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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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Motorcycle LED lights RENEGADE LIGHTS Installation Guide

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Filed Under (Tips and Review) by admin on 29-01-2011

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1. Make sure your bike is cool and parked on a flat secure surface! 2. Find your battery (you may have to remove your seat or side covers in order to get to your battery) Disconnect the NEGATIVE ( -) cable. Negative battery cable must be disconnected from the battery in order to avoid safety hazards! Be sure as you disconnect the Negative cable that it does not touch or make contact with your Positive terminal 3. Your new motorcycle LED lights are polarity sensitive–meaning that the RED wires on the LEDs must be hooked to the Positive (+) terminal and the BLACK wires must be hooked to the Ground (-) . All Red Wires must go to a common power wire and ALL Black Wires must go to a common ground. You cannot run the LED motorcycle lights in a series nor can you run the wires from one motorcycle LED light to another in a loop type installation. ( All of the wires on the motorcycle LED lights which you install will end up together in one place at your battery.) 4. Pick a hidden flat surface around the front of your seat area to mount the switch. ( You must be able to reach the switch when the seat and/or side covers are back on your bike.) You will install your switch later using the double-sided tape provided to you. 5. Next, begin choosing the locations where you would like to mount your motorcycle LED lights. Choose areas which will give you the most light coverage overall, but which will allow the motorcycle LED lights itself to be hidden from easy view when you are standing back and looking at the bike. 6. Clean each area where you choose to place a motorcycle LED light with the alcohol based cleaner making sure all dirt and/or oil is removed from that area

Motorcycle LED lights RENEGADE LIGHTS Disconnection Guide

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Filed Under (Tips and Review) by admin on 29-01-2011

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1. Make sure your bike is cool and parked on a flat secure surface! 2. Find your battery (you may have to remove your seat or side covers in order to get to your battery) Disconnect the NEGATIVE ( -) cable. Negative battery cable must be disconnected from the battery in order to avoid safety hazards! Be sure as you disconnect the Negative cable that it does not touch or make contact with your Positive terminal 3. Disconnect the fuse holder from the battery – both the positive ( +) and negative ( -) sides. 4. Cut the wire to the light that is not working with the side cutters. 5. At the problem light twist the light case back and forth slowly and then pull firmly, DO NOT yank to remove from the motorcycle. 6. If the motorcycle led light does not come off easily, repeat the twisting motion back and froth until you feel the light loosen – then pull. 7. Pull the motorcycle led light away from the motorcycle slowly until the cut end of wire falls free. 8. If you will NOT be using your motorcycle until the new lights arrive, you may stop at this step. SAFETY POINT: Otherwise, where you cut the wire, you need to dead end or tape the cut wire. This will keep it from shorting out until the new motorcycle led light is installed. 9. Reconnect fuse holder to battery. 10. Reconnect the battery and then install the seat. 11. Return the motorcycle led light or lights to Renegade Lights along with Warranty Return Policy Form. 12. Renegade Lights will return your new motorcycle led lights along with instructions for installing them.

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LED SHOW LIGHTING INSTALLATION INSTRUCTIOINS

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Filed Under (Tips and Review) by admin on 27-12-2010

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1. The kit is supplied with 4 “cluster” lights that project a round flood lighting pattern and 4 “array” lights that have a narrow fan type pattern. Determine where you would like to mount the supplied lights, switch and wiring connections. You may want to hook up one of the lights with some long jumper wires connected to the battery and hold it in various places to see what will show off your bike best. The idea is to see the light reflected off your bike and not see the light fixture. 2. Mount the lights and switch using the supplied primer and 2-sided adhesive pad. Apply the primer to the backside of the lights and switch; let it dry for 5 minutes. Remove the protector from one side of the adhesive pad and apply. Apply the primer on the motorcycle where the lights and switch will be mounted and let it dry for 5 minutes. Remove the protector from the adhesive pad and mount the lights and switch. 3. Refer to the provided wiring diagram. The wiring is color-coded and connects in parallel. All of the black wires connect together through the BLACK wire of the 2 conductor black jacketed wire (Ground Wires). All of the colored wires connect together through the RED wire of the 2 conductor black jacketed wire (Power Wires). Connections may be soldered, crimped with solderless connectors, or twisted together. 4. Measure and cut the supplied 2-conductor black-jacketed wire to the lengths that are needed to connect the lights and switch. When routing the wire from any lights that you have mounted to the front make sure you have provided enough slack at the steering head to be able to turn the front wheel full left and full right without damaging the lights or wires. Also be sure the wire is at least æ” from any exhaust pipe. 5. Join each connection and cover with the supplied heat shrink tubing. NOTE; All wire connections must be insulated. Cut a piece of the provided heat shrink tubing long enough to cover the connection completely. 6. Connect one wire from the switch to the RED wire of the lights with one of the supplied blue butt connectors. Connect the second wire from the switch to one wire from the fuse holder with the other blue butt connector. Connect the second wire from the fuse holder to the positive (+) battery terminal using one of the supplied fork connectors. 7. Connect the BLACK wire of the lights using the other fork connector to a ground connection. (The negative (-) battery terminal or motorcycle frame.) 8. Secure all loose wires by using the supplied cable ties. Check the front wheel again to be sure there is enough wire slack for turning.

BMW F 650 GS Repair Manual And Maintenance schedule

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Filed Under (BMW) by admin on 19-11-2010

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Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) every 2years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS ) 40,000 km Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check

POLINI X1 GENERAL INFORMATION AND SPECIFICATIONS

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Filed Under (Polini) by admin on 02-12-2010

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Air cleaner – Clean and reoil daily or after each moto to prevent motor failure and reduced performance. Transmission oil – change after every race, or at end of riding day. Chain – check tension and lubricate before every ride, adjust or replace as needed. Reoil after riding in damp conditions. Clutch – disassemble and clean clutch assembly frequently, every 2-3 races at least. Inspect kickstarter gears at this time. Ignition cover – remove cover and wipe dry after each ride or after washing bike to remove condensation. Piston rings – replace as often as every 3-5 races with expert rider, less often with less aggressive riders. Piston, pin, rod bearing & circlips – replace as often as every 8-10 races with expert rider, less often with less aggressive riders. Coolant – change yearly, make sure there is at least a 50/50 mixture of antifreeze if freezing temperatures are possible. Steering bearings – Check daily for looseness or play. Adjust and regrease as needed. Swingarm – Check often for looseness. Regrease several times a year. Replace bushings if any play is evident. Sprockets – check for worn or curved teeth each time chain is adjusted. Chain roller& wear pads – check roller for free rotation when checking chain. Make sure roller is not bent or damaged. Check chain wear strips on swingarm and chain guide frequently. Replace as needed to prevent chain from damaging motorcycle. Spokes – Check after each race or after each day of riding for looseness or damage. Wheels & tires – check wheels after each race for dents, cracks or other damage. Check tires for cuts, damage or wear. Check tire pressure daily and adjust for riding conditions. Shock – Check shaft area daily for signs of oil leakage or damage. Check swingarm and shock bushings for looseness. Forks – Check forks daily for leaking oil or damage to tubes. Make sure forks are not twisted check for smooth operation. Spark plug – check sparkplug color and condition after each race or end of riding day. Adjust jetting to keep plug from fouling or overheating. Silencer – If bike seems to be getting louder, replace packing and decarbonize inner tube. Expansion pipe – check daily for large dents, damage or leakage. Remove carbon from headpipe when pipe is removed. Have large dents fixed, or any dents within 8″ of the cylinder. Replace o-rings on pipe as needed to maintain a good seal. Footpegs – check daily for proper operation, pegs should spring back into place. Make sure pegs are not bent or overly dull. Handlebars – check bars after any crash for bending. Look for cracks near bar clamps. Replace bars that have been straightened more than 2 or three times, or if bar is badly bent. Aweakened bar can snap suddenly causing injury to rider. Throttle – check throttle for proper operation each time before bike is started. Remove and clean inside of grip and bar as needed. Grips – check grips daily for wear or looseness. Replace as needed. Use grip glue & safety wire to help hold grips in position. Calipers & pads – check pad wear and caliper function daily or after each race. Replace pads and clean calipers as needed. Brake lever – check lever daily for damage or wear. Make sure lever is at proper angle for both seated and standing positions. Leave lever clamp loose enough to allow clamp to rotate during crash rather than breaking lever. Check and adjust freeplay as needed. Brake pedal – Check pedal daily for damage and proper freeplay. Adjust rear caliper as needed. Reeds – Remove and inspect reed block during every ring change. Check reeds for signs of wear, fraying and cracking. Make sure reeds sit flat and seal well. Replace at any sign of wear or damage or at least once a year, more often for expert riders. Nuts & bolts – Check all nuts and bolts regularly. Make sure to check engine mounting bolts and swingarm bolt frequently

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BMW R1200GS Dual Function LED Running Lights and Flashing Brake Lights installation instructions

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

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The flasher is set to flash continuously as long as the brake is applied. To convert to a 5 second flash and then stay solid while the brake is applied, cut the green wire loop on the flasher. Use electrical tape to protect and secure the green wires to the other wires. 2. Remove the rider’s seat. Locate the wire bundle that starts at the rear of the motorcycle. At the most accessible spot carefully remove 3″ to 3½” of protective wire loom. I know, I know…it’s really beautifully done. Cowboy up! Take it off! 3. Mount the flasher in a location that will not crimp wires or interfere with the other bike assemblies. Locate the +12 volt wire ( GRAY wire with BLACK stripe and YELLOW banding) from the brake light Attach the kit RED wire to the brake light positive wire using one of the Posi-Tap connectors in the kit. 4. Locate the Ground wire ( BROWN wire) from the brake light. Attach the kit BLACK wire to the motorcycle ground wire using a Posi-Tap connector. 5. If you have a Fuse Block with ignition switched relay installed, route the Hyper-Lite GRAY wire to a fused circuit on the (relay activated) fuse block . 6. If you do not have a Fuse Block installed, find the alarm circuit connector under the seat . The alarm circuit has a rectangular connector and five wires, White with Black stripe; White with Brown stripe; Red with White; Brown with White; and Green with White stripe. Use a Posi-Tap to attach the Hyper-Lite GRAY wire to the green wire with white stripe. Pull the wire loom back from the wire. Tap into the wire with the Posi-Tap provided. . 7. If using the Hyper-Lite License Plate Mounting bracket, install it now. OR: Clean the side facing reflectors at the rear of the bike with alcohol. Mount the LED modules vertically on the reflectors so that the LEDs point straight back. Press in place for about 5 seconds. The tape can be used only once! If you goof, new tape is required. 8. Route the BLUE and BROWN wires from the flasher and the LED modules. Trim the Blue and Brown wires to remove any excess wire . Use a Posi-Twist to connect the 3 BLUE wires together. Use a Posi-Twist to connect the 3 BROWN wires together. (see Posi-Twist Connector instructions)

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Introducing the New BMW R 1200 RT-P

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

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The new R 1200 RT-P features a completely new LED emergency lighting concept developed by BMW and Code 3 PSE. The new system combines all currently desired emergency lighting into optimally focused compact LED light modules. These modules accommodate an additional 45 degree front LED module that blankets the front quadrants in emergency light. Together with an integrated wiring harness and programmable flash control module, the new system can provide any current flashing sequence / switching combination through settings on the programmable flasher. Example: If the motor will be used in California, program the flasher for steady-burn left front LED light, with no change in the LED light or the wiring. If the motor is sold or operated in a different venue later, change the program flasher for 49 state operation. The rear light module combines rear and side facing LED emergency lights, together with rear-facing brake/tail LED and side turn signal LED lights. Additional rear facing LED emergency lights can be installed and powered in conjunction with the rear facing lights, or controlled by photo- eye to disable the lights during the dark to reduce glare at night / low light situations. The programmable flasher can provide 12 flash patterns, with wiring splitting the motor between left and right side for alternating flash patterns. Light sequencing begins with rear, programmable rear and front side lights, as well as front and 45 degree front lights. A rear cancel switch allows riders to disable the rear lights while retaining the side and front lights – usually used for protective service details. The programmable flasher also provides for a primary and secondary flash pattern, so during code 3 operation, the emergency lights will display the primary pattern until the siren is activated, at which time the flasher changes to the alternative pattern for 7 seconds after each siren tone change. This feature known as InterClear provides a visual and audible alert to those nearby

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BMW R1100 – R850R Maintenance Guide

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Filed Under (BMW) by admin on 27-11-2010

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R1100 Checklist – Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check battery acid level • Fuel filter (replace 24K) • Throttle body sync • Oil and filter (replace 6K) • Check transmission fluid level (replace 12K) • Check rear wheel drive fluid level (replace 12K) • Check tires and pressure • Check all nuts and bolts • Check all air and oil hose clamps • Check all lights PARTS – TOOLS Tools Parts Misc. sockets spark plugs compressed air wrenches oil filter anti seize torque wrench air filter carb cleaner hex sockets brake pads rag hex wrenches oil – 4 qt. BMW #10 grease feeler gauges gear oil – 1 1/4 qt. flexible tubing oil filter tool alternator belt (tygon) flashlight fuel filter, o-ring, clamps measuring cylinder crush washers Mityvac -3 small = trans.drain, rear drive fill and drain digital volt meter -1 medium = oil drain heat gun -1 large = trans.fill tire change tools 5 R1100 Maintenance Steps – Carl Kulow Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet” except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Check Alternator Belt remove four bolts holding black plastic cover(4mm hex), remove cover, check belt for cracks etc., check belt tension, replace belt every 36K miles, leave cover off for valve adjustment (see Jon Diaz “Alternator Belt Adjustment”)

V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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