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Harley Davidson Big Twin EVO Engines Edelbrock Performer-Plus Camshaft , Performer RPM Camshaft , & Performer RPM Camshaft INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-03-2012

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Disconnect the battery. Secure the motorcycle on a suitable stand with the rear wheel off the ground. Remove components necessary for easy access to rocker covers, pushrod covers, and gear case cover, i.e., exhaust system, gas tank, air cleaner, foot rest, etc. Remove spark plugs. 2. Remove top and middle sections of rocker boxes, then rotate engine so both valves are closed on the cylinder head being worked on (put transmission in high gear and move rear wheel to slowly rotate engine). Remove the two 5/16″ bolts nearest the rocker arm shafts (keep all shafts, rocker arms, and pushrods in order so they can be installed in their original position). Remove the pushrod covers and pushrods. NOTE: The use of adjustable time-saver pushrods will simplify installation. Follow the manufacturer’s recommendations for installation of those parts. 3. It is not necessary to remove the tappet guides if you use a cam installation tool such as Crane #9-0020 to hold the tappets in place during cam installation. If you remove the tappet guides, you must use a tappet block alignment tool such as Crane #9- 0021 to re-install the tappet guides. Tappets can be held up in place during removal of guides by using U-shaped piece of safety wire or paper clip hooked to the tappets. 4. Remove ignition covers on gearcase cover by drilling out rivets to gain access to sensor plate. Remove the inner cover, sensor plate and rotor. NOTE: For re-installation, use new rivets H-D #8699 or drill and tap for 10-32 screws. 5. Remove the gearcase cover screws and remove cover while holding end of cam inward. Now remove the camshaft, spacing washer and thrust plate

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HARLEY DAVIDSON PUSHROD COVER RETAINER INSTALLATION AND REMOVAL TOOL

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Filed Under (Harley Davidson) by admin on 31-03-2011

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Figure 1. Pushrod Cover Retainer Installation and Removal Tool There are no Service Parts available with this kit. REMOVAL 1. See Figure 2. Insert the pin of the pushrod cover retainer tool into the retainer loop with the back of the tool towards the cylinder fins. Rotate the tool towards the cylinder to remove the pushrod cover retainer. INSTALLATION 2. See Figure 3. Load the pushrod cover retainer into the tool as shown in figure 3. Place the top edge of pushrod cover against top edge of push rod. 3. See Figure 4. Place the tool on top of the spring cover. Pivot the tool upward to install the pushrod cover retainer is05892a Figure 2. Removing Pushrod Cover Retainer is05895a Figure 3. Loading Pushrod Cover Retainer in Tool is05893a Figure 4. Pushrod Cover Retainer Installation

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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Kawasaki KVF650/ 700, KSV 700 Camshaft Installation Instructions

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Filed Under (Kawasaki) by admin on 29-04-2012

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Liberally apply assembly lube to every surface of the camshaft. Install the camshaft into the cylinder head (the lobes should be pointed down) and align the decompressor shaft dowels with the weight arms. Install one of the camshaft sprocket holder bolts and tighten to less than finger tight, you should be able to move the camshaft very slightly back and forth, roll the crank over until the other bolt hole is exposed and insert the sprocket bolt and tighten to less than finger tight. Install the cam chain tensioner assembly, do not install the spring, spring dowel, washer, and bolt. Using the spring from the cam chain tensioner very slowly push the tensioner shaft in until the cam chain slack has just been taken out, this is witnessed by the very slight lifting of the opposite end of the cam out of the cylinder head cam journal, do not over tighten the cam chain at this point, if you do, remove the tensioner assembly and retract the plunger again and start over. (If it stays too tight it will stretch the cam chain prematurely and cause cam sprocket damage when the engine is assembled) Roll the camshaft toward the back of the machine (clockwise) loading the sprocket bolts against the back of the sprocket bolt holes, while holding the camshaft in that direction, tighten the sprocket mounting bolt to 14 ft/lb of torque. Rotate the engine in the opposite direction that you rotated it earlier and align the TDC mark, tighten the other sprocket-mounting bolt to 14 ft/lb of torque. Verify the cam timing and crankshaft TDC marks are in alignment

Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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2009 Daytona 675 Motorcycle Race Kit Manual

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Filed Under (Triumph) by admin on 29-10-2010

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1. Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Position a piece of solder (with a diameter approximately 1.3 mm) on the four squish surfaces of each piston. Position the solder in line with the corresponding squish surfaces on the cylinder head and hold in place with a small amount of grease. 3. Refit the cylinder head with the head gasket. 4. Slowly turn the engine over, by hand, to compress the solder to the same height as the squish clearance. 5. Remove the cylinder head and head gasket. 6. Measure the compressed thickness of the solder. The squish clearance must be a minimum of 0.65 mm. If the thickness of the solder is less than 0.65 mm repeat steps 2 to 6 with a thicker head gasket until the squish clearance is at an acceptable level. NOTE •In some cases, it may be necessary to use a standard cylinder head gasket to achieve the correct squish clearance. 7. Fit the chosen cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Warning Running the engine at less than the minimum recommended squish height can lead to the pistons contacting the cylinder head, causing major engine damage. This could cause loss of motorcycle control and an accident. Triumph Designs Ltd 2009. Camshaft, Valve Spring & Camshaft Sprocket Kits Parts Supplied Camshaft, Inlet – A9618055 Camshaft, Exhaust – A9618056 Valve Spring Kit – A9618086 Camshaft Sprocket Kit – A9618095 Warning The Race Kit camshaft, valve Spring and camshaft sprockets must be fitted as a complete set. If they are not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.

TOYOTA SPECIALTY AND REPLACEMENT PARTS

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Filed Under (Toyota Manuals) by admin on 30-09-2011

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73-3844 Replaces: 3977775, 3078511 CLIP -HOOD INSULATION Head Dia.: 2″ Length: 3/4″ G.M. ’64/ UNIT PACKAGE 100 79-5126 Replaces: 20064875 CLIP -HOOD INSULATION Head Dia.: 1 21/32″ Length: 3/4″ G.M. ’78/ UNIT PACKAGE 50 79-5127 Replaces: 20030401 CLIP -HOOD INSULATION Head Dia.: 1 3/8″ Length: 1″ G.M. ’80/ UNIT PACKAGE 50 79-5100 Replaces: 388908-S RETAINER -HOOD INSULATION Head Dia.: 1-3/4″ Ford ’80/ UNIT PACKAGE 100 74-3945 Replaces: 385330-S, 6003351 FASTENER -HOOD INSULATION Ford & Chrysler Products ’73/ AMC 4005513 ’76 UNIT PACKAGE 100 92-7067 Replaces: 15678493, 21039141 RETAINER -HOOD INSULATION Head Dia.: 1-9/16″ Length: 1/2″, Hole: 1/4″ Plastic Saturn ’91/ UNIT PACKAGE 25 67-3119 Replaces: 389809, C6GY-16776-A CLIP -HOOD INSULATION RETAINER 1-1/2″ x 1-1/2″ Plastic G.M., Ford Products UNIT PACKAGE 50 72-3718 Replaces: 389089 FASTENER -HOOD INSULATION 2″ x 2″ Plastic G.M. Cars UNIT PACKAGE 50 99-8032 Replaces: 385595-S, 386553-S RETAINER -HOOD INSULATION Plastic Formerly 74-3944 For Heavier Type Insulation Head: 1-3/16 Ford ’74/ UNIT PACKAGE 50 95-7382 Replaces: N-803613-S RETAINER -HOOD INSULATION Hole: 1/4″, Head: 1-3/4″ Stem Length: 7/8″ Plastic Ford Explorer ’91/, Taurus, Sable, Mustang, Continental ’92/ UNIT PACKAGE 50 95-7369 Replaces: W700671-S300 RETAINER -HOOD INSULATION Head Dia.: 25MM, Hole: 8MM Black Plastic Ford Contour & Mercury Mystique ’95/ UNIT PACKAGE 15 96-7577 Replaces: 01644290, 15678979, 01553-0075U RETAINER -SPEAKER, DOOR SILL, BUMPER, HOOD INSULATOR Black Plastic Hole: M6, Barb Length: 12MM Head Dia.: 11MM, O/L: 19MM G.M. Various Models ’86/, Nissan Altima & Maxima 2002/

2004 CM And King secondary shaft bearing retainer

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Filed Under (Cobra) by admin on 10-11-2010

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There is a slim chance (but possible none the less) that the secondary shaft bearing retainer (screw) can back out of it’s intended position. If this retainer comes out of position it can cause an immediate stop to the motorcycle and has to potential to cause substantial damage to the engine. The early button head screw (with high strength thread locking agent) has been replaced with a black oxide bolt, lock washer, and high strength thread locking agent.

Honda CRF/ TRX 450R Camshaft Installation

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

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Break-in of this camshaft is important and you should adhere to all of the following instructions. It is also very important to use plenty of engine assembly lubricant, recommended is Coastal Engine Assembly Lube or Clevite 77, both are available from most automotive supply companies. We recommend you change the engine oil before the initial start-up of the engine after the assembly. Then change the oil again after the break-in of the cams to remove the excess
phosphate from the coated cams. These steps will help ensure that the camshaft breaks-in properly and that you have a long lasting product. Using full synthetic engine oil during break-in is not recommended but, is OK to use after the one-hour break-in period is over. Following a regular maintenance schedule is the best way to ensure durability and performance over the long run. Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. Remove the fuel tank and thoroughly clean the inside of the frame rails, around the carburetor, and behind the radiators. Be sure to remove the ignition coil assembly and using high-pressure air, clean the spark plug hole out before the plug is removed. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly

CAGIVA RAPTOR 1000 AKRAPOVIC SLIP- ON INSTALLATION MANUAL

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Filed Under (Cagiva) by admin on 10-11-2010

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Akrapovic SLIP-ON systems have an interesting background. They are developed by the same team which develops exhaust systems for factory and private racing teams in the Superbike and Supersport classes on the highest levels of world motorcycle sport. This means highly perfected designs, strict production quality control and performance which serves as a benchmark for the competition. The Akrapovic SLIP-ON system is composed of a link pipe and a muffler, a carbon-fiber muffler clamp and compression springs. The link pipe is conical, and available in high-quality stainless steel or titanium. At the connection to the muffler, the diameter of the link pipe widens to 60 mm, which ensures maximum utilization of the shape of the pipe for the flow of the exhaust gases. The link pipe is simple to connect to both the muffler and the header assembly with the help of high- quality silicon-shielded springs. The oval mufflers on both sides of the bike complement the look of the Cagiva Raptor, especially in the carbon-fiber version, with a darker outer sleeve. Of course a titanium version is also available; performance is not affected by the choice. You have to decide whether you prefer the distinctive pattern of carbon-fiber or the satin sheen of titanium. The carbon-fiber clamp holds the mufflers in the standard position, so that the stock hanging bracket is used for installation

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