, place loop end (1) of reminder cord (2) over handlebar grip. For Models with Springer Front Ends 1. See Figure 2. Insert reminder cord (5) into slot on disc lock

K-Drive Click & Lock Saddlebag sets for Triumph Bonneville America And Speedmaster

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Filed Under (Triumph) by admin on 06-11-2010

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Each saddlebagsset is supplied in an individual packing, containing : – 1 pair of click & lock saddlebagsupports; – 1 pair of saddlebags with our clicksystem mounted on the rigid backside of the bags; – All necessary bolts; – 2 keys to lock the bags to the supports. (lock is at the inside of the bags) – 2 keys to lock the bags (only CL bags) . K-Drive Click & Lock saddlebags are fixed to the saddlebagguards by means of a lockable clicksystem. This “Click & Lock” system has many advantages: – Our bags are easily mounted and removed in just a few seconds. – The bags themselves are locked to the motorcycle with a key. – The bags don’t touch the bike and therefore don’t damage it. – They can also be attached to motorcycles without a duo saddle. – As the bags are made specifically (or adapted) for a model, every bag we manufacture fits perfectly. – Our saddlebag holders are discreet, following the contour of the motorcycle, and are perfectly chromed K-Drive is a trademark of Vartex bvba * Iparex is a very strong synthetic leather, made following our technical specifications. It has a luxury leatherlook and is one of the best materials for saddlebags. It is strong, waterproof and don’t need any maintaining. To clean it, just use water, eventually with a light natural soap. Never use any product that is meant for leather, it may harm the Iparex. K-Drive Click & Lock saddlebags are completely reinforced : – Backside : made of a strong hdpi plate; – Upper side, sides and bottom are reinforced with PVC at the inside : – Side flaps are closed with velcro for better protection against the rain. Click & Lock saddlebags have discrete “sliding” grips All buckles, logo & decorative studs are made of “zamack”. A material which is 100% rustfree For maximum protection against the rain, the sideflaps are closed with Velcro

K-Drive removable Click & Lock Saddlebag sets for Kawasaki VN1500/ 1600 Mean Streak

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Filed Under (Kawasaki) by admin on 05-11-2010

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Each saddlebagsset is supplied in an individual packing, containing : – 1 pair of click & lock saddlebagsupports; – 1 pair of saddlebags with our clicksystem mounted on the rigid backside of the bags; – All necessary bolts; – 2 keys to lock the bags to the supports. (lock is at the inside of the bags) – 2 keys to lock the bags (only CL bags) . K-Drive Click & Lock saddlebags are fixed to the saddlebagguards by means of a lockable clicksystem. This “Click & Lock” system has many advantages: – Our bags are easily mounted and removed in just a few seconds. – The bags themselves are locked to the motorcycle with a key. – The bags don’t touch the bike and therefore don’t damage it. – They can also be attached to motorcycles without a duo saddle. – As the bags are made specifically (or adapted) for a model, every bag we manufacture fits perfectly. – Our saddlebag holders are discreet, following the contour of the motorcycle, and are perfectly chromed K-Drive is a trademark of Vartex bvba * Iparex is a very strong synthetic leather, made following our technical specifications. It has a luxury leatherlook and is one of the best materials for saddlebags. It is strong, waterproof and don’t need any maintaining. To clean it, just use water, eventually with a light natural soap. Never use any product that is meant for leather, it may harm the Iparex. K-Drive Click & Lock saddlebags are completely reinforced : – Backside : made of a strong hdpi plate; – Upper side, sides and bottom are reinforced with PVC at the inside : – Side flaps are closed with velcro for better protection against the rain. Click & Lock saddlebags have discrete “sliding” grips All buckles, logo & decorative studs are made of “zamack”. A material which is 100% rustfree For maximum protection against the rain, the sideflaps are closed with Velcro

YAMAHA FZ1 SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 07-11-2010

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INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU26900 ON All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. WARNING EWA10060 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. 1. Push. 2. Turn. 1. Push. 2. Turn.
INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on. EAU11250 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The

Yamaha YZF R1 SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 07-11-2010

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INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10600 ON All electrical circuits are supplied with power, the meter lighting, taillight, license plate light, auxiliary lights and position lights come on, and the engine can be started. The key cannot be re- moved. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. 1. Push. 2. Turn. INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. WARNING EWA10060 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on. EAU11250 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction

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