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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 V-STAR 1300 exhaust system INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Install the bracket (Stamped 439-P, supplied) to the motorcycle chassis using the 10 x 20mm hex head bolt (supplied) and two of the stock mount bolts in the bottom holes (Figure 3). 2. Remove exhaust system and heat shields from protective packaging and place them on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that the hose clamps will loop through (Figure 4). 3. Apply a small amount of anti-seize compound to the threads of the stock O2 sensor and install it into the header assembly. NOTE: Be careful not to overtighten or get anti-seize compound on the sensor tip as this could damage or affect the sensor function. 4. Carefully lay header assembly into the heat shields and loosely install the hose clamps #20 on head pipe heat shields and #24 on collector heat shield (supplied) by feeding the tail end of the clamp into the heat shield clips. Take note of screw head direction (Figure 5), for adjustment purposes they must be accessible when system is installed. NOTE: Do not tighten the clamps at this time. 5. Using stock dome nuts, carefully install system into exhaust ports. (Assistance may be required). NOTE: Install but do not tighten the exhaust nuts at this time. 6. Remove the muffl er heat shield and baffl e assembly from their protective packaging. Place them on a non-abrasive surface such as a blanket or carpet. 7. Insert the large hose clamp (#56, supplied) into the clip on the muffl er heat shield. 8. Carefully slide the baffl e assembly (without damaging the fi berglass packing) into the muffl er heat shield and align the holes in the heatshield with those in the baffl e. Secure the baffl e with the 1/4-20 x 1/2″ button head screws (supplied) and tighten the hose clamp. 9. Install the 5/16″ x 1 1/4″ hex head bolt, washers and locknut (supplied) in the muffl er clamp (supplied) and slip the clamp over the end of the baffl e tube. 10. Slide nut plate (supplied) inside the bracket welded to backside of baffl e (Figure 6). 11. Install the muffl er assembly onto the collector, making sure it slides forward enough to align the edge of the bracket welded to the baffl e with the edge of the mounting bracket. 12. Attach the muffl er assembly to the mounting bracket using the 5/16″ x 5/8″ fl ange head bolts (supplied). 13. Tighten exhaust port nuts evenly on both cylinders. 14. Tighten the muffl er clamp and the 5/16″ fl ange head bolts, securing the muffl er assembly. 15. Insert the O2 sensor plug back into harness and tuck harness back into its original position. Reinstall the cover. 16. Check alignment of heat shields making sure the ends meet squarely to the collector heat shield. Tighten the hose clamps on all the heat shields when properly aligned. 17. Reinstall right side passenger and rider fl oorboards and tighten the 12mm bolts. 18. Check for adequate clearance between all exhaust system components and motorcycle accessories prone to heat damage. 19. All hardware must be properly tightened and the exhaust pipes thoroughly clean before starting motorcycle

HARLEY DAVIDSON QUICK RELEASE DETACHABLE WINDSHIELD KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Installation The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) NOTE Cover the front fender, headlamp and the front of the fuel tank with clean shop towels to prevent scratching. Make sure the windshield assembly does not contact chrome or painted parts. Damage to the finish could result. Turn Signal Relocation Relocate the turn signals according to instructions included in the Turn Signal Relocation Kit, item 20. Assemble the Clamps to the Windshield 1. See Figure 1. Remove the windshield sub-assembly from the packaging and place face down on a clean, soft surface with the mount brackets facing upward. 2. See the Service Parts illustration. Remove both the clamp and hardware kits from the packaging, and separate similar parts in preparation for assembly. Note that upper and lower clamps are exactly alike. 3. See Figure 2. Assemble the clamp assemblies and hardware stacks. The cupped side of the Belleville (cone) washers must face each other and sandwich the windshield mount brackets at each mount point. Failure to orient washers correctly can reduce the windshield’s ability to break away in a collision, which could result in death or serious injury. 4. See Figure 2. One clamp at a time, with the clamp facing upward and inboard of the windshield bracket (2), tighten the shoulder bolts (1) enough to hold the clamp orientation to the windshield during mounting of the windshield to the bike. The bolts will be fully tightened later. Install the Windshield NOTE Keep front wheel straight to prevent brackets from scratching fuel tank. 1. Make sure all four clamps are in the “open” position, then bring the windshield (with the clamp side away from you) to the front of the bike. 1 WARNING 1 WARNING ® Kit Numbers 58779-05, 57160-05 1 of 3 Figure 1. Windshield Mounting Brackets i07503 Figure 2. Windshield MountingClamp i07504 1 Shoulder bolt 2 Right windshield bracket 3 Cup washer 4 Belleville washers (cupped sides face each other with windshield bracket between)

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HARLEY DAVIDSON RONT & REAR HEADPIPE AND HEATSHIELDS INSTALLATION

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Filed Under (Harley Davidson) by admin on 10-11-2010

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1. Remove both left and right saddlebags and set them aside. 2. Remove the right side floorboard from the frame and set aside. 3. Unplug the O 2 sensors on front and rear headpipes from motorcycle wire harnesses. 4. Remove the stock exhaust system. It may be necessary to lubricate the slip joints of the exhaust with WD-40 or similar lubricant to aid in disassembly. The stock muffler slide hangers may be left in place in the rubber mounts for later reinstallation of the mufflers. 5. Remove the stock rear headpipe support-mounting bracket by removing the two starter mounting bolts, this bracket will not be reused. Note: Use caution when removing the bolts so that any tools used do not come in contact with the positive post on the starter. Install the Cobra supplied, exhaust support-mounting bracket, see Figure 1. 6. Remove the stock exhaust flanges, retaining rings and O 2 sensors from the stock headpipes and headpipe support clamp from the front headpipe. Remove the new front headpipe from packaging and install the stock flange, retaining rings and O 2 sensor on to the pipe. 7. On the front headpipe slide the stock headpipe support clamp over it. Install the front headpipe on the motorcycle using the stock flange nuts to secure it to the exhaust port studs, but do not tighten at this time. Slide the headpipe support clamp forward on the headpipe and over the stock exhaust mount on the right side engine case, make sure the clamp’s rectangular hole is on top and the flat part of the clamp is downward, see Figure 2. Install the carriage bolt and nut to secure the tube clamp but do not tighten at this time. 8. Reinstall the muffler onto the front headpipe using one muffler slip clamp. Reinsert two stock 5/16- inch bolts into rear muffler mount, tighten to factory torque specs, do not tighten front muffler slip clamp at this time. (NOTE: On some models equipped with saddlebags the bag rail may need to be adjusted outward to allow proper clearance between muffler body and swing arm / axle nut.) 9. Tighten front headpipe flange nuts then headpipe support clamp to factory torque specifications. 10. Remove front heatshield and hose clamps from packaging. Unscrew the hose clamps and feed the tail end of the clamps through the clips on the inside of the heatshield from the bottom, so the screws are facing toward the bottom and accessible with a screw driver once the heatshield is installed. Install the heatshield over the front headpipe. (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes.) Align heatshield with headpipe and snug clamps but do not tighten .

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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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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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

1997 Honda CBR 1000 F specifications review

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Filed Under (Honda) by admin on 20-12-2011

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Front brakes: Dual disc Rear brakes: Single disc Speed and acceleration Top speed: 255.0 km/h (158.4 mph) Power/weight ratio: 0.5745 HP/kg Other specifications Further information Parts and accessories Check out parts and accessories from our partners. Ask questions Join the 97 Honda CBR 1000 F discussion group Insurance, loans, tests Search the web for dealers, loan and insurance costs, tests, customizing, etc. Related bikes List related bikes for comparison of specs Buying a bike starts at Bikez Get a list of related motorbikes before you buy this Honda. Inspect technical data. Look at photos. Read the riders’ comments at the bike’s discussion group. And check out the bike’s reliability, repair costs, etc. Show any 1997 Honda CBR 1000 F for sale on our Bikez.biz Motorcycle Classifieds. You can also sign up for e-mail notification when such bikes are advertised in the future. And advertise your old MC for sale. Our efficient ads are free. You are also welcome to read and submit motorcycle reviews. Rating sample for this Honda bike Value for money for the 1997 Honda CBR 1000 F: (67.1 out of 100) Click here for complete rating. You can also compare bikes.

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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

Suzuki M 109 WINDSHIELD INSTALLATION AND OWNER'S MANUAL

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Filed Under (Suzuki) by admin on 18-02-2012

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Position the motorcycle securely on its stand or a work stand. Cover the front fender and fuel tank with a cloth to avoid scratches from dropped tools. 1. Use the above diagram toidentify left from right Lower and Upper Mount Brackets. Figure 1 2. Cut each of the clamp spacers in half to make 8 pieces, each 2.5 x 1.55″. 3. Apply one spacer to the inside of each mount bracket. Figure 2 Figure 1 Figure 2 N28201 and N28202 WINDSHIELD INSTALLATION AND OWNER’S MANUAL for Suzuki®M109 Right and Left side of Motorcycle is determined while sitting on the bike. Determine left from right Upper bracket. Washer angles inboard about 5 degrees. Note, Angle distinguishes Right from Left Lower Mount Bracket 1 2 4 3 5 6 8 9 10 National Cycle, Inc. Maywood, IL 60153-0158 USA 708-343-0400 / Fax: 708-343-0625 www.nationalcycle.com / e mail:info@nationalcycle.com Page 1 of 3 10-114056-000 08/07 / Rev B. 03/08 7 3, Left Upper Bracket 4, Right Upper Bracket About 5 0 inboard angle
INSTALLATION Measurements provided for clamp location. From this point you can adjust the brackets 1″ (22mm) higher if you prefer keeping in mind, position of the front nose of windshield should have a minimum of 1/2″ (13mm) clearance from cowling . Figure 3. Right Side Lower Mount Assembly 1. Start on the Right Side of motorcycle. At the top of the fork, place one inner black clamp on the fork tube. Figure 4 2. Hook the RIGHT SIDE lower mount bracket (2) to the inside clamp. Figure 5 3. Slide assembly down fork so bottom edge of bracket is 1.75″ (44mm) from top of lower triple clamp. Adjust bracket so flat in bracket runs parallel with motorcycle. Figure 6 and 7 4. Loosely install one M8 x 16 screw. (6mm Hex Key) Figure 7 Right Side Upper Mount Assembly 5. Place the second inside black clamp on the right fork tube.

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