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2008 KAWASAKI KL650A8F: KLR 650 General And Tuning Engine Specifications

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

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Engine Type 4-stroke, Inline, 1-cylinder, DOHC, Liquid cooled Displacement 651 cc Bore x Stroke 100.0 x 83.0 mm Compression Ratio 9.8:1 Maximum Torque 36.9 lb-ft at 5,500 rpm Carburetor Keihin CVK40, Constant velocity, Diaphragm-type Ignition System Magneto CDI (Rotor) Ignition Advance Electronic Crankshaft Rotation Clockwise from ignition (RH) side Cylinder Material Aluminum alloy with ferrous sleeves Fuel Min 91 Research/87 Avg. Oct. Unleaded OK Coolant 50% distilled water/50% ethylene glycol base antifreeze —Capacity 1.05 L (1.1 qt.) —Level Level with radiator filler neck. Transmission Clutch Type Wet, Multi-disc, Manual Transmission 5-speed, Constant mesh, Return shift Shift Pattern(Bottom up) 1-N-2-3-4-5 Gear Ratios —1st 2.27 (34/15) —2nd 1.44 (26/18) —3rd 1.14 (25/22) —4th 0.95 (21/22) —5th 0.79 (19/24) Primary Ratio 2.28 (75/33) Final Ratio 2.87 (43/15) Overall Ratio (Top Gear) 5.157 Chassis Wheelbase 1,480 mm (58.3 in.) Seat Height 890 mm (35.0 in.) Ground Clearance 210 mm (8.3 in.) Dry Weight 175 kg (386 lb.) Fuel Tank Capacity 22.1 L (5.8 gal.) Tire Size —Front 90/90-21 54S —Rear 130/80-17 65S Brake Type —Front Single Hydraulic Disc —Rear Single Hydraulic Disc Brake Size —Front 254 mm Effective Diameter —Rear 212 mm Effective Diameter Wheel Travel —Front 206 mm (7.9 in.) —Rear 185 mm (7.3 in.) Model Identification Year & Model ’08 KL650A8F:KLR 650 Color 1. Blue 21 (S8) 2. KMT. Candy Lime Green (175) 3. Sunbeam Red (H1) VIN Range JKAKLEE1 * 8DA00101 — Engine No. Range KL650AE007501— Engine No. Location RH top crankcase, below carburetor Tuning Specifications Engine Valve Clearance (Cold) Intake: 0.10-0.20 mm Exhaust: 0.15-0.25mm —Adjustment Method Shim on tappet Spark Plug NGK DPR8EA-9 or ND X24EPR-U9 —Gap 0.8-0.9 mm Ignition Timing 10.0° BTDC (“F” mark) at 1300 rpm 30.0° BTDC (In double marks) at 3300 rpm Pilot Screw Sealed—not adjustable Idle Speed 1300 ±100 rpm Engine Oil API SE, SF, or SG, API SH or SJ of JASO MA Class, 10w40 —w/Filter Change 2.5 L —No Filter Change 1.7 L —Level On center stand, wait 5 min, middle of window —Pressure (Hot) 2.0-2.5 kg/cm2 at 4,000 rpm, 90° C Chassis Fork Oil SAE 10W20 —Capacity 581 – 589 cc dry —Level 170 ±2 mm (fork compressed, spring removed) Fork Air Pressure (Cold) 0.0 kg/cm2 , max 2.5 kg/cm2 Tire Pressure (Cold) —Front 22 psi, change for course and rider preference —Rear 22 psi, change for course and rider preference Drive Chain Slack 35-45 mm (on center stand, tightest point, STD)

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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

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Harley-Davidson FLTR/ FLH/ FLHT/ FLHR EFI models 1995-2001 Variable Pressure Fuel Regulator Intallation manual

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1 . Ensure vehicle runs correctly through all rpm ranges and idles correctly before attempting any work. It is highly recommended that a pressure / flow test be carried out before & after installation of the VariReg to determine fuel system condition . Stock HD 300 kPa / 44 psi, VariReg as delivered 360 kPa / 52 psi Note: In some countries gas stations do not “final filter” the fuel & therefore we recommend that the fuel filter canister be replaced every 15,000 klms (10,000 miles). Restriction of the fuel by way of a blocked or partially blocked filter will result in difficulty in tuning or failure to obtain satisfactory results during tuning. Should you experience difficulties in tuning, see Diagnosing fuel filter and pump faults 2. Remove air filter cover, air filter and backing plate. Check Throttle Position Sensor value at completely closed throttle as best performance will be obtained at the nominated settings. This will require backing off the idle screw and cold start idle actuator and screw adjustment as described in the workshop manual. The original T.P.S. values should be recorded for possible future reference. To set TPS values without the HD breakout box see VariReg TPS Setting for Harley-Davidsons The T.P.S. values must be set to 1995 – 1996 175 mV (+/- 25mV) 1997 – 2001 275 mV (+/- 25mV) Record the original TPS value here. ………………..mV YOU MUST ENSURE THROTTLE PLATES ARE COMPLETELY CLOSED AND NO BINDING EXISTS IN CABLES to obtain the correct value setting. 3. Reset idle screws to approximate previous settings, no need to start the engine. 4. Complete full or partial fuel tank removal as described in workshop manual. 5. Remove stock fuel pressure regulator as described in workshop manual and leave Horn removed from vehicle until after tuning, this will allow ease of access to the regulator

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YAMAHA YZF-R1 engine TechnicaL Specification

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

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The 2006 model runs with the same 998 cc liquid-cooled 4-stroke DOHC 4-cylinder 5-valve layout featuring a 77 x 53.6 mm bore and stroke and 12.4:1 compression ratio. Equipped with a 3-axis transmission, fuel injection and 40 degree forward slanted cylinders, this ultra-compact powerplant is one of the most highly respected supersport engines of all time. Yamaha’s engineers have conducted a thorough examination of the R1′s intake and exhaust efficiency, and for 2006 a range of detailed changes in this area have achieved a 3 Hp increase in power at 12,500 rpm without direct air induction. One of the most significant changes is the use of shorter intake valve guides for 2006. Measuring 27.5 mm, these new guides are 5 mm shorter than the 2005 model, and this 15% reduction in length increases engine efficiency by increasing intake air flow, and reducing frictional power losses. To match the new intake valve guides, the 2006 model also features smoother intake ports. Furthermore, the clutch boss has been modified to increase the oil flow to the clutch assembly. other detail changes The design of the compact cam chain tensioner has been revised, and now features a different sealing system for improved durability. The overall length of the main gear axle is increased by 5 mm, and the engine cover is modified accordingly. engine TechnicaL highLighTS n 998 cc liquid-cooled 4-stroke DOHC 4-cylinder 5-valve n 3 hp power increase to 175 Hp @ 12,500 rpm* n 40 degree forward incline cylinder n Fuel injection n Ultra compact 3-axis transmission n 77 x 53.6 mm bore and stroke n 12.4:1 compression ratio n New smoother intake port design n New shorter intake valve guides n Higher intake and exhaust efficiency n Modified cam chain tensioner n Redesigned clutch boss * Without direct air induction
chaSSiS The R1′s Deltabox V chassis has been developed with the benefit of ongoing structural analysis and repeated testing, all the time using input from our highly successful MotoGp race programme. For 2006 the R1′s class-leading aluminium Deltabox V frame remains externally similar to the existing model, but beneath the skin some subtle yet significant changes have taken place

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BMW K 1300 S, K 1300 R and K 1300 GT SPECIFICATION

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Filed Under (BMW) by admin on 17-11-2010

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The K 1300 S with 175 hp, the K 1300 R with 173 hp and the K 1300 GT with 160 hp. The new K bikes feature updated transmission and clutch assembly, plus smoother engine performance and new switchgear. Von Kuenheim continues: “By raising capacity to 1300 cc, our engineers have not only increased output but also torque on all three models. At the same time the driveline was intensively revised from air/fuel mixture formation right through to the exhaust system. In this way we have been able to optimize partial load behavior as well as throttle response. Now the clutch can be operated with even less effort and with greater refinement. Shifting has been improved tangibly due to constructional changes to the gearbox and drive.” BMW is introducing new options for the 2009 as well. The popular Electronic Suspension Adjustment that first appeared on the 2005 K 1200 S has now been updated with even more on-the-fly adjustability and it’s called ESA II. Also new is the quick-shifter option, racing-style gear shift assistant, borrowed from BMW’s race-ready HP2 Sport. Automatic Stability Control (ASC) is also offered as an option on the new K bikes. “Both the K 1300 S and also the R will also have the shift assistant – familiar from the HP2 Sport – available as an option for the first time,” von Kuenheim emphasized. “We have also advanced the chassis. The new lower longitudinal strut is now made of aluminum and is thus considerably lighter. This makes the front wheel guidance response even more sensitive. The result of this comprehensive development work is superior handling, improved rideability and lower fuel consumption. The electronically adjustable suspension – called ESA in short – was launched as a world first on the K 1200 S. Now we are presenting the new, well-proven ESA II as an option for the K Series. Apart from the suspension and damping this unique system also allows the spring rate to be adjusted at the press of a button. The K Series model revision also heralds a new and innovative generation of switches and controls.

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HONDA CT110 OWNERS MANUAL

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Filed Under (Honda) by admin on 22-04-2011

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ENGINE OIL Engine Oil Level Check Check the engine oil level each day before riding the motorcycle. The level must be maintained between the upper (2) and lower (3) marks on the dipstick (1). 1. Start the engine and let it idle for a few minutes. 2. Stop the engine and hold the motorcycle in an upright position on firm, level ground. 3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the dipstick without screwing it in. The oil level should be between the upper and lower marks on the dipstick. 4. If required, add the specified oil up to the upper level mark. Do not overfill. 5. Reinstall the oil filler cap/dipstick, check for oil leaks. CAUTION Running the engine with insufficient oil can cause serious engine damage. TYRES Proper air pressure will provide maximum stability, riding comfort and tire life. Check tire pressure frequently and adjust if necessary. NOTE Tire pressure should be checked before you ride while the tyres are cold. Select the right replacement tire in accordance with the following specifications: Cold tire pressures kPa ( kg/cm2, psi ) Front: 175 ( 1.75, 25 ) Rear : 225 ( 2.25, 33 ) Tire size Front: 2.75 – 17 41P Rear : 2.75 – 17 41P Check the tires for cuts, embedded nails, ore other sharp objects. See your authorized Honda Dealer for replacement of damaged tires or punctured inner tubes OPERATION PRE-RIDE INSPECTION WARNING If the Pre-ride Inspection is not performed, serious damage or an accident may result. Inspect your motorcycle very day before you ride it. The items listed here will only take a few minutes to check, and in the long run they can save time, expense and possibly you life. 1. Engine oil level – add engine oil if required. Check for leaks. 2. Fuel level – fill the fuel tank when necessary. Check for leaks. 3. Brakes – check operation. Adjust free play if necessary. 4. Tyres – check condition and pressure. 5. Drive chain – check condition and slack. Adjust and lubricate if necessary. 6. Throttle – check for smooth opening and full closing in all steering positions. 7. Lights – check that headlight, tail/brake light, turn signals, indicators. 8. Engine stop switch – check for proper function. 9. Battery electrolyte – check the level and add if necessary Correct any discrepancy before you ride. Contact your authorized Honda dealer for assistance if you cannot correct the proble

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2009 GAS GAS TXT PRO TECHNICAL SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Gas Gas) by admin on 28-11-2010

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ENGINE 2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled. 125 cc. engine Cylinder size 124,8 cc. Bore and stroke 54 x 54.5 mm. 200 cc. engine Cylinder size 175,3 cc. Bore and stroke 64 x 54,5 mm. 250 cc. engine Cylinder size 247,7 cc. Bore and stroke 72,5 x 60 mm. 280 cc. engine Cylinder size 272,2 cc. Bore and stroke 76 x 60 mm. 300 cc. engine Cylinder size 294,1 cc. Bore and stroke 79 x 60 mm. Carburettor, diameter of the diffusor 26 Lubrication system Mixture (50:1)(2%) Ignition system Digital magnetic flywheel CDI TRANSMISSION Transmission type 6 gears, Four / Six system by GAS GAS* (Patented). Clutch type Hydraulic command, 1/3 discs, variable progressive with diaphragm system by GAS GAS* (Patented). Driving system By chain Gear ratio 1st. 2,996 (35x27x28/16x24x23) 2nd. 2,571 (36/14) 3th. 2,187 (35/16) 4st. 2,112 (36x23x24/14x28x24) 5st. 1,125 (27/24) 6th. 0,821 (23/28)
-11- Primary reduction ratio 2,777 (75/27) Final reduction ratio 3,818 (42/11) Overall drive ratio 8,704 (6th. gear) Transmission oil Capacity 550 cc. Type 10W40 API SF o SG. FRAME Type Tubular profile made with Cr-Mo. Tyres Front 2,75 x 21″ Trial Rear 4,00 x 18″ Trial tubeless. Suspension Front Adjustable tele-hydraulic fork ø 40 mm. (125 / 200). Adjustable tele-hydraulic fork ø 40 mm with aluminium bars (250 / 280 / 300) Rear Variable progressive system with mono-shock multiadjustable. Suspension stroke Front 177 mm. Rear 164 mm. Front fork oil SAE 5. Front fork oil level ø 40 mm.(125 / 200) 180 mm. air chamber steel bar ø 40 mm. (250 / 280 / 300) 160 mm. air chamber aluminium bar BRAKES Type Disc brake. Disc diameter Front ø185 mm. 4 piston calipers. Rear ø150 mm. 2 piston calipers. DIMENSIONS Overall height 1180 mm. Overall width 820 mm. Seat height 650 mm. Ground clearance 315 mm. Wheelbase 1330 mm. Fuel tank capacity 3,1 liters.

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YAMAHA XVS 650AK (C) SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-04-2011

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IMPORTANT INFORMATION N 300-008 300-016 EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPEClAL TOOLS” section. 3.When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assem~ bly and allow for the correct installation of all parts. 5.Keep all parts away f REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. E8101020 GASKETS, OIL SEALS AND O-RINGS 1.Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. Page 18 IMPORTANT INFORMATION I 1 T33? WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS 1.lnstall bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of  lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. (D Oil seal Do not use compressed air to spin the bear ings dry. This will damage the bearing sur faces. (D Bearing

YAMAHA XVS1100 (L) SERVICE MANUAL

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

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GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. 1-2 IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCE- DURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EB101020 GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. 1-3 IMPORTANT INFORMATION GEN INFO CAUTION: EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification

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URAL motorcycles Installation and Removal Manual

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Filed Under (Ural) by admin on 02-11-2010

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The Repair Manual provides information on setup, tune-ups, servicing, diagnosing problems, removing and installing components (otherwise referred to as “assembly units”), overhauling components, adjusting repaired components, and testing the repaired motorcycle. The increasing competition in the motorcycle market requires, more than ever, careful attending to the customer in order to assure the owner satisfaction with one’s motorcycle and to maintain customer confidence in the dealer and factory. It is important to repair the client’s vehicles correctly in a well organized and clean repair shop equipped with all necessary tools and parts. In such an environment, and having been trained at the technical training course, a repair technician will prove to be competent and efficient. Repairs on the engine and transmission especially, should be carried out in dust-free places. During breaks, disassembled transmissions and openings leading to the inner engine parts or lubrication holes should be protected from dust by clean rags. Valves, valve springs, spring retainers, rockers, pushrods, tappets, pistons, connecting rods and bearings should be put away in suitable boxes. Disassembled parts have to be cleaned and thoroughly checked for the following: Sliding and rolling surfaces for wear and freedom from scoring marks, all metal parts, particularly castings, tempered parts and welded joints as well for cracks and corrosion, and rubber parts for suitableness. As a rule, all gaskets and tab washers are to replaced upon reassembling. When disassembling parts, attention has to be paid to the arrangement of lock-washers on screws and nuts, spacing washers, gaskets, rubber mounts and so on. If necessary, mark mating parts in order to guarantee correct assembly.

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